For 1990-2009 cars

## Liquid Line Replacement 3.6L Engine

### Tools Required

J 39400 Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant Refer to Refrigerant Recovery and Recharging .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove windscreen wiper arms. Refer to Windshield Wiper Arm Replacement .
4. Remove the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement .
5. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement .
6. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
8. Remove the front air deflector. Refer to Front Air Deflector Replacement .
9. Remove the liquid pipe to the condenser port retaining nut (1).
10. Lower the vehicle.
11. Disconnect the liquid pipe (1) from the condenser port (3).

Important: The sealing washer (2) is a single use item and must be discarded after use.

12. Remove the sealing washer (2). Refer to Sealing Washer Replacement .

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

13. Cap or plug the liquid pipe (1) and the condenser port (3).
14. Remove the cross car brace, if fitted. Refer to Front End Panel Module Carrier Assembly Replacement

Important: The left engine cover has one front and one rear outer retaining clip.

Important: Grasp and pry the left engine cover (1) upwards to detach the left engine cover (1) from the outer retaining clip (2).

15. Detach the left engine cover (1) from the outer retaining clip (2).

Important: Disengage the left engine cover (1) from the ball stud (2) by pulling up firmly on the rear and front of the left engine cover (1).

16. Detach the left engine cover (1) from the ball stud (2).
17. Remove the left engine cover (1).
18. Remove the left engine cover mounting bracket to cylinder head retaining bolt (2).
19. Remove the left engine cover mounting bracket (1) from the cylinder head.
20. Remove the exhaust manifold heat shield to air box retaining clips (2).
21. Remove the exhaust manifold heat shield (1).
22. Remove the insulation panel to air box retaining clips (2).
23. Remove the insulation panel (1) from the engine compartment.
24. Remove the remote battery positive post cover (1).
25. Remove the remote battery positive post to wiring harness retaining bolt (1).
26. Remove the starter motor power cable (2) and position aside.
27. Remove the suction pipe upper to suction pipe lower retaining nut (1).
28. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
29. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
30. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Important: The sealing washer (3) is a single use item and must be discarded after use.

31. Remove the sealing washer (3). Refer to Sealing Washer Replacement .

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

32. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
33. Remove the suction pipe/liquid pipe pad to TX valve retaining nut (1).
34. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).

Important: The sealing washers (2) are a single use item and must be discarded after use.

35. Remove the sealing washers (2). Refer to Sealing Washer Replacement .

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

36. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
37. Remove the liquid pipe (5) from the suction pipe/liquid pipe pad (3).
38. Detach the liquid pipe (3) and the suction pipe (2) from the suction pipe/liquid pipe retaining clip (1).

Important: Have an assistant ensure that the liquid tube flexible hose at the condenser end clears all the vehicle body work and condenser on removal from the engine compartment.

39. Remove the liquid pipe (3) from the engine compartment.

### Installation Procedure

1. Install the liquid pipe (5) to the suction pipe/liquid pipe pad (3).
2. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the TX valve (1).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

3. Install NEW sealing washers (2). Refer to Sealing Washer Replacement .
4. Position the suction pipe/liquid pipe pad (3) to the TX Valve (1).

Notice: Refer to Fastener Notice in the Preface section.

5. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

6. Raise the vehicle.
7. Remove the plugs or caps from the suction pipe liquid pipe (1) and the condenser port (3).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

8. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement .
9. Connect the liquid pipe (1) to the condenser port (3).
10. Install the liquid pipe to condenser port retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

11. Install the air deflector front. Refer to Front Air Deflector Replacement .
12. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

13. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement .
14. Install the suction pipe upper (1) to the suction pipe lower (2).
15. Attach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
16. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
17. Install the suction pipe upper to suction pipe lower retaining nut (1).

Tighten
Tighten the nut to 22 N·m( 16 lb ft).

18. Install the starter motor positive cable (2) to the remote battery positive post.
19. Install the remote battery positive post to wiring harness retaining bolt (1).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

Important: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

20. Install the remote battery positive post cover (1) to the remote battery positive post.
21. Install the insulation panel (1) to the left rear side engine compartment.
22. Install the insulation panel to air box retaining clips (2).
23. Install the exhaust manifold heat shield (1).
24. Install the exhaust manifold heat shield to air box retaining clips (2).
25. Attach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).
26. Install the left engine cover mounting bracket (1)
27. Install the left engine cover mounting bracket to cylinder head retaining bolt (2).

Tighten
Tighten the bolt to 35 N·m (26 lb in).

28. Position the left engine cover (1) over the intake manifold so the grommet is aligned with the ball stud (2).

Important: Press the left engine cover (1) down firmly near the ball stud to attach the left engine cover (1) to the ball stud (2).

29. Attach the left engine cover (1) to the ball stud (2).

Important: The left engine cover has one front and one rear outer retaining clip.

Important: Press the left engine cover (1) down firmly near the outer retaining clips to attach the left engine cover (1) to the outer retaining clip (2).

