Auxiliary Air Conditioning Evaporator Rear Tube Replacement Liquid Line

J 39400-A Halogen Leak Detector

1. Recover the A/C system. Refer to Refrigerant Recovery and Recharging .



2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the engine exhaust. Refer to Exhaust System Replacement .
4. Remove the auxiliary rear liquid line nut from the auxiliary evaporator.
5. Disconnect the auxiliary rear liquid line from the auxiliary evaporator.



6. Loosen the auxiliary rear liquid line to the auxiliary front liquid line fitting (1).
7. Remove the auxiliary rear liquid line from the body retainers.
8. Remove the auxiliary rear liquid line from the vehicle.
9. Remove and discard the O-rings from the auxiliary rear liquid line.

1. Install new O-rings to the auxiliary rear liquid line . Refer to O-Ring Replacement .
2. Install the auxiliary rear liquid line to the vehicle.
3. Install the auxiliary rear liquid line to the body retainers.
4. Connect the rear auxiliary A/C line to the front auxiliary front liquid line.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the liquid line fitting (1).

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

6. Connect the auxiliary rear liquid line to the auxiliary evaporator.



7. Install the auxiliary rear liquid line nut to the auxiliary evaporator.

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

8. Install the engine exhaust. Refer to Exhaust System Replacement .
9. Lower the vehicle.
10. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
11. Leak test the fittings of the components using J 39400-A .

Auxiliary Air Conditioning Evaporator Rear Tube Replacement Suction Line

Tools Required

Important: The auxiliary rear suction line must be sectioned for removal.

1. Recover the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the engine exhaust. Refer to Exhaust System Replacement in Engine Exhaust.
4. Remove the LH rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Remove the auxiliary rear liquid line nut from the auxiliary evaporator.
6. Disconnect the auxiliary rear liquid line from the auxiliary evaporator.
7. Disconnect the auxiliary rear liquid line from the body retainers and reposition the line aside.



8. Remove the auxiliary rear suction line nut from the auxiliary evaporator.
9. Disconnect the auxiliary rear suction line from the auxiliary evaporator.
10. Remove the auxiliary rear suction line from the body retainers.




Important: The auxiliary rear suction line splice area is located through the LH rear wheelhouse opening.

11. Locate the area where the auxiliary rear suction line will be cut.
12. Measure approximately 150 mm (5.9 in) from the sharp bend (a) on the auxiliary rear suction line.
13. Use a tubing cutter in order to cut the auxiliary rear suction line.



14. Loosen the auxiliary rear suction line to the auxiliary front suction line fitting (1).
15. Remove the auxiliary rear suction lines from the vehicle.
16. Remove and discard the O-rings from the auxiliary rear liquid lines.

Important: The length of the replacement line must be the same as the section being replaced.

1. If replacing a section of the auxiliary rear suction line, the replacement line must be the same length as the original line.
2. Use a tubing cutter in order to cut the replacement line to length.



3. Install new O-rings to the auxiliary rear suction lines . Refer to O-Ring Replacement .
4. Install the auxiliary rear suction lines to the vehicle.
5. Connect the rear auxiliary A/C line to the front auxiliary front suction line.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the auxiliary front suction line fitting (1).

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

7. Use the cleaning pad from the J 41425 in order to clean any burrs or grease from the auxiliary rear suction line ends. Be sure to clean at least 19 mm (0.75 in) from the line ends.
8. Use the LOK prep sealant in order to prep the line ends.
9. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line.

Important: Use the 5/8 in connector to splice the forward and rearward auxiliary rear suction lines together.

10. Insert the line ends into the LOK fitting.
11. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines.
12. Install the correct LOK fitting jaws into the J 41425-1 tool.
13. Install the J 41425-1 tool over the LOK connectors.

Verify that the LOK connector ends are positioned in the counter bores of the jaws.

Important: The lines must be inserted fully into the connector to obtain a leak free joint.

14. Hold the J 41425-1 tool body with a 3/8 in breaker bar.
15. Tighten the forcing screw of the J 41425-1 tool.

When fully seated, the LOK connector collars will bottom out on the center shoulder of the LOK fitting.

16. Loosen the forcing screw and remove the J 41425-1 tool from the line.
17. Verify that the LOK fittings are correctly installed.



18. Connect the rearward section of the auxiliary rear suction line to the auxiliary evaporator.
19. Install the auxiliary rear suction line nut to the auxiliary evaporator.

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

20. Install the auxiliary rear suction line to the body retainers.



21. Connect the auxiliary rear liquid line to the auxiliary evaporator.
22. Install the auxiliary rear liquid line nut to the auxiliary evaporator.

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

23. Install the auxiliary rear liquid line to the body retainers.
24. Install the LH rear wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
25. Install the engine exhaust. Refer to Exhaust System Replacement in Engine Exhaust.
26. Lower the vehicle.
27. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
28. Leak test the fittings of the components using J 39400-A .