Tools Required

J 39400-A Halogen Leak Detector

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L.
2. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.



4. Disconnect the electrical connectors.
5. Remove the bypass valve bracket from the outer case.
6. Remove the evaporator tube from the accumulator.
7. Remove the relay bracket.
8. Loosen the evaporator tube nut at the evaporator.
9. Remove the evaporator tube from the evaporator.



10. Remove the screws from the outer evaporator case.
11. Remove the outer case from the module.
12. Remove the screws in order to split the evaporator module in half.
13. Remove the inner case from the module.
14. Remove the evaporator core.

1. If replacing the evaporator core, add the PAG oil to the evaporator. Refer to System Capacities for capacity information.



2. Install the evaporator core.

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.

3. Install the inner case to the evaporator module.
4. Install the evaporator case screws.

Tighten
Tighten the screws to 6 N·m (53 lb in).

5. Install the outer case to the evaporator module.
6. Install the screws to the evaporator case

Tighten
Tighten the screws to 6 N·m (53 lb in).

7. Install a new O-ring. Refer to O-Ring Replacement .
8. Install the evaporator tube to the evaporator.
9. Tighten the evaporator tube nut to the evaporator.

Tighten
Tighten the nut to 28 N·m (20 lb ft).

10. Install the bypass valve bracket to the outer case.
11. Install the relay bracket.
12. Connect the electrical connectors.
13. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .
14. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls 4.3L.