Evaporator Case: Service and Repair

HEATER CORE AND EVAPORATOR CORE HOUSING

Special Tool(s):

SPECIAL TOOL(S)

REMOVAL

Vehicles with air conditioning
1. Drain the air conditioning system.

All vehicles
2. Drain the cooling system.







3. Using the special tool, disconnect the coolant hoses from the heater core.
4. Lower the vehicle.
5. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair







6. Using the special tool, disconnect the refrigerant lines from the evaporator core (pressure pipe shown from below).
- Discard the O-ring seals.







7. Remove the left-hand and right-hand in-vehicle crossbeam retaining bolts.
- Remove the blanking caps.







8. Remove the right-hand air ducts.







9. Remove the in-vehicle crossbeam right-hand retaining bolts.
- Unclip the wiring harness from the in-vehicle crossbeam (one shown).







10. Remove the left-hand air ducts.







11. Detach the central junction box (CJB) from the in-vehicle crossbeam.







12. Remove the in-vehicle crossbeam left-hand retaining bolts.
- Unclip the wiring harness from the in-vehicle crossbeam.







13. Remove the air duct.
- Unclip the wiring harness from the in-vehicle crossbeam.







14. Remove the left-hand and right-hand in-vehicle crossbeam bracket (right-hand side shown).
- Push the in-vehicle crossbeam back.







15. Remove the rear footwell vent air ducts.







16. Unclip the wiring harness from the heater core housing.







17. Remove the heater core housing retaining nut passengers side.







18. Remove the heater core housing retaining nut drivers side.







19. Remove the heater core housing right-hand retaining nut.







20. Remove the heater core housing.

INSTALLATION

1. NOTE:
- Install new refrigerant line O-ring seals.
- Coat the refrigerant line O-ring seals in clean refrigerant oil prior to installation.

To install, reverse the removal procedure.