Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

TOOLS REQUIRED
J 39400-A Halogen Leak Detector

REMOVAL PROCEDURE
1. Remove the right fender.
2. Remove the blower motor resistor.
3. Remove the accumulator.
4. Remove the evaporator tube.
5. Remove the evaporator and blower module heat shield mounting screws.
6. Remove the evaporator and blower module heat shield.







7. Remove the evaporator and blower module mounting bolts and nuts.

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

8. Remove the evaporator and blower module from the vehicle.
9. Remove the 6 retaining screws holding the evaporator case section to the blower case section.







10. Separate the evaporator case section from the blower case section.
11. Remove the evaporator core from the blower case section.
12. Inspect the seals and replace as necessary.







13. Remove the expansion (orifice) tube (2) from the evaporator (1).








INSTALLATION PROCEDURE
1. Install the expansion (orifice) tube (2) to the evaporator (1).

IMPORTANT: If replacing the evaporator core, add the refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information.







2. Install the evaporator core to the blower case section.
3. Assemble the evaporator case section to the blower case section.

IMPORTANT: Ensure that the seal is in place between the 2 case sections.

4. Install the 6 retaining screws.

NOTE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings


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

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

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







6. Install the evaporator and blower module mounting fasteners.

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

Tighten
Tighten the fasteners to.....................4.5 N.m (40 lb in).

7. Install the evaporator and blower module heat shield.
8. Install the evaporator and blower module heat shield mounting screws.

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

9. Install the evaporator tube.
10. Install the accumulator.
11. Install the blower motor resistor.
12. Install the right fender.
13. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
14. Leak test the fittings of the components using the J 39400-A.