Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

REMOVAL PROCEDURE




1. Disconnect the underhood lamp electrical connector, if equipped.
2. Remove the hood.
3. Remove the VCM or the PCM.
4. Remove the coolant recovery tank.
5. Disconnect the electrical connectors from the grille mounted lamps if equipped.
6. Remove the right front headlamp assembly.
7. Remove the front bumper.
8. Remove the right wheelhouse panel.
9. Disconnect the radio antenna cable.
10. Disconnect the electrical connector for the horn.
11. Remove the right fender.
12. Remove the blower motor resistor.
13. Remove the accumulator.
14. Remove the evaporator tube.
15. Remove the evaporator and blower module heat shield mounting screws (Utility).
16. Remove the evaporator and blower module heat shield (Utility).

IMPORTANT: Retain the evaporator and blower module heat shield mounting bracket for installation (Utility).

17. Remove the evaporator and blower module mounting bolts and nuts.
18. Remove the evaporator and blower module from the vehicle.




19. Remove the six evaporator case section to the blower case section retaining screws.
20. Separate the evaporator case section from the blower case section.
21. Remove the evaporator core from the blower case section.
22. Inspect the seals and replace as necessary.

INSTALLATION PROCEDURE




1. Install the evaporator core to the blower case section.

IMPORTANT: Ensure that the seal between the two case sections is in place.

2. Assemble the evaporator case section to the blower case section.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the six evaporator case section to the blower case section retaining screws.

Tighten
Tighten the screws to 1.9 N.m (17 lb in).

IMPORTANT: Ensure that the evaporator and blower module to the bulkhead seal is in place.




4. Install the evaporator and blower module to the vehicle.

IMPORTANT: Install the evaporator and blower module heat shield mounting bracket with the evaporator and blower module mounting nuts (Utility).

5. Install the evaporator and blower module mounting bolts and nuts.

Tighten
Tighten the bolts and the nuts to 4.5 N.m (40 lb in).

6. Install the evaporator and blower module heat shield (Utility).
7. Install the evaporator and blower module heat shield mounting screws (Utility).

Tighten
Tighten the screws to 2.2 N.m (19 lb in).

8. Install the evaporator tube.
9. Install the accumulator.
10. Install the blower motor resistor.
11. Install the right fender.
12. Connect the electrical connector for the horn.
13. Install the radio antenna cable.
14. Install the right wheelhouse panel.
15. Install the front bumper.
16. Install the right front headlamp assembly.
17. Connect the electrical connectors to the grille mounted lamps, if equipped.
18. Install the coolant recovery tank.
19. Install the VCM or the PCM.
20. Install the hood.
21. Connect the underhood lamp electrical connector, if equipped.