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 and the refrigerant hose bracket.



4. Remove the low pressure hose from the evaporator.
5. Remove the O-ring seal and discard.
6. Remove the evaporator tube from the condenser.
7. Remove the evaporator tube O-ring seal from the evaporator and discard.



8. Remove the primary evaporator core cover screws.
9. Remove the primary evaporator core cover from the insulator and cover.



10. Remove the secondary evaporator core cover screws.
11. Remove the secondary evaporator core cover, tube, capture insert, and styrofoam insulator.



12. Remove the spacer.
13. Remove the evaporator.
14. Remove insulation pad from the capillary tube bulb and clamp.
15. Remove the screw and the clamp.
16. Remove the expansion valve from the low pressure fitting.
17. Remove the expansion valve O-ring seal from the low pressure fitting and discard.
18. Remove the expansion valve from the evaporator core.
19. Remove the high pressure elbow from the expansion valve.
20. Remove the high pressure line elbow O-ring seal from the elbow. Discard the O-ring seal.
21. Remove the expansion valve O-ring seal from the evaporator core. Discard the O-ring seal.

1. Coat the new O-ring seal. Use 525 viscosity refrigerant oil.




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.

2. Install the new O-ring seal and the expansion valve to the evaporator core.

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

3. Coat the new O-ring seal. Use 525 viscosity refrigerant oil.
4. Install the new O-ring seal and the high pressure line elbow to the expansion valve.

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

5. Coat the new O-ring seal. Use 525 viscosity refrigerant oil.
6. Install the new O-ring and expansion valve to the low pressure hose fitting.

Tighten
Tighten the fitting to 15 N·m (11 lb ft).

7. Install the screw and the clamp to the capillary tube bulb and low pressure line.
8. Install the insulation pad over the capillary tube bulb and clamp.



9. Install the evaporator.



10. Install the evaporator spacer.
11. Install the secondary evaporator styrofoam insulator, core insert cover, and tube capture insert.
12. Install the secondary evaporator core cover screws.



13. Install the primary evaporator core cover and foam insulator.
14. Install the primary evaporator core cover screws.
15. Coat the new O-ring seal. Use 525 viscosity refrigerant oil.



16. Install the new O-ring and the high pressure hose to the evaporator.
17. Coat the new O-ring seal. Use 525 viscosity refrigerant oil.
18. Install the new O-ring and the low pressure hose to the evaporator.

Tighten

•	Tighten the high pressure hose fitting at the evaporator to 18 N·m (13 lb ft).

•	Tighten the low pressure hose fitting at the evaporator to 32 N·m (24 lb ft).

19. Install the hose bracket and nut.

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

20. Push the right wiper arm linkage carefully onto the wiper arm pivot.
21. Evacuate and recharge the A/c system. Refer to Refrigerant Recovery and Recharging .
22. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .