Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

REMOVAL PROCEDURE




1. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

CAUTION: Refer to SIR Handling Caution in Cautions and Notices.

2. Disable the SIR. Refer to Disabling the SIR System in SIR.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

3. Disconnect the negative battery cable.
4. Remove the Instrument Panel carrier.
5. Remove the bolt (1) and slide the plate (2) counterclockwise in order to remove the evaporator inlet and outlet tubes at the bulkhead.
6. Cap the open refrigerant lines in order to prevent dint and moisture from entering the refrigeration system.




7. Disconnect the evaporator temperature sensor electrical connector from the compressor control module.
8. Remove the 6 screws and 2 nuts (1).
9. Remove the evaporator case from the vehicle.




10. Remove the 5 screws and the insulation from the evaporator case.
11. Separate the evaporator case halves (4).
12. Remove the evaporator from the lower case.
13. Remove the expansion valve (1) from the evaporator by removing the 2 bolts.
14. Remove the evaporator temperature sensor (3) from the evaporator.

INSTALLATION PROCEDURE




1. Install the evaporator to the lower case.
2. Install the evaporator temperature sensor (3) to the evaporator.
3. Install the expansion valve (1) to the evaporator. Secure with the 2 bolts.
4. Connect the evaporator case halves (4). Secure the case halves with the 5 screws.




5. Install the evaporator case to the vehicle.

NOTE: Refer to Fastener Notice in Cautions and Notices.

6. Install the 5 screws and 2 nuts (1).

Tighten
Tighten the evaporator case mounting bolts and nuts to 10 N.m (89 lb in).

7. Connect the evaporator temperature sensor electrical connector to the compressor control module.




8. Install new O-rings to the evaporator pipe fittings. Coat the new O-rings with mineral base 525 Viscosity refrigerant oil.
9. Connect the evaporator inlet and outlet pipes at the bulkhead. Slide the plate (2) clockwise and secure with the bolt (1).
10. Install the Instrument Panel carrier.
11. Enable the SIR. Refer to Enabling the SIR System in SIR.
12. Connect the negative (-) battery cable.
13. Evacuate and recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging.
14. Operate the A/C system and inspect for refrigerant leaks. Refer to Leak Testing.