Air Conditioning Evaporator Front Tube Replacement

Air Conditioning Evaporator Front Tube Replacement

Tools Required

J 39400-A Halogen Leak Detector


Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
2. Remove the battery. Refer to Battery Replacement (Battery Replacement) .




3. Disconnect and remove the A/C tube connector (1) at the evaporator rear line assembly. Refer to Air Conditioning Line/Tube Connector Removal/Replacement (Air Conditioning Line/Tube Connector Removal/Replacement) .




4. Disconnect the front evaporator inlet line from the body retaining clip (1).
5. Disconnect the refrigerant pressure sensor electrical connector (2).




6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
7. Remove the front evaporator inlet line to A/C condenser lower bolt.

Important: Immediately cap or tape the open A/C components immediately in order to prevent contamination.


8. Disconnect the front evaporator line inlet from the A/C condenser.
9. Remove and discard the sealing washer.
10. Cap or tape off the A/C condenser.
11. Lower the vehicle.




12. Disconnect the front evaporator inlet line from the evaporator rear line assembly.
13. Remove and discard the O-rings.
14. Cap or tape the evaporator rear line assembly.




15. Disconnect the surge tank outlet hose and the inlet heater hose from the underhood junction box retainer clip (1).
16. Remove the front evaporator inlet line from the vehicle.



Installation Procedure

1. Install the front evaporator inlet line to the vehicle.




2. Connect the surge tank outlet hose and the inlet heater hose to the underhood junction box retainer clip (1).




3. Remove cap or tape from the evaporator rear line assembly.
4. Install new O-rings to the rear evaporator line assembly. Refer to O-Ring Replacement (O-Ring Replacement) .
5. Connect the front evaporator inlet line to the evaporator rear line assembly.
6. Raise the vehicle.
7. Remove cap or tape from the A/C condenser.
8. Install a new sealing washer to the front evaporator inlet line. Refer to Sealing Washer Replacement (Sealing Washer Replacement) .
9. Connect the front evaporator inlet line to the A/C condenser.

Notice: Refer to Fastener Notice .

10. Install the front evaporator inlet line to A/C condenser lower bolt.

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





11. Lower the vehicle.
12. Connect the front evaporator inlet line to the body retaining clip (1).




13. Connect the refrigerant pressure sensor electrical connector (2).




14. Connect the A/C tube connector (1) at the evaporator rear line assembly. Refer to Air Conditioning Line/Tube Connector Removal/Replacement (Air Conditioning Line/Tube Connector Removal/Replacement) .
15. Install the battery. Refer to Battery Replacement (Battery Replacement) .
16. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
17. Leak test the fittings of the component using J 39400-A .