Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the battery. Refer to Battery Replacement in Engine Electrical.



3. Remove the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.



4. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.



5. Remove the nut retaining the heater pipe bracket to the dash cowl.
6. Reposition the heater pipe bracket to access the refrigerant lines.



7. Remove the front evaporator tube to rear evaporator tube retaining bolt.

Important: Cap or tape the open evaporator tubes immediately to prevent contamination.

8. Disconnect the evaporator tubes, and discard the O-ring.



9. Remove the compressor hose to accumulator retaining bolt.

Important: Cap or tape the open compressor hose and the accumulator immediately to prevent contamination.

10. Disconnect the compressor hose from the accumulator to access the accumulator hose, and discard the O-ring.
11. Reposition the compressor hose end.

Important: Cap or tape the open accumulator hose and the accumulator immediately to prevent contamination.




12. Using a back-up wrench on the accumulator fitting (2), loosen the accumulator hose fitting (1) from the accumulator.



13. Disconnect the accumulator hose from the accumulator, discard the O-ring.



14. Remove the accumulator hose to evaporator retaining bolt.

Important: Cap or tape the open accumulator hose, rear evaporator tube, and the evaporator immediately to prevent contamination.

15. Disconnect the accumulator hose from the evaporator.
16. Discard the O-ring.

Important: Prior to removal, take note of the accumulator hose orientation to the accumulator and the rear evaporator tube.




17. Carefully remove the accumulator hose, separating it from the rear evaporator tube.

1. Remove the cap or tape from the accumulator hose, rear evaporator tube and the evaporator.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the accumulator hose, rear evaporator tube and the evaporator.

Important: DO NOT allow any of the mineral base 525  viscosity refrigerant oil on the O-ring to enter the refrigerant system.




3. Lightly coat the new O-ring (1) with mineral base 525  viscosity refrigerant oil.
4. Carefully slide the new O-rings (1) onto the accumulator hose and the rear evaporator tube until seated.



5. Position the accumulator hose with the rear evaporator tube and install the assembly to the evaporator.




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 accumulator hose to evaporator retaining bolt.

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

7. Remove the cap or tape from the accumulator.
8. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the accumulator hose and the accumulator.



9. Lightly coat the new O-ring seal (1) with mineral base 525  viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525  viscosity refrigerant oil on the O-ring seal (1) onto the accumulator hose until seated.




10. Install the accumulator hose to the accumulator.



11. Using a back-up wrench on the accumulator fitting (2), secure the accumulator hose fitting (1) to the accumulator.

Tighten
Tighten the fitting to 41 N·m  (30 lb ft).

12. Remove the cap or tape from the compressor hose.
13. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose and the accumulator.

Important: DO NOT allow any of the mineral base 525  viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.




14. Lightly coat the O-ring seal (1) with mineral base 525  viscosity refrigerant oil.
15. Carefully slide the new O-ring seal (1) onto the compressor hose until seated.

Leave a light coating on the refrigerant oil on the compressor hose in the area indicated (2) only.




16. Install the compressor hose to the accumulator with retaining bolt.

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

17. Remove the cap or tape from the front evaporator tube and the rear evaporator tube.
18. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the evaporator tubes.

Important: DO NOT allow any of the mineral base 525  viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.




19. Lightly coat the O-ring seal (1) with mineral base 525 viscosity refrigerant oil.



20. Carefully slide the new O-ring seal (1) onto the front evaporator tube until seated.

Leave a light coating of the refrigerant oil on the front evaporator tube in the area indicated (2) ONLY.




21. Install the front evaporator tube to the rear evaporator tube with retaining bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




22. Install the heater pipe bracket to the cowl stud.
23. Install the heater pipe bracket retaining nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).




24. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.



25. Install the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.



26. Install the battery. Refer to Battery Replacement in Engine Electrical.
27. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
28. Leak test the fittings of the component using J 39400-A .