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



11. Loosen the accumulator hose to evaporator retaining bolt.
12. Disconnect the rear evaporator tube from the accumulator hose bracket at the evaporator.
13. Remove and discard O-ring.
14. Cap or tape the open rear evaporator tube and the evaporator.

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



3. Position the rear evaporator tube with the accumulator hose bracket and install 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. Tighten the bolt which secures 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 front evaporator tube.
6. Install a new O-ring to the evaporator tube. Refer to O-Ring Replacement .



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

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




8. Install the heater pipe bracket to the cowl stud.
9. Install the heater pipe bracket retaining nut.

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

10. Install the intake manifold. Refer to Intake Manifold Replacement in Engine Mechanical.
11. Install the battery heat shield. Refer to Battery Heat Shield Replacement in Engine Electrical.
12. Install the battery. Refer to Battery Replacement in Engine Electrical.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the component using J 39400-A .