DIY: Repair Damaged AC Lines Because by Aftermarket Intakes

diddy535

Disclaimer #1
The damaged caused to my car was in NO WAY SHAPE OR FORM Stillen's fault. Their instructions call for a piece of silicone hose which apparently they provide to avoid this issue all together. My problem was I bought the car used and whoever installed the Stillen Gen 3 intakes neglected to put the piece of hosing there. Shame on them and shame on me for not knowing to check for it.

Disclaimer #2
YOU are responsible for making sure that all the refrigerant (r134a, freon, whatever you call it) from your car is properly recaptured and removed. It is a felony to release this material improperly without recapturing it.

Nissan quotes this install as a 4-5 hour job. The part you need is only $27 on Courtesy Parts, found here: http://www.courtesyparts.com/92446a-...-p-620126.html

The part is found highlighted in red here:

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It is located under the drivers side intake.





The repair can be found in the service manual which you can download from this forum. For the 2009 370z it is found in the PDF named "HA" on page 40.

On to the repair.

First you'll need to remove your front bumper, thanks to DIGItonium for making one: DIY: Front Bumper Removal

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Following the bumper removal take this plastic piece off by removing the clips, they can be found highlighted in red.

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I also had to remove this metal piece I which the front wiring is connected in order to reach the intake.

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This shows the Stillen intake pipe that was rubbing against the AC line.

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Once removed you can no plainly see the damaged AC line.

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Close up shows a tiny little hole.

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Now remove the two red 10mm bolts highlighted in red.

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Use a 10mm closed wrench to loosen the bolts.

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Once loose, you can use a long screwdriver to get down and finish removing those bolts.

Now remove this bolt.

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Now use a quick disconnect tool to remove the two lines found here:

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There's a great two and a half minute video here on how to handle those connections.

http://youtu.be/DKgQJ-RinXc

You need to pick up some quick disconnect parts from your local auto store.

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The line on top used a 1/2" piece to remove it.

For the bottom line I used this metal tool (as seen in the YouTube video) using the smallest size "D".

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You have to use the plastic tool for the top one because there is just no room in there for the metal tool.

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Now get your part that you ordered, it's two separate lines but they come together.

Simply reattach everything going in reverse order.

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These quick disconnect points simply connect back in together by being pushed.

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Secure the two bolts from earlier that connects to the radiator.

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Wrap silicone hose around the AC lines where they lay underneath the I take piping.

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Put the intake back in, your bumper back on and you're good to go!

Then take it to your dealer to get recharged.

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