Evaporator Tube Replacement - Inlet

Evaporator Tube Replacement - Inlet

Tools Required

J39400-A Halogen Leak Detector

Removal Procedure

1. Remove the air cleaner assembly.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Remove the wiper motor module.




4. Remove the evaporator inlet tube clamp nut.
5. Disconnect the electrical connector from the A/C pressure sensor.
6. Remove the A/C pressure sensor from the evaporator inlet tube.




7. Remove the evaporator outlet tube to thermal expansion valve (TXV) nut.
8. Disconnect the evaporator outlet tube from the TXV.
9. Disconnect the evaporator inlet tube from the evaporator outlet tube.

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

10. Cap or tape off the TXV.




11. Remove the evaporator inlet tube to condenser fitting bolt.
12. Disconnect the evaporator inlet tube from the condenser.
13. Cap or tape off the condenser.
14. Remove the evaporator outlet tube bracket bolt.






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

15. Remove the evaporator inlet tube.
16. Remove and discard the sealing washers.

Installation Procedure

1. Install new sealing washers onto 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.

2. Install the evaporator inlet tube.

Notice: Refer to Fastener Notice.

3. Install the evaporator outlet tube bracket bolt.

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




11. Install the evaporator inlet tube clamp nut.

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

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

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. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
17. Leak test the fittings of the component using J39400-A.