This procedure covers the removal and installation of AC hose assemblies on the 2018-2024 Toyota Camry 2.5L I4, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly (specify high side, low side, or suction/discharge) × 1 — Use OEM specification
• AC line O-rings (various sizes) × 4 — Use OEM specification
• PAG oil (ND-11 for R-1234yf or ND-12 for R-134a) × 1 — Use OEM specification
• R-134a or R-1234yf refrigerant × 1 — Check underhood label for type and capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Verify refrigerant type from underhood AC specification label
4. Ensure AC recovery/recharge machine is certified and properly calibrated for the refrigerant type in your vehicle
5. Prepare new O-rings and PAG oil for installation
6. Identify which AC hose assembly needs replacement (suction line from evaporator to compressor, discharge line from compressor to condenser, or liquid line from condenser to expansion valve)

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports (low side on suction line, high side on discharge line). Follow machine instructions to recover all refrigerant from the system. Record amount recovered for recharge reference. Once recovery is complete, allow system to equalize for 5 minutes and verify no residual pressure remains.
   ⚠️Never open AC fittings while system is pressurized. Ensure complete refrigerant recovery before proceeding.
2. 2

   Access the AC hose assembly
   For suction/discharge hoses at compressor: Remove engine under cover if equipped using 10mm bolts. For hoses at condenser: Access from front of vehicle, may require removal of front bumper cover or grille depending on specific hose location. For hoses at evaporator: Access from engine bay firewall area, remove any interfering components such as air intake ducts or battery if necessary.
   ℹ️Document routing of AC hoses and nearby wiring/components before removal to ensure proper reinstallation.
3. 3

   Disconnect AC hose at first connection point
   Using appropriate flare nut wrench, loosen AC line fitting at first connection point. Remove bolt or fitting completely. Cap or plug open port immediately to prevent moisture and debris contamination. Use drain pan to catch any residual oil. Remove and discard old O-rings from both male and female fittings using O-ring pick.
   ⚠A small amount of refrigerant oil will drain from opened fittings. Measure and record amount lost to maintain proper oil level during recharge.
   Torque spec

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

   Disconnect AC hose at second connection point
   Repeat disconnection process at opposite end of hose assembly. Use flare nut wrench to prevent rounding of fitting. Remove mounting brackets or clips securing hose to body or engine if present. Note routing and position of any protective sleeves or grommets. Cap open ports immediately.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove AC hose assembly
   Carefully extract AC hose assembly from vehicle, noting routing path through engine bay. Remove any remaining mounting brackets or support clips. Inspect removed hose for damage, leaks, or signs of excessive wear to confirm replacement necessity. Measure and record any residual oil that drains during removal.
   ℹ️Take photos of hose routing before complete removal to aid in installation of new hose.
6. 6

   Inspect connection points and clean fittings
   Inspect all connection ports for damage, corrosion, or debris. Clean fitting surfaces with clean, lint-free cloth. Check threads for damage or cross-threading. Verify O-ring sealing surfaces are smooth and free of scratches. Replace any damaged components before installing new hose.
   ⚠Do not use compressed air to clean AC fittings as this introduces moisture into the system.
7. 7

   Prepare new AC hose assembly
   Unpack new AC hose assembly and verify correct part number and configuration. Install new O-rings on all connection points. Lightly coat new O-rings with appropriate PAG oil (ND-11 for R-1234yf or ND-12 for R-134a). Add specified amount of PAG oil to new hose assembly per service information, typically 10-20ml depending on hose being replaced.
   ⚠Use only fresh PAG oil from sealed container. PAG oil is hygroscopic and absorbs moisture from air rapidly once opened.
8. 8

   Route and position new AC hose assembly
   Route new AC hose assembly through engine bay following original path documented during removal. Ensure hose does not contact hot surfaces (exhaust manifold, engine block), sharp edges, or moving components. Position protective sleeves and grommets as original. Install mounting brackets or support clips loosely to allow final positioning adjustment.
   ⚠Maintain minimum 25mm clearance between AC hoses and exhaust components to prevent heat damage.
9. 9

   Connect AC hose at first fitting
   Remove cap from port. Verify O-ring is properly seated in fitting groove and coated with PAG oil. Hand-thread fitting into port, ensuring alignment to prevent cross-threading. Once hand-tight, use torque wrench and appropriate socket or flare nut wrench to tighten to specification. Do not over-torque as this will damage O-rings and cause leaks.
   ⚠Start threads carefully by hand. Cross-threading aluminum AC fittings will require costly component replacement.
   Torque spec

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

    Connect AC hose at second fitting
    Repeat connection process at opposite end. Ensure no tension or twisting is placed on hose during tightening. Adjust routing slightly if needed before final torque. Tighten to specification using torque wrench. Verify both connections are secure and hose routing is free of kinks or sharp bends.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Secure mounting brackets and verify routing
    Tighten all mounting brackets and support clips. Verify AC hose has proper clearance from all moving parts, hot surfaces, and sharp edges. Check that hose does not interfere with hood closure, belt operation, or cooling fan rotation. Reinstall any components removed for access such as air intake, under covers, or grille.
    Torque spec

    Mounting Bracket Bolts24 Nm (18 lb-ft)
12. 12

    Evacuate AC system
    Connect vacuum pump to AC system service ports. Evacuate system to 29 inches Hg (98 kPa) vacuum. Maintain vacuum for minimum 30 minutes (45 minutes preferred in humid conditions). Monitor vacuum gauge for decay. If vacuum holds steady, system is leak-free. If vacuum decays, locate and repair leak before proceeding.
    ⚠Proper evacuation removes air and moisture from system. Insufficient evacuation will cause poor AC performance and compressor damage.
13. 13

    Recharge AC system
    Using AC recharge machine, charge system with correct refrigerant type and amount as specified on underhood label (typically 425-475g for R-1234yf or 550-625g for R-134a, verify exact specification). Add additional PAG oil if total oil removed during service exceeds amount added to new hose. Follow recharge machine instructions for proper charging procedure.
    ⚠Overcharging or undercharging AC system will cause poor performance and potential compressor damage. Use precise charging equipment and follow label specifications exactly.
14. 14

    Leak test and verify operation
    Start engine and turn AC to maximum cooling. Verify compressor engages and AC operates normally. Use electronic leak detector to check all connections for leaks. Monitor system pressures with manifold gauges to verify normal operation (low side 25-35 psi, high side 180-250 psi at idle with 95°F ambient, values vary with temperature). Verify cold air output from vents.
    ℹ️Allow system to run for 10-15 minutes before final leak check to ensure fittings are fully pressurized and at operating temperature.

Reassembly

1. Reinstall all engine covers, grilles, or bumper components removed for access
2. Verify hood closes properly without interference from AC hoses
3. Double-check all AC line fittings for proper torque and leak-free connections
4. Confirm no tools or parts were left in engine bay

Verification

• Start engine and operate AC system for 15 minutes, verifying consistent cold air output
• Check all AC line connections for leaks using electronic leak detector
• Verify AC system pressures are within normal range using manifold gauges
• Confirm no unusual noises from compressor or AC components
• Test AC operation in both recirculation and fresh air modes
• Verify vent temperature reaches 40-50°F with outside temperature above 80°F
• Inspect for any refrigerant oil leaks at connections after test drive

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