Special Tools

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
2. Drain the engine coolant if necessary. Refer to Cooling System Draining and Filling.



3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
4. Remove the right assist step if necessary. Refer to Assist Step Replacement.
5. Remove the rear wheelhouse liner. Refer to Wheelhouse Panel Replacement.
6. Remove the auxiliary A/C evaporator tubes connector nuts (1) from the intermediate connection point.
7. Remove the auxiliary heater tubes connector nuts (2) if necessary.



8. Remove the retaining nut (1) and the auxiliary A/C evaporator tubes (3) from the auxiliary HVAC module.



9. Remove the heater - A/C tubes retaining push pins (1) at the frame locations.
10. Remove the heater - A/C tubes retaining bolt (2) at the frame location.
11. Remove the auxiliary A/C evaporator tubes (3) from the frame.
12. Remove the auxiliary A/C evaporator tubes from the vehicle.



13. Remove auxiliary heater - A/C tubes clip retaining push pin/bolt (1) if necessary.
14. Use a flat-bladed release tool to open retaining clips (2).
15. Remove auxiliary A/C tubes from vehicle.

Note: The replacement A/C and heater pipes are shipped in front and rear sections.

1. Install the auxiliary A/C evaporator tubes (3) to the retaining clips (2).
2. Install the auxiliary A/C evaporator tubes (3) to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.




3. Install the auxiliary heater - A/C tube nut (2).

Tighten
Tighten the nut to 7 N·m (62 lb in).

4. Install the auxiliary heater - A/C tube push pins (1).



5. Install the auxiliary heater - A/C tubes (3) and the retaining nuts (1) to the auxiliary HVAC module.

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

6. Install new O-rings with replacement auxiliary A/C tubes. Refer to O-Ring Replacement.



7. Install new O-rings with replacement auxiliary A/C tubes. Refer to O-Ring Replacement.

Note: Use a adjustable wrench or equivalent holding tool at tube connections to prevent twisting.

Note: Mandatory torque sequence required for proper connections.

8. Install the auxiliary heater - A/C tube connection nuts (1) to the intermediate connection point.

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

9. Install the auxiliary heater tubes connector nuts (2) if necessary.

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

10. Install the rear wheelhouse liner. Refer to Wheelhouse Panel Replacement.
11. Install the right assist step if necessary. Refer to Assist Step Replacement.
12. Lower the vehicle.
13. Fill the engine coolant. Refer to Cooling System Draining and Filling.
14. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging.
15. Leak test the fittings of the component using the J 39400-A .