Discharge Hose Replacement 3.6L Engine

Special Tools

J 39400 Halogen Leak Tester

Warning: Refer to Safety Glasses Warning in the Preface section.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement
5. Remove the passenger side engine cover. Refer to Engine Cover Replacement.

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



7. Remove the compressor to compressor mounting bracket retaining bolt (1).
8. Position the discharge hose retaining bracket (2) away from the compressor (3).
9. Lower the vehicle



10. Remove the suction pipe upper to suction pipe lower retaining nut (1).



11. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Note: The sealing washer (3) is a single use item and must be discarded after use.

12. Remove the sealing washer (3). Refer to Sealing Washer Replacement.

Discard the sealing washer

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

13. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).



14. Remove the suction/discharge pipes pad retaining bolt (1).



15. Disconnect the suction/discharge pipes (1) from the compressor (3).

Note: The sealing washers (2) are a single use item and must be discarded after use.

16. Remove the sealing washers (2). Refer to Sealing Washer Replacement.

Discard the sealing washers

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

17. Cap or plug the suction/discharge pipes (1) and the ports on the compressor (3).




Note: Remove the upper radiator support brackets by raising the securing lock upwards 10 mm and slide the bracket of the radiator slide pin.

18. Remove the upper radiator support brackets (1).




Note: Gently push the radiator and condenser towards the engine to allow removal of the discharge pipe to condenser retaining nut (1).

19. Remove the discharge pipe to condenser retaining nut (1).



20. Disconnect the discharge pipe (1) from condenser (3).
21. Remove the sealing washer (2). Refer to Sealing Washer Replacement.

Discard the sealing washer.

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

22. Cap or plug the discharge pipe (1) and the condenser (3).

1. Remove the plugs or caps from the discharge pipe (1) and the condenser (3).

Note: DO NOT coat the NEW sealing washer (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (2) useless, as the sealing washer (2) WILL swell causing refrigerant to leak out.

2. Install a NEW sealing washer (2). Refer to Sealing Washer Replacement.
3. Install the discharge pipe (1) to condenser (3).

Caution: Refer to Fastener Caution in the Preface section.





Note: Gently push the radiator and condenser towards the engine to allow installation of the discharge pipe to condenser retaining nut (1).

4. Install the discharge pipe to condenser retaining nut (1) and tighten to 22 N·m( 16 lb ft).



5. Install the upper radiator support brackets (1).



6. Remove the plugs or caps from the suction/discharge pipes (1) and the ports on the compressor (3).

Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

7. Install two NEW sealing washers (2). Refer to Sealing Washer Replacement.
8. Connect the suction/discharge pipes (1) to the compressor (3)



9. Install the suction/discharge pipe to compressor retaining bolt (1) and tighten to 22 N·m(16 lb ft).




Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

10. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
11. Install the suction pipe upper (1) to the suction pipe lower (2).



12. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 N·m( 16 lb ft).
13. Raise the vehicle.



14. Position the discharge hose retaining bracket (2) to the compressor (3).
15. Install the compressor to compressor mounting bracket bolt (1) and tighten to 22  N·m (16 lb ft).
16. Lower the vehicle to the ground.
17. Install the passenger side engine dress cover. Refer to Engine Cover Replacement.
18. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement
19. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
20. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
22. Leak test the fittings of the component using J 39400 .

Discharge Hose Replacement 6.0L Engine

Special Tools

J 39400-A Halogen Leak Tester

Warning: Refer to Safety Glasses Warning in the Preface section.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement
5. Remove the engine cover. Refer to Engine Cover Replacement.



6. Remove the discharge hose retaining bracket to oil pan retaining bolt (1).
7. Position the discharge hose retaining bracket (2) away from the oil pan (3).



8. Remove the suction pipe upper to suction pipe lower retaining nut (1).



9. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Note: The sealing washer (3) is a single use item and must be discarded after use.

10. Remove the sealing washer (3). Refer to Sealing Washer Replacement.

Discard the sealing washer

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

11. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).



12. Remove the suction/discharge pipe to compressor retaining bolt (2).



13. Disconnect the suction/discharge pipes (1) from the compressor (3).

Note: The sealing washers (2) are a single use item and must be discarded after use.

14. Remove the sealing washers (2). Refer to Sealing Washer Replacement.

Discard the sealing washers.

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

15. Cap or plug the suction/discharge pipes (1) and the ports on the compressor (3).




Note: Remove the upper radiator support brackets by raising the securing lock upwards 10 mm and slide the bracket of the radiator slide pin.

16. Remove the upper radiator support brackets (1).




Note: Gently push the radiator and condenser towards the engine to allow removal of the discharge pipe to condenser retaining nut (1).

17. Remove the discharge pipe to condenser retaining nut (1).



18. Disconnect the discharge pipe (1) from condenser (3).
19. Remove the sealing washer (2). Refer to Sealing Washer Replacement.

Discard the sealing washer.

Note: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

20. Cap or plug the discharge pipe (1) and the condenser (3).

1. Remove the plugs or caps from the discharge pipe (1) and the condenser (3).

Note: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

2. Install a NEW sealing washer (2). Refer to Sealing Washer Replacement.
3. Install the discharge pipe (1) to condenser (3).

Caution: Refer to Fastener Caution in the Preface section.





Note: Gently push the radiator and condenser towards the engine to allow installation of the discharge pipe to condenser retaining nut (1).

4. Install the discharge pipe to condenser retaining nut (1) and tighten to 22 N·m (16 lb ft).



5. Install the upper radiator support brackets (1).



6. Remove the plugs or caps from the suction/discharge pipes (1) and the ports on the compressor (3).

Note: DO NOT coat the sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the washer useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

7. Install two NEW sealing washers (2). Refer to Sealing Washer Replacement.
8. Connect the suction/discharge pipes (1) to the compressor (3).



9. Install the suction/discharge pipe to the compressor retaining bolt (2) and tighten to 22 N·m (16 lb ft).



10. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Note: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

11. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
12. Install the suction pipe upper (1) to the suction pipe lower (2).



13. Install the suction pipe upper to suction pipe lower retaining nut (1) and tighten to 22 N·m (16 lb ft).



14. Position the discharge hose retaining bracket (2) to the oil pan (3).
15. Install the discharge hose retaining bracket to oil pan retaining nut (1) and tighten to 22 N·m (16 lb ft).
16. Install the engine cover. Refer to Engine Cover Replacement
17. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
18. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
21. Leak test the fittings of the components using J 39400-A .