Evaporator Core: Service and Repair
FRONT UNIT
1. Disconnect battery ground cable, then discharge system refrigerant.
2. Remove cold air intake.
3. Disconnect hood latch assembly and cable retainer and set aside.
4. Remove windshield washer solvent tank, then disconnect low pressure line and position aside. Cap open connection.
5. Remove accumulator.
6. Disconnect high pressure inlet line from evaporator, then remove connecting bracket.
7. Disconnect blower motor relay and resistor wiring harnesses, then remove relay and resistors.
8. Remove upper fan shroud and radiator.
9. Disconnect heater valve assembly bracket and set aside.
10. Remove the upper screws of the lower insulation, then push it down for clearance.
11. Remove the insulation mounting screws, then remove insulation through hood opening.
12. Remove the coolant recovery tank and bracket.
13. Remove electrical connectors from the core case assembly.
14. Remove the bracket at the evaporator case, then the right marker lamp to gain access.
15. Remove the evaporator inlet line, then cap connections.
16. Remove core case to dash attaching screws and nuts, then the core case.
17. Remove screws, separate case halves and remove evaporator case.
18. Reverse procedure to install, using new "O" rings coated with clean refrigerant oil at connections.
OVERHEAD SYSTEM
1. Disconnect battery ground cable, then discharge system refrigerant.
2. Remove rear duct.
3. Disconnect blower motor harness and ground wire.
4. Disconnect refrigerant lines at evaporator/blower assembly. Cap all open connections.
5. While supporting unit, remove blower/evaporator assembly support screws at roof rail. Place unit upside down on bench, then remove upper to lower case retaining screws. Remove lower case half.
6. Remove upper case to support screws and case from evaporator core.
7. Remove inlet and discharge lines at expansion valve. Cap all open connections.
8. Remove expansion valve sensing bulb from discharge line, then the valve.
9. Remove plastic screen retaining pins at core and screen.
10. Reverse procedure to install, using new "O" rings coated with clean refrigerant at connections. When installing a new evaporator core, add 3 fluid ounces of fresh refrigerant oil to unit prior to installation.