Evaporator Inlet Tube and Evaporator Outlet Tube Replacement w/C60

Tools Required

J 39400-A Halogen Leak Detector

Important: Cap or tape the open air conditioning (A/C) components immediately in order to prevent system contamination.

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging .
3. Remove the suction line to evaporator outlet tube bolt (1).
4. Remove the suction line from the evaporator outlet tube.
5. Cap or tape the suction line opening.
6. Remove and discard the sealing washer (2).



7. Reposition the heater hoses in order to access the thermal expansion valve (TXV).
8. Remove the evaporator inlet/outlet tube block nut at the TXV.
9. Remove the evaporator inlet/outlet tube block from the TXV.
10. Remove and discard the sealing washers.
11. Cap or tape the TXV openings.



12. Remove the evaporator inlet tube to condenser bolt (2).
13. Remove the evaporator inlet tube (5) from the condenser.
14. Remove and discard the sealing washer.
15. Cap or tape the condenser opening.
16. Remove the electrical connector (3) from bracket.
17. Remove the evaporator inlet/outlet tube bracket bolt (4).
18. Remove the evaporator inlet/outlet tube clip to shock tower nut (6).
19. Remove the evaporator inlet/outlet tube assembly.
20. Remove the evaporator outlet tube (8) from the inlet tube (5).

1. Install the evaporator outlet tube (8) to the inlet tube (5).
2. Install the evaporator inlet/outlet tube assembly.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the evaporator inlet/outlet tube clip to shock tower nut (6).

Tighten
Tighten the nut to 5.5 N·m (49 lb in).

4. Install a NEW sealing washer to the condenser end of the evaporator inlet tube.
5. Remove the cap or tape from the condenser opening.
6. Install the evaporator inlet tube (5) to the condenser.
7. Install the evaporator inlet tube to condenser bolt (2).

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

8. Install the evaporator inlet/outlet tube bracket bolt (4).

Tighten
Tighten the bolt to 27 N·m (20 lb ft).

9. Install the electrical connector (3) to bracket.



10. Install NEW sealing washers to the TXV end of the evaporator inlet/outlet tube.
11. Remove the caps or tape from the TXV openings.
12. Install the evaporator inlet/outlet tube block to the TXV.
13. Install the evaporator inlet/outlet tube block nut at the TXV.

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




14. Install a NEW sealing washer (2) to the suction line.
15. Remove the cap or tape from the suction line opening.
16. Install the suction line to the evaporator outlet tube.
17. Install the suction line to evaporator outlet tube bolt (1).

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

18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .