Evaporator Core: Service and Repair
Removal Procedure1. Remove the HVAC module from the vehicle. Service and Repair
2. Release the HVAC module vacuum harness from both of the harness retainers on the HVAC module case, below the air inlet housing.
3. Remove the defroster valve vacuum actuator to better access the HVAC module case retaining screw which is under the actuator.
4. Remove the screws retaining the HVAC module case - upper to the HVAC module case - lower.
To access the screw hidden under the air inlet valve, open the valve and retain in the open position.
5. Release the retaining tab (1) securing the HVAC module case - upper to the HVAC module case - lower.
6. Separate the HVAC module case - upper from the HVAC module case - lower.
7. Remove and discard the HVAC module case seals.
Start to remove the HVAC module case primary (blower motor side of case) seal (2) from the HVAC module case - lower at the position shown (1).
8. Remove the evaporator core from the HVAC module case - lower.
9. Remove and discard the evaporator core lower seals.
10. Remove and discard the evaporator core upper seal.
11. Remove and discard the evaporator core side seal.
12. Remove and discard the evaporator core water core filter.
Installation Procedure
1. Install a new water core filter to the evaporator core.
2. Install a new side seal to the evaporator core. Line the evaporator core side seal up with the corners of the evaporator core.
3. Install a new upper seal to the evaporator core.
4. Install two new lower seals to the evaporator core.
Locate the seals at the outer corners (or edges) of the evaporator core.
5. Install the evaporator core to the HVAC module case - lower.
6. Install new case seals to the HVAC module case - lower.
Start to install the HVAC module case primary (blower motor side of case) seal (2) to the HVAC module case - lower from the position shown (1).
Important: Inspect the condition of the retaining tab on the HVAC module case - upper prior to installing to the HVAC module case - upper to the HVAC module case - lower. If the retaining tab is broken or damaged, install an external retaining clip (P/N 52458793, or equivalent).
7. Align and install the HVAC module case - upper to the HVAC module case - lower.
Align and secure the retaining tab (1) on the HVAC module case - upper to the retaining slot on the HVAC module case - lower.
8. Install the HVAC module case - upper to the HVAC module case - lower retaining screws.
Tighten
Tighten the HVAC module case - upper to HVAC module case - lower retaining screws to 1.6 N.m (14 lb in).
9. Install the defroster valve vacuum actuator.
10. Secure the HVAC module vacuum harness to both of the harness retainers on the HVAC module case, below the air inlet housing.
11. Install the HVAC module to the vehicle.