Evaporator Core: Service and Repair

NOTE: Whenever an A/C evaporator core is replaced, it is necessary to replace suction accumulator/drier. Before an A/C evaporator core is replaced, it must be leak tested in vehicle. If it is necessary to replace an evaporator core, new core is serviced with a service replacement A/C evaporator housing which has new core. All vacuum control motors, heater core, vacuum reservoir tank and bracket, blower motor, vacuum lines and air ducts from old evaporator housing must be transferred to new evaporator housing.

Fig. 7 Evaporator Core Replacement (Part 1 Of 2):

Fig. 7 Evaporator Core Replacement (Part 2 Of 2):

1. Remove evaporator case from vehicle. Service and Repair
2. Remove heater core from case.
3. Remove vacuum control motor arm from damper door cam and disconnect vacuum hose harness from motor, then remove vacuum motor retaining screws and vacuum control motor.
4. Remove retaining screws and damper door cam, then unclip door from air inlet door shaft and remove.
5. Remove air inlet door shaft from recirculating air duct.
6. Remove vacuum reservoir retaining screws and two vacuum hose tubes from vacuum check valve, then vacuum reservoir tank and bracket.
7. Remove vacuum hose harness from attachment points.
8. Loosen heater air damper retaining nuts, disconnect vacuum hoses, remove vacuum motor arm from door and vacuum control motor.
9. Disconnect jumper wire harness from heater blower motor switch resistor, remove retaining screws and remove resistor.
10. Remove blower motor.
11. Remove retaining screws and heater outlet floor duct.
12. Remove evaporator case support bracket retaining screws and bracket.
13. Remove drain tube seal.
14. Reverse procedure to install. Torque evaporator case support bracket retaining screws to 40-55 in lb.