Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the left fender. Refer to Front Fender Replacement - Left Side , or to Front Fender Replacement - Right Side in Body Front End.
3. Remove the left wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
4. Disconnect the evaporator tube from the evaporator core fitting.
5. Remove the accumulator.
6. Remove the evaporator case heat shield retaining screws.
7. Remove the heat shield from the evaporator case.
8. Disconnect electrical connector from the blower motor.



9. Remove the evaporator case retaining screws and nuts.
10. Remove the evaporator case assembly from the vehicle.
11. Disassemble the evaporator case sections.
12. Remove the evaporator core from the evaporator case.

1. Install the evaporator core to the evaporator case.
2. Assemble the evaporator case sections.

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.

3. Install the evaporator case screws.

Tighten
Tighten the screws to 2.5 N·m (22 lb in).

4. Install the evaporator case assembly to the vehicle.
5. Install the bolts and nuts which retain the evaporator case to the bulkhead.

Tighten
Tighten the bolts and nuts to 4.5 N·m (40 lb in).

6. Connect electrical connector to the blower motor.
7. Install the heat shield to the evaporator case.

Tighten
Tighten the screws to 2.5 N·m (22 lb in).

8. Install the accumulator.
9. Connect the evaporator tube to the evaporator core fitting.
10. Install the left wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
11. Install the left fender. Refer to Front Fender Replacement - Left Side , or to Front Fender Replacement - Right Side in Body Front End.
12. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
13. Leak test the fittings of the repaired or reinstalled component using the J 39400-A .