Evaporator Core: Service and Repair

NOTE: It will be necessary to remove the instrument panel to change the evaporator. Be sure a replacement evaporator is available before beginning disassembly.

1. Fit manifold gauges to service ports and discharge A/C system. Be sure to recycle freon.
2. Disconnect expansion valve from evaporator.
3. Disconnect wire connectors from ignition coil and remove coil.

Plenum Cover Bolts:

4. Remove 4 bolts from plenum cover.
5. Remove instrument cluster.

Instrument Cluster:

a. Disconnect battery ground cable.
b. Remove two lower screws.
c. Depress each side of cluster bezel to detach clips.
d. Depress two clips at top of cluster and remove bezel.
e. Remove three screws attaching cluster to instrumental panel.
f. Pull cluster assembly out far enough to disconnect electrical multi-plugs and speedometer cable.
g. Remove cluster.

10. Remove steering wheel.
11. Rotate screws 1/4 turn to remove steering column covers.
12. Remove console tray and console switches.
13. Release shift lever boot.

Instrument Panel:

14. Press clips 1 and 2 to lift out console.
15. Remove screws 3, 4, and 5.
16. Remove steering column ground wires.
17. Lift instrument panel to clear vent channels and clips 6.

Heater Hoses:

18. Remove four screws that retain blower box assembly.
19. Disconnect electrical connections.

Air Blower Assembly:

20. Clamp heater hoses and disconnect at firewall.
21. Remove blower box assembly by pulling it out to right.

Evaporator Housing Bolts:

22. Remove four bolts and remove evaporator housing. Two of these bolts are accessible from inside passenger compartment under driver's side of instrument panel.
23. Remove evaporator.
24. Fit new evaporator.
25. Reverse steps 1-23 to refit.