Tools Required

J 39400-A Halogen Leak Detector

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the radiator air baffle bolts.
5. Remove the radiator air baffle.
6. Remove the evaporator outlet tube to suction line bolt.
7. Remove the auxiliary evaporator outlet tube to suction line bolt.



8. Disconnect the evaporator outlet tube from the suction line (2).
9. Disconnect the auxiliary evaporator tube from the suction line.



10. Remove the suction line to compressor nut.
11. Disconnect the suction line from the compressor.
12. Remove the suction line.
13. Discard the sealing washers.

1. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant hose and the A/C refrigerant component.

Important: Flat washer type seals do not require lubrication.

2. Carefully slide the new sealing washer onto the suction line until seated.
3. Install the suction line.



4. Connect the suction line to the compressor.

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. Install the suction line fitting nut.

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

6. Install a new sealing washer at the suction line to evaporator outlet tube fitting.
7. Install a new sealing washer at the auxiliary suction line to evaporator outlet tube fitting.



8. Connect the suction line (2) to the evaporator outlet tube fitting.
9. Install the suction line to evaporator outlet tube fitting bolt.

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

10. Connect the auxiliary suction line to the evaporator outlet tube fitting.
11. Install the suction line to evaporator outlet tube fitting bolt.

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

12. Install the radiator air baffle.
13. Install the radiator air baffle bolts.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

14. Lower the vehicle.
15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
16. Leak test the fittings of the component using J 39400-A
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.