AC Hose Assembly

This procedure covers the removal and installation of the AC hose assembly on a 2005 Dodge Viper, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM specification for specific line being replaced
• AC O-ring kit × 1 — Use OEM specification
• PAG oil (for AC system) × 1 — PAG 46 or per compressor specification

Fluids

• R-134a refrigerant

Preparation

1. Park vehicle on level ground and set parking brake
2. Allow engine to cool completely (minimum 2 hours after operation)
3. Disconnect negative battery cable
4. Verify you have the correct replacement AC hose assembly for your specific routing (consult factory service manual for hose identification)
5. Recover all AC refrigerant using approved recovery equipment per EPA regulations

Procedure

1. 1

   Locate and identify the AC hose assembly
   Identify which AC hose assembly requires replacement. The 2005 Viper has multiple AC lines: suction line (low pressure, larger diameter), discharge line (high pressure from compressor), and liquid line (from condenser to evaporator). Common replacement is the discharge line from compressor to condenser. Trace the routing and note any brackets or clips securing the hose along its path.
2. 2

   Remove hose mounting brackets
   Locate all mounting brackets or clips securing the AC hose to the engine bay or chassis. The discharge line typically has 2-3 mounting brackets along its routing. Remove the fasteners securing these brackets. Note the exact position of each bracket for reinstallation.
3. 3

   Disconnect hose at compressor fitting
   Using a flare nut wrench to prevent rounding, loosen the AC line fitting at the compressor. The fitting type must be confirmed for this vehicle; it may be a spring-lock coupling, a threaded flare nut fitting, or a block/peanut style fitting secured by a single bolt. Identify the type before selecting tools. If spring-lock type, use the appropriate disconnect tool. If threaded, carefully loosen and remove. Cap or plug the compressor port immediately to prevent contamination and moisture entry. Remove and discard the O-rings from the fitting.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Disconnect hose at condenser or evaporator fitting
   Locate the opposite end of the hose assembly (typically at the condenser for discharge lines, or at the evaporator inlet for liquid lines). Using a flare nut wrench, carefully loosen and disconnect the fitting. Cap or plug this port immediately to prevent contamination. Remove and discard the O-rings from this fitting as well.
5. 5

   Remove the AC hose assembly
   Carefully route the old AC hose assembly out of the engine bay, noting its exact path through any brackets, clips, or routing channels. Pay attention to how the hose is positioned relative to other components to avoid interference during reinstallation. Inspect the old hose for signs of damage, abrasion, or oil residue that might indicate the failure point.
6. 6

   Prepare new AC hose assembly
   Unpack the new AC hose assembly and verify it matches the old hose in length, fitting types, and configuration. Install new O-rings on both fittings of the new hose (these should be included with quality replacement hoses). Lightly coat the new O-rings with the appropriate PAG oil specified for your compressor type (verify the correct PAG viscosity against the compressor label or factory service manual). This lubricates the O-rings and ensures proper sealing.
7. 7

   Route new hose assembly
   Route the new AC hose assembly through the engine bay following the exact path of the original hose. Ensure the hose does not contact any sharp edges, exhaust components, or moving parts. The hose should have adequate clearance from the engine and not be kinked or stressed at any point in its routing.
8. 8

   Connect hose at first fitting
   Remove the cap from the compressor port. Verify the new O-ring is properly seated in the hose fitting. Thread the fitting onto the compressor port by hand until finger-tight, ensuring it threads smoothly without cross-threading. Using a torque wrench and flare nut wrench, tighten the fitting to specification.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
9. 9

   Connect hose at second fitting
   Remove the cap from the condenser or evaporator port. Verify the new O-ring is properly seated. Thread the fitting by hand until finger-tight, ensuring proper alignment and no cross-threading. Using a torque wrench and flare nut wrench, tighten the fitting to specification.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reinstall mounting brackets
    Reinstall all mounting brackets and clips in their original positions. Ensure the hose is properly secured and supported along its entire length to prevent vibration damage. The hose should not be under tension or compression at any bracket location.
11. 11

    Add refrigerant oil
    Add the appropriate amount of fresh PAG oil to the AC system to replace what was lost with the old hose and during recovery. Consult the factory service manual for the exact PAG oil quantity to add for this hose; a small amount (roughly the volume lost with the removed component) is typical, but verify before adding. Consult factory service manual for exact quantity. Add the oil through the compressor service port or using the AC machine's oil injection feature.
12. 12

    Evacuate AC system
    Connect the AC manifold gauge set to the service ports. Using an AC vacuum pump, evacuate the system to at least 29 inches of mercury (Hg) vacuum. Hold this vacuum for at least 30 minutes to ensure there are no leaks and to remove all moisture from the system. If the vacuum does not hold, there is a leak that must be found and corrected.
13. 13

    Recharge AC system
    After successful evacuation, recharge the AC system with the specified amount of R-134a refrigerant according to the underhood label specifications. The exact R-134a charge for the 2005 Viper must be verified with the specific underhood label on your vehicle or the factory service manual before charging, as the correct capacity cannot be assumed. Charge through the low-side service port with the engine running and AC on maximum.
14. 14

    Reconnect battery and test system
    Reconnect the negative battery cable. Start the engine and activate the AC system. Monitor the manifold gauge pressures to verify proper system operation. Low side pressure should typically be 25-35 psi and high side pressure should be 200-250 psi with ambient temperature around 70-80°F. Verify cold air output from cabin vents.

Reassembly

1. Ensure all mounting brackets are properly secured and the AC hose has adequate clearance from all moving parts and hot surfaces
2. Double-check all fittings are torqued to specification to prevent refrigerant leaks
3. Verify refrigerant charge matches the specification on the underhood label
4. If adding UV dye for future leak detection, add the appropriate amount during the recharge process

Verification

• Start engine and run AC system on maximum cold setting for at least 10 minutes
• Verify cold air output from all cabin vents (vent temperature should be 40-50°F with ambient temperature around 75°F)
• Check all AC line fittings for signs of refrigerant leaks using electronic leak detector or soap solution
• Monitor AC system pressures with manifold gauges to ensure they remain stable and within specification
• Verify compressor clutch engages and disengages properly without unusual noises
• Inspect the new hose routing to ensure no contact with moving parts or excessive heat sources
• Road test the vehicle and verify AC performance under various operating conditions

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