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 .
3. Remove the intake manifold. Refer to Intake Manifold Replacement .



4. Disconnect the front evaporator inlet line from the body retaining clip.
5. Disconnect the refrigerant pressure sensor electrical connector.



6. Disconnect and remove the A/C tube connectors from the evaporator rear line assembly. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .

Important: Immediately cap or tape the open A/C components immediately in order to prevent contamination.

7. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
8. Remove and discard O-rings.
9. Cap or tape the front evaporator inlet line.
10. Disconnect the A/C compressor line from the evaporator rear line assembly.
11. Remove and discard the O-rings.
12. Cap or tape the front evaporator line and A/C compressor line.



13. Remove the heater pipe bracket retaining nut (1) from the cowl stud.
14. Remove the thermal expansion valve (TXV) block fitting nut (2).
15. Disconnect the evaporator rear line assembly from the TXV (3).
16. Disconnect the evaporator rear line assembly from the retainer bracket stud.
17. Remove the rear evaporator line assembly from the vehicle.
18. Remove and discard the seal washers.
19. Cap or tape the TXV (3).

Important: If replacing the evaporator rear line assembly, add the specified amount of polyalkylene glycol (PAG) oil directly to the evaporator rear line assembly. Refer to Refrigerant System Capacities .

1. Remove the cap or tape from the TXV (3).
2. Install new seal washers to the evaporator rear line assembly . Refer to Sealing Washer Replacement .
3. Install the evaporator rear line assembly to the vehicle.
4. Connect the evaporator rear line assembly to the retainer bracket stud.



5. Connect the evaporator rear line assembly to the TXV (3).

Notice: Refer to Fastener Notice in the Preface section.

6. Install the TXV block fitting nut (2).

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

7. Install the heater pipe bracket retaining nut (1) to the cowl stud.

Tighten
Tighten the nut to 10 N·m (7 lb ft).




8. Remove cap or tape from the front evaporator line and A/C compressor line.
9. Install new O-rings to the rear evaporator line assembly. Refer to O-Ring Replacement .
10. Connect the A/C compressor line to the evaporator rear line assembly.
11. Connect the front evaporator line to the evaporator rear line assembly.
12. Connect the A/C tube connectors onto the evaporator rear line assembly. Refer to Air Conditioning Line/Tube Connector Removal/Replacement .
13. Connect the refrigerant pressure sensor electrical connector (2).



14. Connect the front evaporator inlet line to the body retaining clip.
15. Install the intake manifold. Refer to Intake Manifold Replacement .
16. Install the battery. Refer to Battery Replacement .
17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
18. Leak test the fittings of the component using J 39400-A .