Special Tools

J 39400-A Halogen Leak Detector

Note: The desiccant is inside the condenser and is not serviced separately. The condenser must be replaced if new desiccant is required.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the left and right headlamp assembly. Refer to Headlamp Replacement.
3. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.



4. Remove both upper radiator support bracket bolts.



5. Remove both upper radiator support brackets.



6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
7. Remove the lower radiator air deflector retainers.
8. Remove the lower radiator air deflector.



9. Remove the right front fender liner. Refer to Front Fender Liner Replacement.
10. Remove the right radiator air deflector retainers.
11. Remove the right radiator air deflector.



12. Remove the left radiator air deflector retainers.
13. Remove the left radiator air deflector.



14. Remove the liquid line and compressor hose bolt from condenser.
15. Remove the compressor hose from the condenser.
16. Remove the liquid line from the condenser.



17. Remove both lower radiator mounting bracket bolts.
18. Remove both lower radiator mounting brackets.



19. Remove and discard the condenser mounting bolts.
20. Remove and discard the condenser mounting nuts.



21. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.
22. Remove the condenser.
23. Remove the upper seal.

Note: Cap all A/C components immediately to prevent system contamination.

24. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to Sealing Washer Replacement.
3. Install the upper seal.
4. If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to Refrigerant System Capacities.



5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.



6. Insert condenser mounting tabs into the radiator clips.

Caution: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

Note: Replace the condenser mounting bolts and nuts.

7. Install the condenser mounting nuts.

Caution: Refer to Fastener Caution in the Preface section.




8. Install the condenser mounting bolts and tighten to 6 N·m (53 lb in).



9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.



10. The radiator air side seals must be in the proper position for proper airflow.
11. Install both lower radiator mounting brackets.



12. Install both lower radiator mounting brackets bolts and tighten to 60 N·m (44 lb ft).
13. Install the liquid line to the condenser.
14. Install the compressor hose to the condenser.



15. Install the liquid line and compressor hose bolt to the condenser and tighten the bolt to 20 N·m (15 lb ft).




Note: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.



18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner. Refer to Front Fender Liner Replacement.



21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Remove the rope attached to the radiator and upper tie bar.



25. Install both upper radiator support brackets.




Note: Do not allow the upper bracket to twist when tightening the radiator mounting bolts or vibration may result.

26. Install both upper radiator support bracket bolts and tighten to 10 N·m (89 lb in).
27. Install the left and right headlamp assembly. Refer to Headlamp Replacement.
28. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
29. Leak test the fittings using the J 39400-A .