A/C - Low Pressure Line Refrigerant Leaks
No: 82/02/98/NASRef: WSM Section 82
Issue: 1
Date: 03/06/98
PRIDE VI 6-21
Rear A/C Pipe Failure
AFFECTED VEHICLE RANGE:
DISCOVERY (U) ALL WITH REAR A/C
SITUATION:
REFRIGERANT LEAK IN REAR A/C LOW PRESSURE LINE
A refrigerant leak in the low-pressure line for the rear air conditioning may be caused by the upper spring perch of the left rear wheel hitting the low pressure line and damaging the line.
RESOLUTION:
INSTALL PROTECTIVE SLEEVE AND/OR REPLACE REFRIGERANT LINE
Inspect the low-pressure line for damage. If evidence of contact is found but the line has not failed, install only the protective sleeve (LRN000003). If the low-pressure line is significantly damaged or has failed, pre-install the line protector on the new line and replace the low-pressure line.
NOTE:
The repairs outlined in this TIB are to be performed to resolve customer complaint of the symptoms described.
PARTS INFORMATION:
LRN000003 Line Protector
BTR8587 Low Pressure Line
STC3148 Receiver/Dryer (Used when line has failed and refrigerant has escaped)
Sourced Locally
^ 3M 08001 Super Weather-strip Adhesive
^ Refrigerant C134a (Used when line has failed and refrigerant has escaped)
^ PAG Compressor oil (Used when line has failed and refrigerant has escaped)
WARRANTY CLAIMS:
82.25.89/28 Time 0.20 hrs.
Install line protector
82.25.89/27 Time 0.50 hrs.
Replace Rear Low Pressure Refrigerant Line and Install line protector
82.17.03 Time 0.45 hrs.
Replace Receiver/Dryer
82.30.02 Time 1.50 hrs.
Evacuate and Recharge System
FAULT CODE: X
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
INSPECT REAR LOW PRESSURE REFRIGERANT LINE
1. View refrigerant line through left rear wheel well.
2. If foam covering is damaged where the line contacts the upper spring perch, but the line itself is still intact, follow procedure below for protective sleeve installation.
3. If rear line is significantly damaged or leaking, replace rear line with new part. Install protective sleeve before installation of new line onto the vehicle.
INSTALL REFRIGERANT LINE PROTECTIVE SLEEVE
1. Using the line protector as a gauge, measure one length of the protector along the foam padding from the forward junction. Mark this location.
2. Measure one more protector length from the first mark along the foam and mark that location.
3. Carefully cut the foam at the marks.
4. Remove the segment of foam from the line (Figure 1).
5. Coat inside surface of protector with the 3M adhesive (08001) and snap the protector onto the low-pressure line where foam was removed.
REPLACE REAR LOW-PRESSURE REFRIGERANT LINE
REMOVAL
1. Place vehicle on ramp.
WARNING:
Refrigerants are hazardous. Always observe the precautions in the Workshop Manual and verify that the system is discharged before opening a fitting.
2. Disconnect negative battery cable.
3. Raise rear of vehicle by axle.
4. Remove left rear road wheel.
5. Remove three fasteners at top of left rear mudflap/fender brace.
6. Remove brace fastener at floor of load space.
NOTE:
The nut is not secured and access to the left lower loadspace may be required.
7. Remove fastener holding brace to fender and remove brace assembly.
CAUTION:
Take care to clean area of all dirt and debris to prevent contamination of refrigerant system.
8. Loosen A/C pipe fittings.
9. Remove pipe from vehicle by sliding it to the rear and positioning the pipe so that it comes out from under the rear bumper.
INSTALLATION
CAUTION:
Leave the protective caps on the new line to minimize the chance of dirt or debris entering the new pipe during installation.
1. Modify new A/C pipe insulation and install line protective sleeve as described in "Install Refrigerant Line Protective Sleeve" section above.
2. Feed new A/C pipe into position from under the rear bumper.
3. Remove protective caps, lightly oil O-rings with refrigerant oil and tighten fittings.
4. Reinstall support assembly and mudflap.
5. Reinstall road wheel and lower vehicle.
CAUTION:
Ensure that correct amounts and type of refrigerant and PAG oil are used when charging the system.
6. Refer to Workshop Manual Section 82 and perform the following:
^ Replace the receiver/dryer.
^ Charge the A/C system observing all precautions.
7. Reconnect battery negative cable.
8. Test A/C system for proper operation.