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 fender. Refer to Front Fender Replacement in Body Front End.
3. Remove the left wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
4. Disconnect the evaporator tube from the evaporator core fitting. Refer to Evaporator Tube Replacement
5. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement .
6. Remove the evaporator case heat shield retaining screws.
7. Remove the heat shield from the evaporator case.
8. Disconnect the EGR exhaust pipe from the exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
9. Disconnect electrical connector from the blower motor.



10. Remove the evaporator case retaining screws and nuts.
11. Remove the evaporator case assembly from the vehicle.
12. Disassemble the evaporator case sections.
13. Remove the evaporator core from the evaporator case.

1. Install the evaporator core to the evaporator case.
2. Assemble the evaporator case sections.

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.

3. Install the evaporator case screws.

Tighten
Tighten the evaporator case screws to 2.5 N·m (22 lb in).

4. Install the evaporator case assembly to the vehicle.
5. Install the bolts and nuts which retain the evaporator case to the bulkhead.

Tighten
Tighten the evaporator case mounting bolts and nuts to 4.5 N·m (40 lb in).

6. Connect electrical connector to the blower motor.
7. Connect the EGR pipe to the exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
8. Install the heat shield to the evaporator case.

Tighten
Tighten the evaporator case heat shield mounting screws to 2.5 N·m (22 lb in).

9. Install the accumulator. Refer to Air Conditioning Accumulator Replacement .
10. Connect the evaporator tube to the evaporator core fitting. Refer to Evaporator Tube Replacement
11. Install the left wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
12. Install the left fender. Refer to Front Fender Replacement in Body Front End.
13. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging .
14. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A .