For 1990-2009 cars

#### Tools Required

J 39400-A Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the right rear inner wheelhouse liner if necessary. Refer to Rear Wheelhouse Panel Liner Replacement.
4. Remove auxiliary evaporator tube nut (1) and pull downward to release the auxiliary A/C evaporator tubes (2) from the auxiliary HVAC module (4).
5. Remove auxiliary evaporator tube clip nuts (3) and release tubes from clips.
6. Remove air cleaner duct. Air Cleaner Outlet Duct Replacement.
7. Remove the retaining nuts (1) and the auxiliary A/C evaporator tubes (2) from the TXV tube and condenser tube.
8. Remove the heater/A/C tubes retaining nuts (1) from the retaining studs and clips along the frame in four places.
9. Remove the auxiliary A/C evaporator tubes (3) from the clamps (2).
10. Remove the auxiliary A/C evaporator tubes from the vehicle.

### Installation Procedure

Note: The replacement A/C and heater pipes are shipped in two sections and spliced together upon installation. Refer to Auxiliary Heater and Air Conditioning Pipe Replacement/Repair.

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

Caution: Refer to Fastener Caution in the Preface section.

3. Install the heater/A/C tubes retaining nut (1) to the retaining studs and clips (2) along the frame in four places.

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

4. Install the auxiliary A/C evaporator tubes (2) to the TXV tube and condenser tube and install the retaining nuts (1).

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

5. Install air cleaner duct. Air Cleaner Outlet Duct Replacement.
6. Install the auxiliary A/C evaporator tubes (2) to the HVAC module (4) and install retaining nut (1).

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

7. Install auxiliary evaporator tubes to retaining clips and install nuts (3) to secure.

Tighten
Tighten the nuts to 4 N·m (35 lb in).

8. Install the right rear inner wheelhouse liner if necessary. Refer to Rear Wheelhouse Panel Liner Replacement.
9. Lower the vehicle.
10. Recharge the refrigerant to the system. Refer to Refrigerant Recovery and Recharging.
11. Leak test the fittings of the component using the J 39400-A .