K 3500 Truck 4WD V8-6.6L DSL Turbo VIN 1 (2001)
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Collision damage
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Leakage in the system
Follow the Straight Line Repair procedure in order to repair the type of damage described above.
If the A/C or heater lines have visible damage or a leak in a bend area, replace the lines. Section the lines in order to obtain the original line shapes.
Maintaining the original line shape will prevent vibrations and rub-through.
Follow the A/C Line Sectioning Repair procedure in order to repair any damage in a bend area.
Straight Line Repair
1. If you are repairing the A/C lines, evacuate, charge and leak test the system. Refer to Refrigerant Recovery and Recharging.
2. If you are repairing the heater lines, drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Locate the area that requires repair.
5. Use a tubing cutter in order to cut the damaged line for repair.
6. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the A/C line.
7. Use the LOK prep sealant in order to prep the A/C line.
8. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line.
9. Install the correct LOK fitting into the jaws:
9.1. Insert the line ends into the LOK fitting.
9.2. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines.
10. Verify that the connector ends are positioned in the counter bores of the jaw.
11. Install the J 41425-1 tool over the connectors and the tubes.
12. Hold the tool body with a 3/8 breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK
fitting.
13. Loosen the forcing screw. Remove the tool from the repaired line.
14. Verify that the LOK fitting is correctly installed.
15. Lower the vehicle.
16. If you drained the cooling system, refill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
17. If you are repairing the A/C lines, recharge and leak test the system. Refer to Refrigerant Recovery and Recharging.
A/C Line Sectioning Repair
1. If you are repairing the A/C lines, evacuate the system. Refer to Refrigerant Recovery and Recharging.
2. If you are repairing the heater lines, drain the cooling system. Refer to Draining and Filling Cooling System Cooling System.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Obtain a new A/C line for sectioning.
5. Scribe a mark on the damaged A/C line that will be cut. Refer to the Minimum Tube Length Required table.
6. Scribe a mark on the new line that will be sectioned.
7. Use a tubing cutter in order to cut both of the A/C lines.
8. Use the cleaning pad from the J41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (0.75 in) from the A/C line.
9. Use the LOK prep sealant in order to prep the A/C line.
10. Apply one drop of the J 41425-3 sealing compound to the outside of each line end.
11. Install the correct LOK fitting into the jaws:
11.1. Insert the line ends into the LOK fitting.
11.2. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines.
12. Verify that the connector ends are positioned in the counter bores of the jaw.
13. Install the J 41425-1 tool over the connectors and the tubes.
14. Hold the tool body with a 3/8 breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the LOK
fitting.
15. Loosen the forcing screw. Remove the tool from the repaired line.
16. Verify that the LOK fitting is correctly installed.
17. Repeat Steps 4-13 for the other end of the repair line.
18. Lower the vehicle.
19. If you drained the cooling system, refill the coolant. Refer to Draining and Filling Cooling System in Cooling System.
20. If you are repairing the A/C lines, recharge and leak test the system. Refer to Refrigerant Recovery and Recharging.
