Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the hood latch support bracket. Refer to Hood Latch Support Replacement in Body Front End.
3. Remove the right headlamp assembly (L67 engine only). Refer to Headlamp Replacement in Lighting Systems.
4. Remove the upper radiator seal.
5. Remove the compressor hose bolt from the condenser.



6. Remove the compressor hose and the evaporator hose from the condenser.
7. Remove and discard the O-rings from the compressor hose and the evaporator hose.
8. Remove the condenser hose bracket bolt from the radiator.

Notice: 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.




9. Remove the condenser to radiator mounting bolts.
10. Remove the condenser from the vehicle.

1. Add the proper amount of refrigerant oil to the new condenser. Refer to Refrigerant System Capacities .



2. Install the condenser to the vehicle.

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.

Notice: 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.

3. Install the condenser mounting bolts.

Tighten
Tighten the bolts to 6 N·m (53 lb in).




4. Install the condenser hose bracket bolt to the radiator.

Tighten
Tighten the bolt to 2.5 N·m (23 lb in).

5. Install the new O-rings to the compressor hose and the evaporator hose. Refer to O-Ring Replacement .
6. Install the compressor hose and the evaporator hose to condenser.
7. Install the compressor hose bolt to the condenser.

Tighten
Tighten the bolt to 24 N·m (18 lb ft).




8. Install the upper radiator seal.
9. Install the right headlamp assembly (L67 engine only). Refer to Headlamp Replacement in Lighting Systems.
10. Install the hood latch bracket assembly. Refer to Hood Latch Support Replacement in Body Front End.
11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
12. Leak test the fittings of the A/C component using the J 39400-A .