DIY: Repair Damaged AC Lines Because by Aftermarket Intakes
 

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:

Attachment 70683

It is located under the drivers side intake.

http://img.tapatalk.com/d/13/06/09/bujubaba.jpg



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: http://www.the370z.com/diy-section-d...r-removal.html

Attachment 70684


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

Attachment 70685

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

Attachment 70686

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

Attachment 70687

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

Attachment 70688

Close up shows a tiny little hole.

Attachment 70696

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

Attachment 70689

Use a 10mm closed wrench to loosen the bolts.

Attachment 70690

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

Now remove this bolt.

Attachment 70691

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

Attachment 70692

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.

Attachment 70693

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".

Attachment 70694

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

Attachment 70695

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

Simply reattach everything going in reverse order.

Attachment 70697

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

Attachment 70698


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

Attachment 70699

Attachment 70700

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

Attachment 70701

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

Then take it to your dealer to get recharged.

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.

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

Yeah it does and you're welcome!

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

DIY: Repair Damaged AC Lines Because by Aftermarket Intakes
 

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...

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.

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

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

let me know

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

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

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

Yea I'm slow. Glad you found it :tup: 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.

did u guys replace the o-rings too