Air Conditioning (A/C) Coupling Assembly Replacement High Pressure

Special Tools

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement.



3. Remove the A/C coupling (2, 3) from the evaporator hose (4).



4. Remove the sealing valve (1) from the A/C coupling (2).



5. Remove the sealing valve (1) from the A/C coupling (2).

1. Coat the new sealing valves with PAG oil.



2. Install the sealing valve (1) to the A/C coupling (2).



3. Install the sealing valve (1) to the A/C coupling (2).

Caution: Refer to Fastener Caution in the Preface section.




4. Install the A/C coupling (2, 3) to the evaporator hose (4).

Tighten
Tighten the fittings to 35 N·m (26 lb ft).

5. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
7. Leak test the fittings of the components using the J 39400-A .

Air Conditioning (A/C) Coupling Assembly Replacement Low Pressure

Special Tools

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Remove the air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Assembly Replacement for the 6.6L engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Air Cleaner Replacement for the 7.2L (Caterpillar) engine

3. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement.
4. Remove the evaporator outlet tube. Refer to Air Conditioning Evaporator Hose Assembly Replacement.



5. Remove the air conditioning (A/C) coupling (2, 4) from the evaporator tube (1, 3).



6. Remove the sealing valve (1) from the A/C coupling (2).



7. Remove the sealing valve (1) from the A/C coupling (2).

1. Coat the new sealing valves with polyalkylene glycol (PAG) oil.



2. Install the sealing valve (1) to the A/C coupling (2).



3. Install the sealing valve (1) to the A/C coupling (2).

Caution: Refer to Fastener Caution in the Preface section.




4. Install the A/C coupling (2, 4) to the evaporator tube (1, 3).

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

5. Install the evaporator outlet tube. Refer to Air Conditioning Evaporator Hose Assembly Replacement.
6. Install the air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Assembly Replacement for the 6.6L engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Air Cleaner Replacement for the 7.2L (Caterpillar) engine

7. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement.
8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
9. Leak test the fittings of the components using the J 39400-A .