Tools Required

J 39400-A Halogen Leak Detector

1. Remove the right fender. Refer to Front Fender Replacement in Body Front End.
2. Remove the blower motor resistor. Refer to Blower Motor Resistor Assembly Replacement .
3. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
4. Remove the evaporator tube. Refer to Evaporator Tube Replacement .
5. Remove the evaporator and blower module heat shield mounting screws.
6. Remove the evaporator and blower module heat shield.

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




7. Remove the evaporator and blower module mounting bolts and nuts.
8. Remove the evaporator and blower module from the vehicle.
9. Remove the 6 retaining screws holding the evaporator case section to the blower case section.



10. Separate the evaporator case section from the blower case section.
11. Remove the evaporator core from the blower case section.
12. Inspect the seals and replace as necessary.



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

Important: If replacing the evaporator core, add the refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information.




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 fasteners 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. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fittings of the components using the J 39400-A .