Evaporator Tube Replacement - Inlet

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Remove the air cleaner assembly.
2. Disconnect the cruise control module electrical connector.
3. Reposition the cruise control module aside.




4. Remove the cruise control module mounting bracket bolts.
5. Remove the cruise control module mounting bracket.
6. Recover the refrigerant from the A/C system.
7. Remove the wiper motor module.




8. Remove the evaporator inlet tube clamp nut.
9. Disconnect the electrical connector from the A/C pressure sensor.
10. Remove the A/C pressure sensor from the evaporator inlet tube.




11. Remove the evaporator outlet tube to TXV nut.
12. Disconnect the evaporator outlet tube from the TXV.
13. Disconnect the evaporator inlet tube from the evaporator outlet tube.
14. Cap or tape off the TXV.

IMPORTANT: Cap or tape the A/C refrigerant components immediately to prevent system contamination.




15. Remove the evaporator inlet tube to condenser fitting bolt.
16. Disconnect the evaporator inlet tube from the condenser.
17. Cap or tape off the condenser.
18. Remove the evaporator outlet tube bracket bolt.




19. Remove the evaporator inlet tube.

IMPORTANT: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.

20. Remove and discard the sealing washers.

INSTALLATION PROCEDURE
1. Install new sealing washers onto the evaporator inlet tube.




2. Install the evaporator inlet tube.

IMPORTANT: Gently lift up on the evaporator outlet tube bracket to allow enough clearance to slide the evaporator inlet tube underneath.

3. Install the evaporator outlet tube bracket bolt.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the bolt to 5.5 N.m (45 lb in).




4. Remove the cap or tape from the condenser.
5. Connect the evaporator inlet tube to the condenser.
6. Install the evaporator inlet tube to condenser bolt.

Tighten
Tighten the bolt to 16 N.m (12 lb ft).

7. Remove the cap or tape from the TXV.
8. Connect the evaporator inlet tube to the evaporator outlet tube.
9. Connect the evaporator outlet tube to the TXV.




10. Install the evaporator outlet tube nut.

Tighten
Tighten the nut to 16 N.m (12 lb ft).




11. Install the evaporator inlet tube clamp nut.

Tighten
Tighten the nut to 3.3 N.m (29 lb in).

12. Install the A/C pressure sensor to the evaporator inlet tube.

Tighten
Tighten the sensor to 5 N.m (44 lb in).

13. Connect the electrical connector to the A/C pressure sensor.
14. Install the wiper motor module.
15. Install the air cleaner assembly.




16. Install the cruise control module mounting bracket.
17. Install the cruise control module mounting bracket bolts.

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

18. Install the cruise control module into the mounting bracket.
19. Connect the cruise control module electrical connector.
20. Evacuate and recharge the A/C system.
21. Leak test the fittings of the component using J 39400-A.