Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

1. Remove the air cleaner outlet front duct. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
2. Remove the engine coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.
3. Discharge and recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.
4. Remove the instrument panel compartment. Refer to Instrument Panel Carrier Replacement Service and Repair in Instrument Panel, Gauges and Console.
5. Remove the electrical connectors, as necessary.
6. Remove the accumulator tube from the evaporator. Refer to Accumulator Replacement Service and Repair.
7. Remove the center floor air distribution duct.
8. Remove the TCM and the mounting tray. Refer to Transmission Control Module Replacement Service and Repair in Automatic Transmission.
9. Remove the hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement Service and Repair in Interior Trim.
10. Remove the blower motor (4). Refer to Blower Motor and Fan Replacement Service and Repair.
11. Remove the steering column. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column Replacement.
12. Disconnect and tilt back the instrument panel assembly. Refer to Instrument Panel Carrier Replacement Service and Repair in Instrument Panel, Gauges, and Console.
13. Disconnect the heater hoses. Refer to Heater Hoses Replacement (LP4/L21 Inlet) Heater Hoses Replacement (LP4/L21 Inlet)Heater Hoses Replacement (LP4/L21 Outlet) Heater Hoses Replacement (LP4/L21 Outlet)Heater Hoses Replacement (LG5 Inlet) Heater Hoses Replacement (LG5 Inlet)Heater Hoses Replacement (LG5 Outlet) Heater Hoses Replacement (LG5 Outlet).
14. Disconnect the evaporator hose from the evaporator. Refer to Receiver Dehydrator Replacement (LG5) Receiver Dehydrator Replacement (LG5)Receiver Dehydrator Replacement (LP4/L21) Receiver Dehydrator Replacement (LP4/L21).
15. Remove the bolt and the bracket from the evaporator hose.
16. Remove the washer solvent container. Refer to Washer Pump/Reservoir Replacement Service and Repair in Wiper/Washer Systems.




17. Remove the PCM (3). Refer to Powertrain Control Module Replacement Service and Repair in Engine Controls.
18. Remove the bolt and bracket located just above the inlet and outlet hoses.
19. Remove the 2 screws located below the Underhood Fuse Block.
20. Remove the bolt from the PCM mounting bracket.




21. Remove the bolt (1) from the top of the evaporator case.
22. Disconnect the electrical connectors from the evaporator case.
23. Pull the evaporator case partially out from the instrument panel.
24. Disconnect the mode door actuator. Refer to Mode Actuator Replacement Mode Actuator Replacement.
25. Remove the ground nut from the right A-pillar.
26. Remove the evaporator case.
27. Remove the 7 screws from the heater core cover and the cover.
28. Remove the heater core and seal. Refer to Mode Actuator Replacement Mode Actuator Replacement.
29. Remove the 6 screws that hold the evaporator case cover to the HVAC module assembly.
30. Remove the evaporator case cover.
31. Remove the evaporator core.

Installation Procedure

1. Install the evaporator core. If the evaporator is being replaced refer to Refrigerant Oil Distribution Specifications [1][2]Refrigerant Oil.
2. Install the evaporator case cover.
3. Install the 6 screws to the evaporator case cover.
4. Install the heater core and seal. Refer to Heater Core Replacement Service and Repair.
5. Install the 7 screws to the heater core cover.
6. Install the evaporator case.
7. Install the ground nut to the right A-pillar.

Tighten the nut to 3 Nm (27 lb in).

8. Connect the mode door actuator. Refer to Mode Actuator Replacement Mode Actuator Replacement.
9. Connect the electrical connectors to the evaporator case.




10. Install the bolt (1) to the top of the evaporator case.

Tighten the bolt to 7 Nm (62 lb in).




11. Install the bolt to the PCM mounting bracket.

Tighten the bolt to 2.5 Nm (22 lb in).

12. Install the 2 screws located below the Underhood Fuse Block.

Tighten the screws to 2.5 Nm (22 lb in).

13. Install the bolt and bracket above the heater inlet and outlet hoses.

Tighten the bolt to 6 Nm (53 lb in).

14. Install the PCM (3). Refer to Powertrain Control Module Replacement Service and Repair in Engine Controls.
15. Install the washer solvent container. Refer to Washer Pump/Reservoir Replacement Service and Repair in Wiper/Washer Systems.
16. Connect the evaporator hose fitting to the evaporator fitting. Refer to Receiver Dehydrator Replacement (LG5) Receiver Dehydrator Replacement (LG5)Receiver Dehydrator Replacement (LP4/L21) Receiver Dehydrator Replacement (LP4/L21).
17. Install the bolt and the bracket to the evaporator hose.

Tighten the bolt to 7 Nm (62 lb ft).

18. Install the accumulator tube to the evaporator. Refer to Accumulator Replacement Service and Repair.
19. Install the heater hoses. Refer to Heater Hoses Replacement (LP4/L21 Inlet) Heater Hoses Replacement (LP4/L21 Inlet)Heater Hoses Replacement (LP4/L21 Outlet) Heater Hoses Replacement (LP4/L21 Outlet)Heater Hoses Replacement (LG5 Inlet) Heater Hoses Replacement (LG5 Inlet)Heater Hoses Replacement (LG5 Outlet) Heater Hoses Replacement (LG5 Outlet).
20. Install the steering column. Refer to Steering Column Replacement Steering Column Replacement in Steering Wheel and Column Replacement.
21. Install the blower motor. Refer to Blower Motor and Fan Replacement Service and Repair.
22. Install the hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement Service and Repair in Interior Trim.
23. Install the TCM and the mounting tray. Refer to Transmission Control Module Replacement Service and Repair in Automatic Transmission.
24. Install the center floor air distribution duct.
25. Install the electrical connectors, as necessary.
26. Connect the instrument panel compartment. Refer to Instrument Panel Carrier Replacement Service and Repair in Instrument Panel, Gauges and Console.
27. Add engine coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling in Engine Cooling.
28. Install the air cleaner outlet front duct. Refer to Air Cleaner Outlet Front Duct Replacement Air Cleaner Outlet Front Duct Replacement in Engine Controls.
29. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.
30. Inspect the system for leaks. Refer to Leak Testing Leak Testing.