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Home >> Fiat >> 2016 >> 500 Turbo, Standard Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 41 (Heating & Air Conditioning (Service Information) 500 - Electric) >> Plumbing >> Line, A/C Suction >> Installation >> A/C Suction Line Installation

A/C Suction Line Installation

WARNING: This page is about a different variant/trim than selected.
CAUTION:

Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. 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, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to STANDARD PROCEDURE  .

NOTE:

The Fiat 500e A/C system uses a

UNIQUE POE OIL 

in high voltage compression because it is non conductive.

NOTE:

Replacement of the refrigerant line seals is required anytime a refrigerant line is disconnected. Failure to replace the seals may result in a refrigerant system leak.

  1. Position the A/C suction line into the engine compartment.
  2. Install the power distribution center (PDC) bracket and securely fasten the four PDC nuts.
  3. Attach the 12-volt junction box to the high-voltage PDC bracket.
    Fig 1: High-Voltage PDC Nuts & High-Voltage PDC
    GC0157867Courtesy of CHRYSLER GROUP, LLC
  4. Position the high-voltage PDC (2) and securely fasten the two nuts (1).
    Fig 2: A/C Suction Line Bracket Bolt
    GC0157686Courtesy of CHRYSLER GROUP, LLC
  5. Install the A/C suction line bracket bolt (1) to the high-voltage PDC bracket and securely tighten.
    Fig 3: High-Voltage Interlock (HVIL) Connector & High-Voltage Connector
    GC0157895Courtesy of CHRYSLER GROUP, LLC
  6. Connect the high-voltage connector (2) and the high-voltage interlock (HVIL) connector (1) to the high-voltage PDC.
  7. Attach the wire harness retainers to the high-voltage PDC bracket.
  8. Attach the two 12-volt battery cable routing clips to the A/C suction line.
    Fig 4: Battery Coolant Chiller TXV Fitting Nut
    GC0157644Courtesy of CHRYSLER GROUP, LLC
  9. Remove the tape or plug from the opened suction line fitting and the thermostatic expansion valve (TXV) port.
  10. Lubricate a new seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for this vehicle.
  11. Install the suction line to the battery coolant chiller (BCC) TXV and securely fasten the nut (1).
    Fig 5: HVAC Thermostatic Expansion Valve (TXV) Outlet Fitting Nut
    GC0157773Courtesy of CHRYSLER GROUP, LLC
  12. Remove the tape or plug from the opened suction line fitting and the thermostatic expansion valve (TXV) port.
  13. Lubricate a new seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is mad of a special material for the R-134a system. Use only refrigerant oil of the type recommended for this vehicle.
  14. Attach the high-voltage routing clip to the A/C suction line.
  15. Connect the A/C suction line to the HVAC TXV and securely fasten the nut (1).
  16. Raise the vehicle. Refer to STANDARD PROCEDURE .
    Fig 6: Ground Strap Bolt
    GC0157878Courtesy of CHRYSLER GROUP, LLC
  17. Install the ground strap to the electric A/C compressor (EAC) and securely fasten the bolt (1).
    Fig 7: Electric A/C Compressor (EAC) Suction Fitting Nut
    GC0157847Courtesy of CHRYSLER GROUP, LLC
  18. Remove the tape or plugs from the opened suction line fitting and the compressor port.
  19. Lubricate a new seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for this vehicle.
  20. Connect the A/C suction line (1) to the EAC and securely fasten the nut (1).
  21. Lower the vehicle.
  22. Connect the 12-volt negative battery cable and power up the high-voltage system. Refer to ELECTRIC VEHICLE CONTROL SYSTEM, STANDARD PROCEDURE .
  23. Evacuate the refrigerant system. Refer to STANDARD PROCEDURE  .
  24. Adjust the refrigerant oil level. Refer to STANDARD PROCEDURE  .
  25. Charge the refrigerant system. Refer to STANDARD PROCEDURE  .
  26. Install the electric motor trim cover.
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