Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the upper diagonal brace from the left front fender. Refer to Front Fender Upper Diagonal Brace Replacement in Body Front End.
3. Remove the air cleaner assembly. Refer to the following procedures:

•	Air Cleaner Assembly Replacement in Engine Controls - 3.1L

•	Air Cleaner Assembly Replacement in Engine Controls - 3.8L

4. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
5. Remove the accumulator tube clip.



6. Disconnect the evaporator inlet tube nut from the condenser tube.
7. Disconnect the evaporator inlet tube from the condenser tube.



8. Remove the evaporator tube to evaporator block fitting bolt.

Important: Remove the evaporator tube carefully.

9. Disconnect the evaporator inlet tube from the evaporator.
10. Remove the O-ring and discard.

Important: Coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.

1. Install the new O-ring seals on to the evaporator tube. Refer to O-Ring Replacement .
2. Connect the evaporator inlet tube to the condenser tube.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Connect the inlet tube to the evaporator.
4. Install the outlet tube to the evaporator block fitting.
5. Install the evaporator block fitting bolt to the evaporator.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).




6. Connect the evaporator tube to the condenser tube.
7. Tighten the evaporator tube nut.

Tighten
Tighten the nut to 27 N·m (20 lb ft).

8. Install the accumulator tube clip.
9. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
10. Install the air cleaner assembly. Refer to the following procedures:

•	Air Cleaner Assembly Replacement in Engine Controls - 3.1L

•	Air Cleaner Assembly Replacement in Engine Controls - 3.8L

11. Install the upper diagonal brace to the left front fender. Refer to Front Fender Upper Diagonal Brace Replacement in Body Front End.
12. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
13. Leak test the fittings of the component using J 39400-A .