Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the coolant recovery or the surge tank. Refer to Coolant Recovery Reservoir Replacement or Radiator Surge Tank Replacement in Engine Cooling.
3. Remove the air cleaner from the vehicle. Refer to the appropriate procedure:

•	Air Cleaner Assembly Replacement in Engine Controls - 4.3L

•	Air Cleaner Assembly Replacement in Engine Controls - 5.0L/5.7L

•	Air Cleaner Assembly Replacement in Engine Controls - 6.5L

•	Air Cleaner Assembly Replacement in Engine Controls - 8.1L

4. Remove the compressor hose assembly (2) from the accumulator.



5. Remove the auxiliary hose (1) connection from the compressor hose assembly (3).



6. Remove the compressor hose assembly (4) from the condenser.
7. Remove the compressor hose assembly bolt (2) from the compressor (6).
8. Remove the compressor hose assembly from the compressor.
9. Cap or plug all open connections to prevent contamination.
10. Remove the compressor hose assembly  (3) from the vehicle.

1. Remove the cap or plugs from the connections.
2. Install the hose (3) to the compressor.




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. Install the compressor hose assembly retaining bolt (2) to the compressor.

Tighten
Tighten the bolt to 45 N·m (33 lb ft).

4. Install the compressor hose assembly to the condenser (4).

Tighten
Tighten the nut to the condenser to 28 N·m (21 lb ft).




5. Install the auxiliary hose (1) connection at the compressor hose assembly (3)

Tighten
Tighten the auxiliary hose connection to the compressor to 48 N·m (35 lb ft).




6. Install the compressor hose assembly (2) to the accumulator (1).

Tighten
Tighten the A/C line to the accumulator to 48 N·m (35 lb ft).

7. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
8. Install the air cleaner to the vehicle. Refer to the appropriate procedure:

•	Air Cleaner Assembly Replacement in Engine Controls - 4.3L

•	Air Cleaner Assembly Replacement in Engine Controls - 5.0L/5.7L

•	Air Cleaner Assembly Replacement in Engine Controls - 6.5L

•	Air Cleaner Assembly Replacement in Engine Controls - 8.1L

9. Install the coolant recovery or the surge tank. Refer to Coolant Recovery Reservoir Replacement or Radiator Surge Tank Replacement in Engine Cooling.
10. Leak test the fittings of the components using the J 39400-A .