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 air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Replacement for the 6.6L (LBZ and LLY) engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Caterpillar® 3126 Unit Repair Manual for the 7.2L (Caterpillar) engine




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



5. Remove the compressor hose assembly retaining nuts (4).
6. Remove the compressor hose assembly (4) from the condenser (1).
7. Plug the condenser fitting.
8. Remove the compressor hose assembly retaining bolt from the compressor.
9. Remove the compressor hose assembly.

1. Remove the plug from the condenser fitting.
2. Install the new compressor sealing washers to the compressor hose assembly. Refer to Sealing Washer Replacement .
3. Install the compressor hose assembly.

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.

4. Install the compressor hose assembly retaining bolt to the compressor.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

5. Install the new sealing washers to the compressor hose assembly. Refer to Sealing Washer Replacement .



6. Install the compressor hose assembly (4) to the condenser (1).
7. Install the compressor hose assembly nuts (3).

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




8. Install the compressor hose assembly (3) to the accumulator (1).
9. Install the compressor hose assembly nut (2).

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

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

•	Air Cleaner Replacement for the 6.6L (LBZ and LLY) engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Caterpillar® 3126 Unit Repair Manual for the 7.2L (Caterpillar) engine

12. Leak test the fittings of the components using the J 39400-A .