Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
3. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
4. Remove the washer bottle. Refer to Windshield Washer Solvent Container and Pump Replacement .
5. Remove the battery. Refer to Battery Replacement .
6. Remove the battery box bolts from the battery box.
7. Disconnect the negative battery cable nut from the wheelhouse.



8. Remove the nut retaining the liquid line to the strut tower.
9. Disconnect the harness and vent hose retainers from the liquid line.



10. Remove the evaporator outlet hose and liquid line retainer plate nut from the thermal expansion valve (TXV).
11. Remove the evaporator outlet hose and liquid line from the TXV.



12. Remove the liquid line nut from the condenser.
13. Remove the liquid line from the condenser.



14. Remove the bolt retaining the liquid line to the body.



15. Position the battery box inboard to allow for routing of the liquid line.
16. Route the liquid line above the battery box and the ground lug.
17. Lift the rear portion of the liquid line upward and remove the liquid line from the vehicle.
18. Remove and discard the sealing washer from the liquid line. Refer to Sealing Washer Replacement .
19. Install protective caps to the condenser, the evaporator outlet hose, and the TXV to prevent contamination and desiccant saturation.

1. Route the liquid line below the battery box and the ground lug.

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.

2. Connect the negative battery cable nut to the wheelhouse.

Tighten
Tighten the nut to 12 N·m (106 lb in).




3. Remove the protective caps from the condenser, the evaporator outlet hose, and the TXV.
4. Install the new sealing washer to the liquid line. Refer to Sealing Washer Replacement .
5. Route the condenser end of the liquid line into position.
6. Install the liquid line to the condenser.

Important: Use a large pair of pliers to hold the fitting while tightening the nut. Be careful not to twist the line.

7. Install the liquid line nut to the condenser.

Tighten
Tighten the nut to 22 N·m (16 lb ft).




8. Install the bolt to retain the liquid line to the body.

Tighten
Tighten the nut to 9 N·m (80 lb in).




9. Remove the protective cap from the TXV, the liquid line, and the evaporator outlet hose.
10. Install new seal washers to the liquid line and the evaporator outlet hose. Refer to Sealing Washer Replacement .
11. Install the liquid line and the evaporator outlet hose to the TXV.
12. Install the liquid line and evaporator outlet hose retainer plate nut to the TXV.

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




13. Install the four battery box bolts to the inside of the battery box.

Tighten
Tighten the nut to 15 N·m (11 lb ft).

14. Install the battery box bolt to the outside of the battery box.

Tighten
Tighten the nut to 10 N·m (86 lb in).

15. Install the battery. Refer to Battery Replacement .



16. Install the liquid line to the strut tower.
17. Install the liquid line nut to the strut tower.

Tighten
Tighten the nut to 9 N·m (80 lb in).

18. Connect the harness and vent hose retainers to the liquid line.
19. Install the surge tank. Refer to Radiator Surge Tank Replacement .
20. Install the washer bottle. Refer to Windshield Washer Solvent Container and Pump Replacement .
21. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
22. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
23. Test the affected A/C joints for leaks using J 39400-A .