A/C Refrigerant Suction Line, Front: Overview

WARNING:

Review safety precautions and warnings in this group before performing this procedure. Failure to follow the warnings and cautions may result in serious or fatal injury. Refer to GENERAL INFORMATION .

Removal

NOTE:

On models equipped with the rear heating-A/C system, the A/C suction line also includes a connection to the underbody lines.

-- Disconnect and isolate the negative battery cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Recover the refrigerant from the refrigerant system. Refer to REFRIGERANT SYSTEM, RECOVERY .

-- Remove the air cleaner housing and inlet duct from the engine compartment. Refer to Air Cleaner Housing for CJRA engines .

-- Remove the nut (3) that secures the A/C suction line (4) to the A/C compressor (2).

Fig 1: Identifying A/C Discharge Line, Suction Line And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket.

-- Remove the bolt (1) that secures the A/C suction line (3) to the right front frame rail (2).

Fig 2: Identifying Suction Line To Frame Rail Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- On models equipped with the rear heating-A/C system, loosen the extension line fitting nut, disconnect the A/C suction extension line from the A/C suction line and remove the O-ring seal.

-- When equipped, remove the bolt that secures the suction line bracket to the strut tower.

-- Remove the nut (3) that secures the A/C suction line (1) and the A/C liquid line (5) to the A/C expansion valve (2).

-- Disconnect the A/C suction and liquid lines from the A/C expansion valve and remove and discard the washer seals.

-- Separate the A/C liquid line from the tapping block (4) of the A/C suction line.

Fig 3: Identifying A/C Suction Line, Expansion Valve, Liquid Line And Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disengage the A/C suction line from the retaining brackets located near the center of the dash panel and at the rear of the receiver/drier.

-- Remove the A/C suction line from the engine compartment.

-- Install plugs in, or tape over all the opened refrigerant line fittings and the compressor and expansion valve ports.

Installation

CAUTION:

Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE:

When replacing multiple A/C system components, refer to the refrigerant oil capacities chart to determine how much oil should be added to the refrigerant system. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE .

Replacement of the refrigerant line seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals, metal gaskets or washer seals may result in a refrigerant system leak.

-- Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve and compressor ports.

-- Lubricate new seals with clean refrigerant oil and install them onto the opened refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

-- Position the A/C suction line (1) into the engine compartment.

-- Engage the A/C suction line to the retaining brackets located near the center of the dash panel and at the rear of the A/C receiver/drier.

-- Install the A/C liquid line (5) into the suction line tapping block (4).

-- Connect the A/C suction and liquid lines to the A/C expansion valve (2).

-- Install the nut (3) that secures the A/C suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).

Fig 4: Identifying A/C Suction Line, Expansion Valve, Liquid Line And Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- When equipped, install the bolt that secures the suction line bracket to the strut tower. Tighten the bolt securely.

-- On models equipped with the rear heating-A/C system, connect the A/C suction extension line to the A/C suction line and tighten the extension line fitting nut to 23 N.m (17 ft. lbs.).

-- Install the bolt (1) that secures the A/C suction line (3) to the right front frame rail (2). Tighten the bolt to 9 N.m (80 in. lbs.).

Fig 5: Identifying Suction Line To Frame Rail Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the A/C suction line (4) onto the A/C compressor (2).

-- Install the nut (3) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.).

Fig 6: Identifying A/C Discharge Line, Suction Line And Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the air cleaner housing and inlet duct. Refer to Removal and Installation .

-- Connect the negative battery cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Evacuate the refrigerant system. Refer to REFRIGERANT SYSTEM, EVACUATE .

-- Adjust the refrigerant oil level. Refer to A/C COMPRESSOR REFRIGERANT OIL CHARGE .

-- Charge the refrigerant system. Refer to REFRIGERANT SYSTEM, CHARGING .