Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

REMOVAL PROCEDURE




1. Drain the engine coolant.
2. Recover the refrigerant.
3. Remove the heater core.
4. Remove the temperature control cable bolt.
5. Remove the temperature control cable from the module.




6. Remove the accumulator bolt (2) at the module.
7. Discard the O-ring seal.




8. Remove the air conditioning (NC) evaporator tube bolt at the module.
9. Discard the O-ring seal.




10. Remove the heater rear case bolts.
11. Remove the heater rear case (4):
11.1. Slide the heater rear case (4) downward in order to disengage the upper case clip.
11.2. Remove the heater rear case.
11.3. Use a small hand saw to remove the perforated section of the heating, ventilation and air conditioning (HVAC) evaporator module.
This section will be reused.
11.4. Water may leak onto the carpeting when performing this procedure. Place a mat on the passenger side floor.
11.5. Remove the A/C evaporator bracket nut (1).
11.6. Remove the A/C evaporator bracket.
11.7. Remove the bolts from the engine compartment side of the A/C evaporator upper and lower case.
Open the case slightly.
11.8. Remove the A/C evaporator seal.
11.9. Remove the evaporator (6).
11.10. Transfer the A/C evaporator air filter (5) to the new evaporator.

INSTALLATION PROCEDURE




1. Install the NEW A/C evaporator (6).
2. Install a NEW A/C evaporator seal.
3. Apply sealer between the evaporator upper and lower case.
Do not use epoxy glue as a sealer.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the bolts to the engine side of the A/C evaporator upper and lower case.

Tighten
Tighten the A/C evaporator upper and lower case bolts to 2 N.m (18 in).

5. Install the A/C evaporator bracket.
6. Install the A/C evaporator bracket bolt (1).

Tighten
Tighten the A/C evaporator bracket bolt (1) to 2 N.m (18 lb in).

7. Position the perforated section of the evaporator module.
Use epoxy glue in order to adhere the perforated section to the module.
Allow the epoxy to dry.
8. Use your thumb in order to grade the sealant on the inside and the outside in order to ensure a water-tight seal.
9. Use the following steps in order to install the heater rear case (4):
9.1. Slide the heater rear case upward into position until the upper clip engages.
9.2. Engage the snap on the left edge of the heater rear case to the distributor case.
9.3. Install the bolts to the heater rear case.

Tighten
Tighten the heater rear case bolts to 2.0 N.m (18 lb in).




10. Install a new O-ring seal.
11. Install the A/C evaporator tube bolt at the module.

Tighten
Tighten the A/C evaporator tube bolt to 16 N.m (12 lb ft).




12. Install a new O-ring seal.
13. Install the accumulator bolt at the module.

Tighten
Tighten the accumulator bolt (2) to 16 N.m (12 lb ft).




14. Install the temperature control cable to the module.
15. Install the temperature control cable bolt.

Tighten
Tighten the temperature control cable bolt to 1.9 N.m (17 lb in).

16. Install the heater core.
17. Recharge the refrigerant.
18. Refill the cooling system.