Tools Required

J 39400-A Halogen Leak Detector

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable.
2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .



3. Remove the compressor suction/discharge hose assembly bolt and the washer.
4. Remove the compressor suction/discharge hose assembly from the compressor.
5. Remove the sealing washers.



6. Remove the compressor suction hose assembly from the accumulator.
7. Remove the O-ring seal and discard.



8. Remove the battery tray. Refer to Battery Tray Replacement in Engine Electrical.
9. Disconnect the evaporator tube assembly from the two clips located on top of the radiator shroud.
10. Remove the evaporator tube assembly from the condenser.
11. Remove the O-ring seal and discard.

1. Install a new O-ring seal. Refer to O-Ring Replacement in Heating,Ventilation and Air Conditioning.




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. Install the evaporator tube assembly to the condenser.

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

3. Install the evaporator tube assembly to the two clips located on top of the radiator shroud.
4. Install the battery tray. Refer to Battery Tray Replacement in Engine Electrical.
5. Install a new O-ring seal. Refer to O-Ring Replacement in Heating,Ventilation and Air Conditioning.



6. Install the compressor suction hose assembly to the accumulator.

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

7. Install the sealing washers. Refer to Compressor Sealing Washers Replacement .



8. Install the compressor suction/discharge assembly to the compressor.
9. Install the compressor suction/discharge hose assembly washer and the bolt.

Tighten
Tighten the bolt to 33 N·m (24 lb ft).

10. Connect the negative battery cable.
11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .