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 air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Replacement for the 6.6L (LBZ and LLY) engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Caterpillar® 3126 Unit Repair Manual for the 7.2L (Caterpillar) engine

3. Remove the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .



4. Remove the retaining bolt (2) from the evaporator inlet tube bracket (3).



5. Remove the retaining nut (3) from evaporator inlet tube (5).
6. Remove the sealing washer.



7. Disconnect the evaporator tube fitting (3) from the evaporator hose fitting (2).

Notice: Refer to Fastener Notice in the Preface section.




1. Connect the evaporator tube fitting (3) to the evaporator hose fitting (2).

Tighten
Tighten the fittings to 35 N·m (18 lb ft).

2. Install the new seal washer. Refer to Sealing Washer Replacement .



3. Install the evaporator inlet tube to the evaporator.
4. Install the evaporator tube retaining nut (3).

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




5. Install the retaining bolt to the evaporator inlet tube bracket (3).

Tighten
Tighten the bolt to 9 N·m (60 lb in).

6. Install the air cleaner. Refer to the appropriate procedure:

•	Air Cleaner Replacement for the 6.6L (LBZ and LLY) engine

•	Air Cleaner Replacement for the 8.1L engine

•	Air Cleaner Replacement for the 7.8L engine

•	Caterpillar® 3126 Unit Repair Manual for the 7.2L (Caterpillar) engine

7. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement .
8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
9. Leak test the fittings of the components using the J 39400-A .