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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diddy535

Be careful not to over torque the screws, since the threads are aluminum they can strip easily. If you do strip, go to Home Depot, get a longer bolt and nut and "sandwich" the pieces together with the bolt head on top and nut on bottom.

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350izh

Thanks for writing this up, I have encountered the same problem on. Mine may have the two lines there punctured. Does the kit you bought include both lines ??? Thanks for any help this is going to save me money big time

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My 370z
r35 Hood CF/Black fangs/Glossy black OEM sports wheels/Stillen G3 intakes/Tein Lowering Springs

diddy535

Yeah it does and you're welcome!

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350izh

Hey how much did the dealer charge you to refill ac lines, they just quoted me 230!

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My 370z
r35 Hood CF/Black fangs/Glossy black OEM sports wheels/Stillen G3 intakes/Tein Lowering Springs

diddy535

I honestly don't know. I first took it to an unnamed dealer (not Lou which was my first mistake) and they worked on it for 3 hrs not finding a leak. So since there was no broken part that they could see, I got stuck with the bill. It was recharged and a week later no AC. Once I took it to Lou they figured out what was going on and after i decided to fix it, i took it back to this unnamed dealer and had them recharge it for free since I already paid for 3 hours of labor that did nothing. $230 seems high, but you saved so much from doing it yourself already - I wouldn't go with one of those autozone recharge cans...

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wsarver

Thank you for this thread Diddy +1. I got this line replaced because mine blew as well and from Stillen g3 intakes. I'll insulate the lines asap.
EDIT: I also purchased pre-owned and had no idea this would happen. No fault on Stillen.

kdawg8526

just had this happen on my g37 does anyone know what the p/n is for the line that's right beside it because both mine got damaged from intake

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wsarver

I will look when I get home from work. I think I still have the service paperwork.

kdawg8526

let me know

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kdawg8526

nevermind found out I don't need the part number listed above. turned out I rubbed on the line that goes by the radiator p/n 92446-jk20b

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martin82

I refilled mine with from a kit from pepboys w gauge and can for about $80 dollars works perfect don't waste ur money

kdawg8526

I have a buddy that's gonna hook me up with ac recharge

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wsarver

Yea I'm slow. Glad you found it Looking at it again I think I would try the refill kit on my own to save a few bucks. I was just at the mercy of time. I had to have it done asap as its my daily driver and temps are hitting 95 daily. I hate Florida temps. I just couldn't show up at the office soaked with sweat every morning.

kdawg8526

did u guys replace the o-rings too

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