Evaporator Case: Service and Repair

EVAPORATOR CORE HOUSING

REMOVAL

All vehicles
1. Recover the refrigerant.
2. Raise the vehicle.
3. Remove the RH front wheel and tire.







4. Remove the screws from the RH fender apron and remove the fender apron.







5. Remove the nuts.
6. Lower the vehicle.

Vehicles with manual A/C







7. Disconnect the blower motor resistor electrical connector.

Vehicles with EATC







8. Disconnect the blower motor speed control electrical connector.

All Vehicles







9. Disconnect the evaporator air discharge temperature sensor electrical connector.







10. Disconnect the evaporator outlet spring lock coupling.
- Discard the O-ring seals.







11. Disconnect the evaporator inlet spring lock coupling.
- Discard the O-ring seals.







12. Remove the nuts and position the purge valve and bracket away from the evaporator core housing.







13. Clamp off and disconnect the heater hoses at the heater core.







14. Disengage the connectors from the bracket.







15. Disconnect the blower motor electrical connector.







16. Remove the nut and reposition the wire harness away from the evaporator housing.







17. Disengage the wire harness from the bracket.







18. Remove the pin-type retainer and clip and remove the instrument panel lower insulator.







19. Fold back the carpet and remove the screw.







20. From inside the vehicle, remove the screw.







21. Remove the bolts.


Vehicles with EATC







22. Remove the in-car temperature sensor hose and elbow from the evaporator housing (if equipped).

All vehicles
23. Remove the evaporator core housing.

INSTALLATION
1. To install, reverse the removal procedure.
- Clean and lubricate the coolant hoses with coolant hose lubricant or plain water only if needed.
- Install new O-ring seals lubricated in clean PAG oil.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

2. Evacuate, leak test and charge the refrigerant system.