Suction Hose Replacement (3.6L Engine)

Suction Hose Replacement (3.6L Engine)

Tools Required

J 39400-A Halogen Leak Tester


Removal Procedure


Important: With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the vacuum brake booster power reserve.


1. Deplete the vacuum brake booster power reserve.
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
4. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
5. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .





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).


6. 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).


7. Detach the left engine cover (1) from the ball stud (2).
8. Remove the left engine cover (1).




9. Disconnect the vacuum hose (1) and the vacuum brake booster check valve (3) from the vacuum brake booster (2).
10. Detach the vacuum hose (1) from the bulkhead mounted vacuum hose retaining bracket (4) and position aside.




11. Remove the left engine cover mounting bracket to cylinder head retaining bolt (3).
12. Remove the left engine cover mounting bracket (1) from the cylinder head (2).




13. Remove the remote battery positive post cover (1).




14. Remove the remote battery positive post to wiring harness retaining bolt (1).
15. Remove the starter motor power cable (2) and position aside.




16. Remove the suction pipe upper to suction pipe lower retaining nut (1).




17. Remove the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).
18. Detach the liquid pipe (1) from the suction pipe/liquid pipe retaining clip (2).




19. Disconnect the suction pipe upper (1) from the suction pipe lower (2).

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


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


21. Cap or plug the suction pipe upper (1) and the suction pipe lower (2).




22. Detach the suction pipe (2) and the liquid pipe (3) from the suction pipe/liquid pipe retaining clip (1).




23. Remove the suction pipe/liquid pipe pad to TX valve retaining nut (1).




24. 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.


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


26. Cap or plug the suction pipe (4), liquid pipe (5) and the TX valve (1).
27. Remove the liquid pipe (5) from the suction pipe/liquid pipe pad (3).
28. Remove the suction pipe/liquid pipe pad (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.


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





Notice: Refer to Fastener Notice (Fastener Notice) .

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

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





5. 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.


6. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
7. Install the suction pipe upper (1) to the suction pipe lower (2).




8. Attach the liquid pipe (1) to the suction pipe/liquid pipe retaining clip (2).
9. Install the suction pipe/liquid pipe retaining clip to left front chassis rail retaining bolt (3).




10. Install the suction pipe upper to suction pipe lower retaining nut (1).

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





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

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.


13. Install the remote battery positive post cover (1).




14. Attach the suction pipe (2) and the liquid pipe (3) to the suction pipe/liquid pipe retaining clip (1).




15. Connect the vacuum hose (1) and the vacuum brake booster check valve (3) to the vacuum brake booster (2).
16. Attach the vacuum hose (1) to the bulkhead mounted vacuum hose retaining bracket (4).




17. Install the left engine cover mounting bracket (1) to the cylinder head (2).
18. Install the left engine cover mounting bracket to cylinder head retaining bolt (3).

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





19. 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).


20. 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).


21. Attach the left engine cover (1) to the outer retaining clip (2).
22. Install the cross car brace, if fitted. Refer to Front End Panel Module Carrier Assembly Replacement (Service and Repair) .
23. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .
24. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
25. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
26. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
27. Leak test the fittings of the component using electronic leak detector.