Hose/Line HVAC: Service and Repair

Evaporator Tube Replacement (Non HP2)

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the upper radiator air baffle and deflector.
3. Remove the air cleaner assembly.
4. Remove the surge tank hold down nut and bolt and position aside.

Important: Do not open cooling system.




5. Remove the evaporator tube nut from the evaporator.
6. Disconnect the evaporator tube from the evaporator.
7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped.
8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped.




9. Remove the evaporator tube nut from the condenser.
10. Disconnect the evaporator tube from the condenser.
11. Remove the evaporator tube from the vehicle.
12. Discard all of the used sealing washers. Cap all of the open connections.

Installation Procedure

1. Connect the evaporator tube to the condenser using new sealing washers.

Notice: Refer to Fastener Notice.




2. Install the evaporator tube nut to the condenser.

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

3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped.
4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped.

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

5. Install the evaporator tube to the evaporator.




6. Install the evaporator tube nut to the evaporator.

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

7. Install the surge tank hold down nut and bolt and position aside.
8. Install the air cleaner assembly.
9. Install the upper radiator air baffle and deflector.
10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging.
11. Leak test the fittings of the components using the J 39400-A.