Special Tools

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .



3. Remove the auxiliary evaporator hose nuts (1) from the main evaporative hose connections.
4. Separate auxiliary evaporator hoses (3) and O-rings (2).



5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the right assist step if necessary. Refer to Assist Step Replacement .
7. Remove the front wheelhouse liner if necessary. Refer to Wheelhouse Panel Replacement .
8. Remove the auxiliary A/C tubes connector nuts (1) from the intermediate connection point.



9. Remove the auxiliary A/C tubes clip push pins (1) from vehicle frame locations.
10. Remove the auxiliary A/C tubes (2) from vehicle.



11. Remove auxiliary A/C tubes clip retaining push pin/bolt (1) if necessary.
12. Use a flat-bladed release tool to open retaining clips (2).
13. Remove auxiliary A/C tubes from vehicle.

Important: The replacement A/C and heater pipes are shipped in front and rear sections.

1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2).
2. Install the auxiliary A/C evaporator tubes (3) to the vehicle.



3. Install the auxiliary A/C tubes clip push pins (1) to vehicle frame locations.



4. Install new O-rings with replacement auxiliary A/C tubes. Refer to O-Ring Replacement .

Notice: Refer to Fastener Notice in the Preface section.

Important: Use a adjustable wrench or equivalent holding tool at tube connections to prevent twisting.

Important: Mandatory torque sequence required for proper connections.

5. Install the auxiliary A/C tube connection nuts (1) to the intermediate connection point.

Tighten
Tighten the nuts to 16 N·m (12 lb ft).

6. Install the right assist step if necessary. Refer to Assist Step Replacement .
7. Lower the vehicle.



8. Install new O-rings with replacement auxiliary A/C tubes. Refer to O-Ring Replacement .
9. Install the auxiliary evaporator hose nuts (1) to the main evaporative hose connections.

Tighten
Tighten the nuts to 16 N·m (12 lb ft).

10. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
11. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings of the component using the J 39400-A .