Tools Required

J 39400-A Halogen Leak Detector

1. Disconnect the underhood lamp electrical connector, if equipped.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Remove the PCM. Refer to the appropriate procedure:

•	Powertrain Control Module Replacement in Engine Controls - 2.2 L

•	Powertrain Control Module Replacement in Engine Controls - 4.3 L

4. Remove the coolant recovery tank. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
5. Disconnect the electrical connectors from the grille mounted lamps, if equipped.
6. Remove the right front headlamp assembly. Refer to Headlamp Replacement in Lighting Systems.
7. Remove the front bumper. Refer to Front Bumper Impact Bar Replacement in Bumpers.
8. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
9. Disconnect the radio antenna cable.
10. Disconnect the electrical connector for the horn.
11. Remove the right fender. Refer to Front Fender Replacement in Body Front End.
12. Remove the blower motor resistor. Refer to Blower Motor Resistor Assembly Replacement .
13. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
14. Remove the evaporator tube. Refer to Evaporator Tube Replacement .
15. Remove the evaporator and blower module heat shield mounting screws.
16. Remove the evaporator and blower module heat shield.

Important: Retain the evaporator and blower module heat shield mounting bracket for installation.




17. Remove the evaporator and blower module mounting bolts and nuts.
18. Remove the evaporator and blower module from the vehicle.
19. Remove the 6 retaining screws holding the evaporator case section to the blower case section.



20. Separate the evaporator case section from the blower case section.
21. Remove the evaporator core from the blower case section.
22. Inspect the seals and replace as necessary.



23. Remove the expansion (orifice) tube (2) from the evaporator (1).

1. Install the expansion (orifice) tube (2) to the evaporator (1).



2. Install the evaporator core to the blower case section.

Important: Ensure that the seal is in place between the 2 case sections.

3. Assemble the evaporator case section to the blower case section.

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 6 retaining screws.

Tighten
Tighten the screws to 1.9 N·m (17 lb in).

Important: Ensure that the evaporator and blower module to the cowl seal is in place.

5. Install the evaporator and blower module to the vehicle.

Important: Install the evaporator and blower module heat shield mounting bracket with the evaporator and blower module mounting nuts.




6. Install the evaporator and blower module mounting fasteners.

Tighten
Tighten the to 4.5 N·m (40 lb in).

7. Install the evaporator and blower module heat shield.
8. Install the evaporator and blower module heat shield mounting screws.

Tighten
Tighten the screws to 2.2 N·m (19 lb in).

9. Install the evaporator tube. Refer to Evaporator Tube Replacement .
10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .
11. Install the blower motor resistor. Refer to Blower Motor Resistor Assembly Replacement .
12. Install the right fender. Refer to Front Fender Replacement in Body Front End.
13. Connect the electrical connector for the horn.
14. Install the radio antenna cable.
15. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
16. Install the front bumper. Refer to Front Bumper Impact Bar Replacement in Body Front End.
17. Install the right front headlamp assembly. Refer to Headlamp Replacement in Lighting Systems.
18. Connect the electrical connectors to the grille mounted lamps.
19. Install the coolant recovery tank. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
20. Install the PCM. Refer to the appropriate procedure:

•	Powertrain Control Module Replacement in Engine Controls - 2.2 L

•	Powertrain Control Module Replacement in Engine Controls - 4.3 L

21. Install the hood. Refer to Hood Replacement in Body Front End.
22. Connect the underhood lamp electrical connector.
23. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
24. Leak test the fittings components using the J 39400-A .