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 air baffle bolts.
5. Remove the air baffle.



6. Remove the auxiliary evaporator outlet tube to suction hose nut (2).
7. Remove the evaporator outlet tube to suction hose bolt (1).
8. Disconnect the suction hose from the evaporator outlet tube and the auxiliary evaporator outlet tube.

Important: Cap or tape the open A/C lines and A/C refrigerant components immediately to prevent system contamination.

9. Cap or tape off the evaporator outlet tube and the auxiliary evaporator outlet tube.



10. Remove the suction hose to compressor nut.
11. Disconnect the suction hose from the compressor.
12. Remove the suction hose.
13. Discard the sealing washers.
14. Cap or tape off the compressor suction port.

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 compressor end of the suction hose until seated.
3. Install the suction hose.
4. Remove the cap or tape from the compressor suction port.



5. Connect the suction hose 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.

6. Install the suction hose to compressor nut.

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

7. Remove the cap or tape from the evaporator outlet tube and the auxiliary evaporator outlet tube.
8. Install a new sealing washer at the suction hose to evaporator outlet tube fitting.
9. Install a new sealing washer at the suction hose to auxiliary evaporator outlet tube fitting.



10. Connect the suction hose to the evaporator outlet tube and the auxiliary evaporator outlet fittings.
11. Install the suction hose to evaporator outlet tube fitting bolt (1).

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

12. Install the auxiliary evaporator outlet tube to suction hose nut (2).

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




13. Install the air baffle.
14. Install the air baffle bolts.

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

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