For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 38042 Dual O-Ring Joint Separator

• | J 39500-B A/C Refrigerant Recovery, Recycling, and Recharging (ACR4) System

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Place the J 38042 on the refrigerant line directly behind the female nut of the dual O-ring joint.

Hold pressure against the nut.

3. Loosen the female nut until the seal of the dual O-ring joint is broken. This procedure aids in the seal separation.
4. After the seal is broken, slightly tighten the female nut to facilitate the J 38042 removal.
5. Remove the female nut. Separate the connection.
6. Use a non-metallic tool to remove the O-rings.

The use of a non-metallic tool minimizes the chance of impairing the seal surfaces.

7. Inspect the line for kinks and dents.
8. Inspect the connection for the burrs and nicks.

### Installation Procedure

#### Tools Required

J 39400 Electronic Halogen Leak Detector

1. Lubricate the O-rings using 525 oil or mineral oil before installation.
2. Install the O-rings.
3. Oil the bore using a small amount of refrigerant oil before assembly.
4. Align the end forms for pilot-to-bore insertion.
5. Push the pilot and the bore 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.

6. Install the female nut.

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

7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
8. Leak test the system. Refer to Leak Testing .