Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 3.8L engine or to Air Cleaner Assembly Replacement for the 5.3L engine.
3. Remove the brake pressure modulator valve bracket (BPMV). Refer to Brake Pressure Modulator Valve Bracket Replacement .



4. Remove the A/C line coupling from the evaporator tube to condenser tube. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
5. Disconnect the evaporator tube from the condenser tube.
6. Remove the evaporator tube mounting bolt.
7. Remove the block fitting nut that secures the A/C compressor hose to the evaporator tube.
8. Disconnect the A/C compressor hose from the evaporator tube.



9. Remove the block fitting nut (1) that secures the evaporator tube to the thermostatic expansion valve (TXV).
10. Disconnect the evaporator tube from the TXV.
11. Remove the evaporator tube from the support clip on the left fender rail.
12. Disconnect the wire harness electrical connector from the A/C pressure sensor.
13. Remove the evaporator tube from the vehicle.



14. Remove the A/C pressure sensor.
15. Remove and discard the O-ring seals and seal washers.

1. Replace the O-ring seals on the evaporator tube and A/C pressure sensor. Refer to O-Ring Replacement .

Notice: Refer to Fastener Notice in the Preface section.




2. Install the A/C refrigerant pressure sensor.

Tighten
Tighten the sensor to 4.7 N·m (41 lb in).

3. Replace the seal washers on the evaporator tube. Refer to Sealing Washer Replacement .
4. Install the evaporator tube to the vehicle.
5. Connect the evaporator tube to the support clip.
6. Install the evaporator tube to the TXV.



7. Install the evaporator tube to TXV nut (1).

Tighten
Tighten the nut to 17 N·m (13 lb ft).

8. Connect the evaporator tube to the condenser tube.



9. Install the A/C line coupling to the evaporator tube and condenser tube. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
10. Connect the A/C compressor hose assembly to the evaporator tube.
11. Install the A/C compressor hose assembly to evaporator tube block fitting nut.

Tighten
Tighten the nut to 17 N·m (13 lb ft).

12. Install the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement .
13. Install the master cylinder to the brake booster.
14. Install the nuts to the master cylinder.

Tighten
Tighten the nuts to 25 N·m (18 lb ft).

15. Connect the electrical connector to the brake fluid level sensor.
16. Install the engine vacuum line to the brake booster.
17. Connect the electrical connector to the A/C refrigerant pressure sensor.
18. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement for the 3.8L engine or to Air Cleaner Assembly Replacement for the 5.3L engine.
19. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
20. Leak test the fittings of the component using J 39400-A .