Evaporator Case: Service and Repair

A/C Evaporator Housing Assembly

NOTE:Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier.

NOTE:If an evaporator leak is suspected, the A/C evaporator core must be leak-tested before it is removed from the vehicle. Service and Repair

Special Tools:

Removal

1. Disconnect battery ground cable (14301).

2. Remove instrument panel (04320). Service and Repair

3. Place a drain pan or suitable container under the heater water hose connections at the cowl panel.

4. Recover refrigerant from A/C system at service access gauge port valve located on suction line. Observe all safety precautions. Service and Repair

5. Remove suction accumulator/drier as outlined.

6. Remove two nuts retaining A/C accumulator bracket (19D606) to cowl panel and remove A/C accumulator bracket.

7. Disconnect condenser to evaporator tube (19835) from A/C evaporator core inlet tube at cowl panel using Spring Lock Coupling Disconnect Tool T8IP-19623-G2 or equivalent. Cap refrigerant lines and evaporator core tube to prevent entrance of dirt and excess moisture.

Accumulator Mounting Bracket:

8. Disconnect heater water hoses (18472) from heater core tubes and plug heater water hoses with suitable 5/8-inch and 3/4-inch plugs Cap heater core tubes to prevent coolant loss from heater core (18476) during removal of A/C evaporator housing (19850).

Heater Water Hoses:

9. Disconnect vacuum supply hose (black) from vacuum source in engine compartment.

10. Remove nut retaining A/C evaporator housing to cowl panel.

Vacuum Supply Hose:

11. Inside passenger compartment, remove one screw retaining the bottom of the A/C evaporator housing to cowl panel.

12. Remove screw retaining A/C evaporator case support bracket (19A639) to cowl top panel

13. Remove nut retaining A/C evaporator case mounting bracket (19A865) to cowl top panel.

14. Disconnect wire harness connector at blower motor (18527).

15. Carefully pull A/C evaporator housing away from cowl panel and remove A/C evaporator housing assembly from vehicle.

A/C Evaporator Housing Removal:

Installation

1. Install A/C evaporator housing to cowl panel.

2. Install nut retaining A/C evaporator housing to cowl top bracket. Tighten to 10.2-13.8 Nm (91-121 lb-in).

3. Install screw retaining A/C evaporator housing to cowl top bracket. Tighten to 10.2-13.8 Nm (91-121 lb-in).

4. Install screw retaining the bottom of the NC evaporator housing to cowl panel. Tighten screw to 1.6-2.2Nm (15-19 lb-in).

5. Working under hood (16612), install nut retaining A/C evaporator housing to cowl panel. Tighten nut to 6.6-9.4 Nm (59-83 lb-in).

6. Connect vacuum supply hose (black) to vacuum source in engine compartment.

7. Connect two heater water hoses to heater core inlet and outlet tubes.

8. Connect condenser to evaporator tube to A/C evaporator core inlet tube.

9. Install A/C accumulator bracket to cowl panel and secure with two nuts. Tighten to 6.6-9.4 Nm (59-83 lb-in).

10. Install suction accumulator/drier as outlined.

11. Install instrument panel. Service and Repair

12. Connect battery ground cable.

13. Charge refrigerant system. Observe all safety precautions. Service and Repair

14. After service has been completed, check the engine coolant level in the radiator (8005) and in the radiator coolant recovery reservoir (8A080). Fill as required with the recommended coolant mixture.