Evaporator Core: Service and Repair
Evaporator Core
Removal
1 Remove the engine cover.
2 Evacuate the A/C system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair
3
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
4 Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding - Vehicles With: Supercharger Service and Repair
5 Remove the driver side front seat. For additional information, refer to Front Seat Front Seat
6 Remove the floor console. For additional information, refer to Floor Console Floor Console
7 Remove the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section Instrument Panel Upper Section
8 Release the 3 ground cables from the driver side lower A-pillar.
- Remove the 2 nuts.
9 Disconnect the 5 electrical connectors from the driver side lower A-pillar.
10 Disconnect the 3 electrical connectors.
11 Release the 3 ground cables from the passenger side lower A-pillar.
- Remove the 2 nuts.
12 Disconnect the 5 electrical connectors from the passenger side lower A-pillar.
13 Disconnect the central junction box (CJB) three electrical connectors.
14 Disconnect 2 electrical connectors from the instrument panel center reinforcement.
15
CAUTION: Cover fiber optic cable connectors to minimize dust ingress and avoid bending the cables in a radius of less than 30 mm.
If installed, disconnect the instrument panel center reinforcement fibre optic cables.
- Disconnect the electrical connector.
16 Remove the heater housing center ducts.
17 Disconnect the steering column intermediate shaft from the steering column.
- Note the fitted position.
- Remove the special bolt and discard the nut.
18 Release the heater housing from the instrument panel carrier.
- Remove the 7 Torx screws.
19 Remove the plenum chamber panel.
20 Remove the instrument panel carrier to bulkhead Torx bolt.
21 With assistance, remove the instrument panel.
- Remove the 6 Torx bolts.
22
CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Disconnect 2 heater hoses from the bulkhead.
- Release the 2 clips.
23
CAUTION: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture.
Release the 2 A/C refrigerant lines.
- Remove the nut and bolt.
- Remove and discard the O-ring seals.
24 Remove the 2 adapter panels.
- Remove the 4 nuts.
25 Disconnect 2 drain tubes from the heater housing.
26 Remove the driver side footwell duct.
- Remove the 2 Torx screws.
27 Remove the passenger side footwell duct.
- Remove the 2 Torx screws.
28 Driver side: Remove the heater housing to bulkhead Torx bolt.
29 Passenger side: Remove the heater housing to bulkhead Torx bolt.
- With assistance, remove the heater and evaporator core housing.
30 Remove the A/C control module.
31 Disconnect the evaporator core temperature sensor electrical connector.
32 Disconnect the electrical connector.
33 Detach the wiring harness.
34 Remove the bolt from the support bracket.
35 Remove the heater and evaporator core housing.
- Remove the 8 clips.
- Carefully release the 2 clips.
36 Remove the thermostatic expansion valve.
37 Remove the evaporator core.
- Release the temperature sensor.
Installation
1 Install the evaporator core.
- Secure the temperature sensor.
2 Secure the heater core housing.
- Install the clips.
3 Install the thermostatic expansion valve.
- Tighten the bolts to 3.5 Nm (2.5 lb.ft).
4 Install the wiring harness.
5 Install and tighten the bolt.
6 Connect the temperature sensor electrical connector.
7 Install the CC module.
- Tighten the bolts.
8 Passenger side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
- With assistance, install the heater and evaporator core housing.
9 Driver side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).
10 Install the footwell ducts.
- Tighten the Torx screws.
11 Connect the drain tubes to the heater housing.
12 Install the adapter panels.
- Tighten the nuts to 6 Nm (4 lb.ft).
13 Secure the A/C refrigerant lines.
- Clean the components.
- Install new O-ring seals.
- Tighten the bolt to 5 Nm (4 lb.ft).
- Tighten the nut to 6 Nm.
14 Connect the bulkhead heater hoses.
15 With assistance, install the instrument panel.
- Tighten the Torx bolts to 25 Nm (18 lb.ft).
16 Install the instrument panel carrier to bulkhead Torx bolt and tighten to 25 Nm (18 lb.ft).
17 Install the plenum chamber panel.
18 Secure the heater housing.
- Tighten the screws.
19 Connect the steering column intermediate shaft.
- Install the special bolt and tighten the new nut to 22 Nm (16 lb.ft).
20 Install the heater housing center ducts.
21 Connect the instrument panel center reinforcement fibre optic cables.
22 Connect the instrument panel center reinforcement electrical connectors.
23 Connect the CJB electrical connectors.
24 Connect the electrical connectors to the passenger side lower A-pillar.
25 Connect the ground cables to the passenger side lower A-pillar.
- Tighten the nuts to 10 Nm (7 lb.ft).
26 Connect the electrical connectors to the driver side lower A-pillar.
27 Connect the ground cables to the driver side lower A-pillar.
- Tighten the nuts to 10 Nm (7 lb.ft).
28 Connect the 3 electrical connectors.
29 Install the instrument panel upper section. For additional information, refer to Instrument Panel Upper Section Instrument Panel Upper Section
30 Install the floor console. For additional information, refer to Floor Console Floor Console
31 Install the front seat. For additional information, refer to Front Seat Front Seat
32 Recharge the A/C system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair
33 Refill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding - Vehicles With: Supercharger Service and Repair
34 Install the engine cover.