J 39400-A Electronic Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the upper tie bar support brace bolts at the upper tie bar.
3. Loosen the support brace bolts at the headlamp and bumper fascia mounting panel and position out of the way.



4. Remove the upper radiator seal.



5. Remove the upper radiator mounting brackets.



6. Disconnect the compressor hose from the condenser.
7. Remove the front headlamps. Refer to Headlamp Replacement in Lighting Systems.



8. Disconnect the evaporator hose from the condenser.



9. Remove the fasteners (1) from the left and right sides of the headlamp and bumper fascia mounting panel.
10. Lift the headlamp and bumper fascia mounting panel and pull forward in car to obtain access to the condenser mounting bolts.

Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

11. Remove the two condenser to radiator mounting bolts.
12. Separate the condenser from the radiator by lifting out of the lower mounting tabs.
13. Disconnect and remove the coolant sensor. (RPO UB7 only.)



14. Remove the two A/C condenser seals (1).
15. Lift the condenser up and remove from the vehicle.

1. Fill the new condenser with the proper amount of refrigerant oil. Refer to Refrigerant Oil Distribution.
2. Position the condenser into the vehicle.
3. Install and connect the low coolant sensor and wiring harness.
4. Install the condenser into the lower radiator mounting tabs.

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.

Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

5. Install the condenser mounting bolts.

Tighten
Tighten the connections to 6 N·m (53 lb in).




6. Install the new A/C condenser seals (1).



7. Reposition the headlamp and bumper fascia mounting panel and install the fasteners (1).

Tighten
Tighten the nut and bolt to 9 N·m (7 lb ft).

Important: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.
Flat washer type seals do not require lubrication.



8. Install the evaporator hose and nut to the condenser.

Tighten
Tighten the nut to 20 N·m (15 lb ft).




9. Install the compressor hose and nut to the condenser.

Tighten
Tighten the nut to 20 N·m (15 lb ft).




10. Install the upper radiator mounting brackets and bolts.

Tighten
Tighten the bolts to 9 N·m (7 lb ft).




11. Install the upper radiator seal.
12. Install the front fascia to tie bar support brackets and bolts.

Tighten
Tighten the bolts to 9 N·m (7 lb ft).

13. Install the front headlamps. Refer to Headlamp Replacement in Lighting Systems.
14. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
15. Test the A/C system for leaks using the J 39400-A . Refer to Leak Testing .