Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation Air Conditioning and Heater Module Assembly.





2. Remove the insulation (1) from the thermal expansion valve (TXV).





3. Remove the HVAC line clamp screw.





4. Remove the HVAC line clamp.





5. Remove the TXV to evaporator bolts (1).





6. Remove the TXV line bracket.





7. Remove the TXV from the evaporator core.

8. Separate the TXV from the A/C lines by pulling straight out.

9. Remove the TXV.

10. Remove the screws that hold the case together.





11. Remove the clips that hold the case together.





12. Disconnect the thermistor electrical connector.





13. Separate the HVAC module.





14. Remove the thermistor from the evaporator core.





15. Remove the evaporator core.

Installation Procedure

1. Add refrigerant oil. Refer to Refrigerant System Specifications [1][2]Fluid Type Specifications.

2. Install new evaporator core seals to evaporator.





3. Install the evaporator core.





4. Install the thermistor to the evaporator into the same position as removed.





5. Slide the HVAC module together.

Caution:
Refer to Fastener Caution Fastener Caution.

6. Install the screws that hold the case together and tighten to 1 Nm (8 lb in).

7. Install the clips that hold the case together.





8. Connect the thermistor electrical connector.

9. Lube A/C lines with refrigerant oil before installing. Refer to Air Conditioning O-Ring Seal Replacement Service and Repair.

10. Install the A/C lines into the TXV.





11. Carefully slide the TXV onto the evaporator core until seated.





12. Install the TXV line bracket.





Caution:
Refer to Fastener Caution Fastener Caution.

13. Install the TXV to evaporator bolts (1) and tighten to 3.5 Nm (31 lb in).





14. Install the HVAC line clamp.





15. Install the HVAC line clamp screw and tighten to 1 Nm (8 lb in).





16. Install the insulation (1) onto the lines and TXV.

17. Install the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation Air Conditioning and Heater Module Assembly.