Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging .
2. Remove the left body side rear trim panel. Refer to Body Side Trim Panel Replacement - Left Side in Interior Trim.



3. Remove the air outlet duct assembly. Refer to Auxiliary Air Outlet Duct Replacement .
4. Disconnect the electrical connectors.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



6. Remove the retaining nut in order to remove the auxiliary evaporator rear tube assembly from the core.
7. Lower the vehicle.
8. Remove the bolts that retain the case to the vehicle.



9. Remove the auxiliary evaporator module assembly from the vehicle.
10. Remove the screws from the case.
11. Separate the case halves.
12. Remove the evaporator core seal.
13. Remove the core from the case.
14. Inspect the gaskets and the seals for damage.
15. Replace the gaskets and the seals.

1. If replacing the evaporator, add the proper amount of PAG oil.



2. Install the evaporator core into the case.
3. Install the evaporator core seal.
4. Reassemble the case halves.
5. Install the auxiliary evaporator module assembly to the vehicle.




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.

6. Install the bolts that retain the case to the vehicle.

Tighten
Tighten the bolts to 10 N·m (86 lb in).

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Install new seal washers. Refer to Sealing Washer Replacement .
9. Install the auxiliary evaporator underbody rear tube assembly to the core with the retaining nut.

Tighten
Tighten the nut to 10 N·m (86 lb in).

10. Lower the vehicle.



11. Connect the electrical connectors.
12. Install the air outlet duct assembly. Refer to Auxiliary Air Outlet Duct Replacement .
13. Install the left body side rear trim panel. Refer to Body Side Trim Panel Replacement - Left Side in Interior Trim.
14. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
15. Leak test the fittings of the component using the J 39400-A .