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 right wiper arm linkage from the wiper arm pivot.
3. Remove the nut (2) from the hose bracket.
4. Remove the nut (3) from the hose bracket.



5. Remove the evaporator outlet hose (1) from the evaporator.
6. Remove the evaporator outlet hose O-ring seal.
7. Remove the evaporator inlet hose (2) from the evaporator.
8. Remove the evaporator inlet hose O-ring seal.



9. Remove the primary evaporator core cover screws.
10. Remove the primary evaporator core cover, foam insulator, and cover.
11. Remove the secondary evaporator core cover screws.
12. Remove the secondary evaporator core cover, the capture insert, and Styrofoam insulator.



13. Remove the primary evaporator spacer.



14. Remove the evaporator.

1. If replacing the evaporator add refrigerant oil. Refer to Refrigerant System Capacities .



2. Install the evaporator.



3. Install the evaporator spacer.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the secondary evaporator core Styrofoam insulator, cover, tube capture insert, and screws.

Tighten
Tighten the screws to 2 N·m (17 lb in).




5. Install the primary evaporator core cover and foam insulator.
6. Install the primary evaporator core cover screws.

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

7. Install the new O-ring seals. Refer to O-Ring Replacement .



8. Install the evaporator outlet hose (1) to the evaporator.

Tighten
Tighten the fitting to 32 N·m (24 lb ft).

9. Install the evaporator inlet hose (2) to the evaporator.

Tighten
Tighten the fitting to 18 N·m (13 lb ft).




10. Install the hose bracket and nut (2).

Tighten
Tighten the nut to 30 N·m (22 lb ft).

11. Install the hose bracket and nut (3).

Tighten
Tighten the nut to 30 N·m (22 lb ft).

12. Push the right wiper arm linkage carefully onto the wiper arm pivot and install the retaining screw.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the repaired or reinstalled components using the J 39400-A .