Tools Required

J 39400-A Halogen Leak Detector

1. Remove the HVAC module - auxiliary assembly. Refer to Auxiliary HVAC Module Replacement .
2. Remove the heater core - auxiliary. Refer to Auxiliary Heater Core Replacement .
3. Remove the inverted TORX studs from the evaporator block - auxiliary.



4. Remove the backing plate (1) from the evaporator core.



5. Remove the screws from the blower motor control processor - auxiliary.
6. Remove the blower motor control processor - auxiliary.
7. Remove the screws from the HVAC module - auxiliary case sump (2).
8. Remove the HVAC module - auxiliary case sump (2).



9. Remove the evaporator core (3) from the HVAC module - auxiliary (1).
10. Carefully remove the foam insulator (2) from around the evaporator core - auxiliary (3).

1. If replacing the evaporator core, add the proper amount of refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for the capacity information.



2. Transfer the foam insulator (2) to the replacement evaporator core-auxiliary (3).
3. Transfer the thermal expansion valve-auxiliary to the replacement evaporator core - auxiliary.

Install the evaporator core - auxiliary (3) to the rear HVAC module - auxiliary (1).




4. Install the HVAC module - auxiliary case sump (2).

Notice: Refer to Fastener Notice in the Preface section.

5. Install the screws to the HVAC module - auxiliary case sump.

Tighten
Tighten the screws to 2 N·m (18 lb in).

6. Install the blower motor control processor - auxiliary.



7. Install the backing plate (1) to the evaporator core - auxiliary.
8. Install the evaporator block - auxiliary.
9. Install the inverted TORX studs to the evaporator block - auxiliary.

Tighten
Tighten the TORX studs to 2 N·m (18 lb in).

10. Install the heater core-auxiliary. Refer to Auxiliary Heater Core Replacement .
11. Install the HVAC module - auxiliary assembly. Refer to Auxiliary HVAC Module Replacement .
12. Leak test the fittings of the component using the J 39400-A .