Air Conditioning Compressor Hose Replacement Gasoline Engines

Tools Required

J 38042 Dual O-Ring Separator

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 negative battery cable.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
3. Remove the grille. Refer to Grille Replacement



4. Remove the bolt.
5. Disconnect the hose assembly from the top of the compressor.
6. Remove the sealing washers.
7. Disconnect the hose assembly from the accumulator using the J 38042 .
8. Remove the O-Ring seals from the accumulator hose.
9. Disconnect the hose assembly from the condenser.
10. Remove the O-ring seal from the condenser hose.
11. Cap or plug all of the open connections.

1. Coat the new O-ring seal with 525 viscosity refrigerant oil.
2. Install the new O-ring seal to the condenser hose.

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 hose assembly to the condenser.

Tighten
Tighten the hose assembly to 45 N·m (33 lb ft).

4. Coat the new dual O-ring seals with 525 viscosity refrigerant oil.
5. Install the new dual O-ring seals to the accumulator hose.
6. Connect the hose assembly to the accumulator.

Tighten
Tighten the hose assembly to 34 N·m (25 lb ft).

7. Install the sealing washers.
8. Connect the hose assembly to the top of the compressor.
9. Install the bolt.

Tighten
Tighten the bolt to 34 N·m (25 lb ft).

10. Install the grille. Refer to Grille Replacement
11. Connect the negative battery cable.
12. Charge the system. Refer to Refrigerant Recovery and Recharging
13. Inspect the system for leaks. Refer to Leak Testing .

Air Conditioning Compressor Hose Replacement Diesel Engines

Tools Required

J 38042 Dual O-Ring Separator

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 negative battery cable.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
3. Remove the grille. Refer to Grille Replacement



4. Remove the bolt.
5. Disconnect the hose assembly from the top of the compressor.
6. Remove the sealing washers.
7. Disconnect the hose assembly from the accumulator using the J 38042 .
8. Remove the O-Ring seals from the accumulator hose.



9. Disconnect the hose assembly from the condenser.
10. Remove the O-ring seal from the condenser hose.
11. Cap or plug all of the open connections.

1. Coat the new O-ring seal with 525 viscosity refrigerant oil.
2. Install the new O-ring seal to the condenser hose.

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 hose assembly to the condenser.

Tighten
Tighten the hose assembly to 45 N·m (33 lb ft).




4. Coat the new dual O-ring seals with 525 viscosity refrigerant oil.
5. Install the new dual O-ring seals to the accumulator hose. Refer to Servicing Dual O-Ring Seals.
6. Connect the hose assembly to the accumulator.

Tighten
Tighten the hose assembly to 34 N·m (25 lb ft).

7. Install the sealing washers.
8. Connect the hose assembly to the top of the compressor.
9. Install the bolt.

Tighten
Tighten the bolt to 34 N·m (25 lb ft).

10. Install the grille. Refer to Grille Replacement
11. Connect the negative battery cable.
12. Charge the system. Refer to Refrigerant Recovery and Recharging
13. Inspect the system for leaks. Refer to Leak Testing .