For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 38042 Dual O-ring Joint Separator

• | J 39500-B Air Conditioning Refrigerant Recovery, Recycling and Recharging (ACR4) System

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Place the J 38042 on the refrigerant line directly behind the dual O-ring joint female nut. Hold pressure against the nut.
3. Back off the female nut until the dual O-ring joint seal is broken. Breaking the dual O-ring joint seal aids in seal separation.
4. After the seal is broken, slightly tighten the female nut in order to facilitate tool removal.
5. Remove the J 38042

.

6. Remove the female nut.
7. Separate the connection.

Important: Use non-metallic tools in order to prevent damage to the seal surfaces.

8. Remove the O-rings.
9. Inspect the line for kinks and dents.
10. Inspect the connection for burrs and nicks.

### Installation Procedure

#### Tools Required

J 39400 Electronic Halogen Leak Detector

1. Lubricate the O-rings with 525 refrigerant oil.
2. Install the O-rings.
3. Oil the bore using a small amount of refrigerant oil.
4. Push the components together completely.

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.

5. Assemble the female nut.

Tighten
Tighten the nut to 24 N·m (18 lb ft).

6. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
7. Using the J 39400 , leak test the A/C system. Refer to Leak Testing .