Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to one of the following procedures:

•	Air Cleaner Assembly Replacement in Engine Controls-3.4L

•	Air Cleaner Assembly Replacement in Engine Controls-3.8L

3. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
4. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
5. Remove the bracket to the evaporator tube/suction hose.
6. Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling.



7. Loosen the tube nut at the condenser. Disconnect the tube from the condenser.
8. Lower the vehicle.
9. Disconnect the electrical connector from the A/C refrigerant pressure sensor.



10. Loosen the evaporator inlet tube nut. Disconnect the evaporator tube from the condenser tube.

Important: Handle the condenser tube carefully.

11. Remove the condenser tube.
12. Remove and discard the O-ring.
13. Remove the A/C pressure sensor from the condenser tube.

1. Install the A/C pressure sensor to the condenser tube.

Important: Coat the new O-ring with mineral base 525 viscosity refrigerant oil.

2. Install the new O-ring onto the condenser tube. Refer to O-Ring Replacement .
3. Install the condenser tube into place.
4. Connect the evaporator inlet tube to the condenser tube.




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.

5. Tighten the evaporator inlet tube nut.

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

6. Install the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling.
7. Connect the electrical connector to the A/C refrigerant pressure sensor.



8. Connect the condenser tube to the condenser. Tighten the condenser tube nut.

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

9. Lower the vehicle.
10. Install the bracket to the evaporator tube/suction hose.
11. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
12. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
13. Install the air cleaner assembly. Refer to one of the following procedures:

•	Air Cleaner Assembly Replacement in Engine Controls-3.4L

•	Air Cleaner Assembly Replacement in Engine Controls-3.8L

14. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
15. Leak test the fittings of the component using J 39400-A .