Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.



3. Remove the evaporator tube assembly from the evaporator.
4. Remove the O-ring seal and discard.



5. Remove the battery tray. Refer to Battery Tray Replacement in Engine Electrical.
6. Remove the evaporator tube assembly from the condenser.
7. Remove the O-ring seal and discard.



8. Remove the lower fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
9. Remove the screws holding the evaporator tube to the two clips located under the radiator support assembly.
10. Remove the evaporator tube from the vehicle.

1. Install the evaporator tube to the vehicle.

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.

2. Install the screws holding the evaporator tube to the two clips located under the radiator support assembly.

Tighten
Tighten evaporator tube clip screws to 1.9 N·m (17 lb in).

3. Install the lower fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.



4. Install a new O-ring seal. Refer to O-Ring Replacement in Heating,Ventilation and Air Conditioning.
5. Install the evaporator tube to the condenser.

Tighten
Tighten the evaporator tube to 27 N·m (20 lb ft).

6. Install the battery tray. Refer to Battery Tray Replacement in Engine Electrical.



7. Install a new O-ring seal. Refer to O-Ring Replacement in Heating,Ventilation and Air Conditioning.
8. Install the evaporator tube to the evaporator.

Tighten
Tighten the evaporator tube to 27 N·m (20 lb ft).




9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
11. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .