Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the left front fender upper diagonal brace. Refer to Front Fender Upper Diagonal Brace Replacement in Body Front End.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 3.4L or Air Cleaner Assembly Replacement in Engine Controls 3.8L.
4. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
5. Remove the evaporator tube/suction hose bracket.



6. Disconnect the evaporator inlet tube nut from the condenser tube.
7. Disconnect the evaporator inlet tube from the condenser tube.



8. Remove the evaporator outlet tube to evaporator block fitting bolt.

Important: Use care when removing the evaporator tube.

9. Disconnect the evaporator inlet tube from the evaporator.
10. Remove the O-ring and discard.

Important: The new O-ring seal must be coated with mineral base 525 viscosity refrigerant oil.

1. Install the new O-ring seals on to the evaporator tube. Refer to O-Ring Replacement .
2. Connect the evaporator inlet tube to the condenser tube.




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.

3. Connect the evaporator inlet tube to the evaporator.

Tighten
Tighten the evaporator outlet tube to evaporator block fitting bolt to 16 N·m (12 lb ft).




4. Tighten the evaporator inlet tube nut.

Tighten
Tighten the evaporator inlet tube nut to 27 N·m (20 lb ft).

5. Install the evaporator tube/suction hose bracket.
6. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement in Hydraulic Brakes.
7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 3.4L or Air Cleaner Assembly Replacement in Engine Controls 3.8L.
8. Install the left front fender upper diagonal brace. Refer to Front Fender Upper Diagonal Brace Replacement in Body Front End.
9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
10. Leak test the fittings of the component using J 39400-A .