30. Attach the left engine cover (1) to the outer retaining clip (2).
31. Install the cross car brace, if fitted. Refer to Front End Panel Module Carrier Assembly Replacement
32. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement .
33. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement
34. Install the plenum chamber cover panel. Refer to Air Inlet Grille Panel Replacement .
35. Install the windscreen wiper arms. Refer to Windshield Wiper Arm Replacement .
36. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
37. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
38. Leak test the fittings of the component using J 39400 .

## Liquid Line Replacement 6.0L Engine

### Tools Required

J 39400 Halogen Leak Detector

### Removal Procedure

1. Recover the refrigerant Refer to Refrigerant Recovery and Recharging.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove windscreen wiper arms. Refer to Windshield Wiper Arm Replacement.
4. Remove the air inlet grill panel. Refer to Air Inlet Grille Panel Replacement.
5. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement.
6. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
7. Remove the engine cover. Refer to Engine Cover Replacement.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
9. Remove the front air deflector. Refer to Front Air Deflector Replacement.
10. Remove the liquid pipe to the condenser port retaining nut (1).
11. Lower the vehicle.
12. Disconnect the liquid pipe (1) from the condenser port (3).

Important: The sealing washer (2) is a single use item and must be discarded after use.

13. Remove the sealing washer (2). Refer to Sealing Washer Replacement.

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

14. Cap or plug the liquid pipe (1) and the condenser port (3).
15. Remove the exhaust manifold heat shield to air box retaining clips (2).
16. Remove the exhaust manifold heat shield (1).
17. Remove the insulation panel to air box retaining clips (2).
18. Remove the insulation panel (1) from the engine compartment.
19. Remove the remote battery positive post cover (1).
20. Remove the remote battery positive post to wiring harness retaining bolt (1).
21. Remove the starter motor power cable (2) and position aside.
22. Remove the suction pipe upper to suction pipe lower retaining nut (1).
23. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
24. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
25. Disconnect the suction pipe upper (1) from suction pipe lower (2).

Important: The sealing washer (3) is a single use item and must be discarded after use.

26. Remove the sealing washer (3). Refer to Sealing Washer Replacement.

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

27. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).
28. Remove the suction pipe/liquid pipe pad to thermal expansion (TX) valve retaining nut (1).
29. Disconnect the suction pipe/liquid pipe pad (3) from the TX valve (1).

Important: The sealing washers (2) are a single use item and must be discarded after use.

30. Remove the sealing washers (2). Refer to Sealing Washer Replacement.

Discard the sealing washers

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

31. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
32. Remove the liquid pipe (5) from the suction pipe/liquid pipe pad (3).
33. Detach the liquid pipe (3) and the suction pipe (2) from the suction pipe/liquid pipe retaining clip (1).

Important: Have an assistant ensure that the liquid tube flexible hose at the condenser end clears all the vehicle body work and condenser on removal from the engine compartment.

34. Remove the liquid pipe (3) from the engine compartment.

### Installation Procedure

1. Install the liquid pipe (5) to the suction pipe/liquid pipe pad (3).
2. Remove the plugs or caps from the suction pipe (4), liquid pipe (5) and the thermal expansion (TX) valve (1).

Important: DO NOT coat the NEW sealing washers (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washers (2) useless, as the sealing washers (2) WILL swell causing refrigerant to leak out.

3. Install NEW sealing washers (2). Refer to Sealing Washer Replacement.
4. Position the suction pipe/liquid pipe pad (3) to the TX valve (1).

Notice: Refer to Fastener Notice in the Preface section.

5. Install the suction pipe/liquid pipe pad to TX valve retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

6. Raise the vehicle.
7. Remove the plugs or caps from the suction pipe liquid pipe (1) and the condenser port (3).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

8. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
9. Connect the liquid pipe (1) to the condenser port (3).
10. Install the liquid pipe to condenser port retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

11. Install the air deflector front. Refer to Front Air Deflector Replacement .
12. Remove the plugs or caps from the suction pipe upper (1) and the suction pipe lower (2).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

13. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
14. Install the suction pipe upper (1) to the suction pipe lower (2).
15. Attach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).
16. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
17. Install the suction pipe upper to suction pipe lower retaining nut (1).

Tighten
Tighten the nut to 22 N·m( 16 lb ft).

18. Install the starter motor positive cable (2) to the remote battery positive post.
19. Install the remote battery positive post to wiring harness retaining bolt (1).

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

Important: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.

20. Install the remote battery positive post cover (1) to the remote battery positive post.
21. Install the insulation panel (1) to the left rear side engine compartment.
22. Install the insulation panel to air box retaining clips (2).
23. Install the exhaust manifold heat shield (1).
24. Install the exhaust manifold heat shield to air box retaining clips (2).
25. Attach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).
26. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
27. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement.
28. Install the engine cover. Refer to Engine Cover Replacement.
29. Install the plenum chamber cover panel. Refer to Air Inlet Grille Panel Replacement.
30. Install the windscreen wiper arms. Refer to Windshield Wiper Arm Replacement.
31. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
33. Leak test the fittings of the component using J 39400 .