Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
2. Remove the battery. Refer to Battery Replacement in Engine Electrical.
3. Remove the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.
4. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.



5. Remove the nut retaining the heater pipe bracket to the dash cowl.
6. Reposition the heater pipe bracket to access the refrigerant lines.



7. Remove the bolt which secures the front evaporator tube to the rear evaporator tube.

Important: Cap or tape the open A/C components immediately to prevent system contamination.

8. Disconnect the evaporator tubes.
9. Remove and discard the O-ring.
10. Cap or tape the front and rear evaporator tubes.



11. Remove the bolt which secures the compressor hose to the accumulator.
12. Disconnect the compressor hose from the accumulator to access the accumulator hose.
13. Remove and discard the O-ring.
14. Cap or tape the open compressor hose and the accumulator.
15. Reposition the compressor hose end.



16. Using a back-up wrench on the accumulator fitting (2). Loosen the accumulator hose fitting (1) from the accumulator.



17. Disconnect the accumulator hose from the accumulator.
18. Remove and discard the O-ring.
19. Cap or tape the open accumulator hose and the accumulator.



20. Remove the bolt that secures the accumulator hose to the evaporator.

Important: Cap or tape the open A/C components immediately to prevent system contamination.

21. Disconnect the accumulator hose from the evaporator.
22. Discard the O-ring.



23. Carefully remove the accumulator hose. Separate the hose from the rear evaporator tube.
24. Remove and discard the O-ring.
25. Cap or tape the open accumulator hose, the rear evaporator tube and the evaporator core.

1. Remove the cap or tape from the accumulator hose, the rear evaporator tube, and the evaporator.
2. Install a new O-ring to the accumulator hose. Refer to O-Ring Replacement .



3. Position the accumulator hose with the rear evaporator tube and connect the assembly to the evaporator.




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.

4. Install the bolt which retains the accumulator hose to the evaporator.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

5. Remove the cap or tape from the accumulator.



6. Install a new O-ring to the accumulator hose. Refer to O-Ring Replacement .
7. Connect the accumulator hose to the accumulator.



8. Using a back-up wrench on the accumulator fitting (2), secure the accumulator hose fitting (1) to the accumulator.

Tighten
Tighten the fitting to 41 N·m  (30 lb ft).

9. Remove the cap or tape from the compressor hose.
10. Install a new O-ring to the compressor hose assembly. Refer to O-Ring Replacement .



11. Install the bolt which retains the compressor hose to the accumulator.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

12. Remove the cap or tape from the front evaporator tube and the rear evaporator tube.
13. Install new O-rings to the evaporator tube. Refer to O-Ring Replacement .



14. Install the front evaporator tube to the rear evaporator tube with the retaining bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




15. Install the heater pipe bracket to the cowl stud.
16. Install the nut which retains the heater pipe bracket.

Tighten
Tighten the nut to 10 N·m (89 lb in).

17. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.
18. Install the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.
19. Install the battery. Refer to Battery Replacement in Engine Electrical.
20. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
21. Leak test the fittings of the component using J 39400-A .