Evaporator Tube Replacement Front

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the upper radiator support. Refer to Radiator Support Replacement in Engine Cooling.
4. Remove the refrigerant pressure sensor. Refer to A/C Refrigerant Pressure Sensor Replacement .
5. Remove the evaporator tube - front to condenser retaining bolt.

Important: Cap or tape the open evaporator tube - front and the condenser immediately.

6. Disconnect the evaporator tube - front from the condenser, discard the O-ring seal and cap or tape the evaporator tube - front and the condenser to prevent contamination.



7. Remove the evaporator tube - front to evaporator tube - rear retaining bolt.

Important: Cap or tape the open evaporator tube - front and the evaporator tube - rear immediately.

8. Disconnect the evaporator tube - front from the evaporator tube - rear, discard the O-ring seal and cap or tape the evaporator tubes to prevent contamination.

1. Remove the cap or tape from the evaporator tube - front (rear end) and the evaporator tube - rear.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the evaporator tube - front and the evaporator tube - rear.
3. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

4. Carefully slide the new O-ring seal (1) onto the evaporator tube - front until seated.

Leave a light coating of the refrigerant oil to remain on the evaporator tube - front in the area indicated (2) ONLY.




5. Install the evaporator tube - front to the evaporator tube - rear.

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 evaporator tube - front to evaporator tube - rear retaining bolt.

Tighten
Tighten the evaporator tube - front to evaporator tube - rear retaining bolt to 27 N·m (20 lb ft).




7. Remove the cap or tape from the evaporator tube - front and the condenser.
8. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the evaporator tube - front and the condenser.
9. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

10. Carefully slide the new O-ring seal (1) onto the evaporator tube - front until seated.

Leave a light coating of the refrigerant oil to remain on the evaporator tube - front in the area indicated (2) ONLY.




11. Install the evaporator tube - front to the condenser.
12. Install the evaporator tube - front to condenser retaining bolt.

Tighten
Tighten the evaporator tube - front to condenser retaining bolt to 27 N·m (20 lb ft).

13. Install the refrigerant pressure sensor. Refer to A/C Refrigerant Pressure Sensor Replacement .
14. Install the upper and lower radiator supports. Refer to Radiator Support Replacement in Engine Cooling.
15. Connect the negative battery cable.

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

16. Program the transmitters. Refer to Transmitter Programming/Synchronization in Keyless Entry.
17. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
18. Check the evaporator tube - front joints for leaks. Refer to Leak Testing .