Operation CHARM: Car repair manuals for everyone.

Front Evaporator Core





REMOVAL

1. Set parking brake.
2. Disconnect battery negative cable.

A/C Service Ports:






3. Using a refrigerant recovery machine, remove refrigerant from the A/C system.
4. Remove Wiper module.
5. Pinch off rear heater lines if equipped.

Heater Hoses:






6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines.

Expansion Valve Plate:






7. Remove suction and liquid lines at the expansion valve.
8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair".Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel.

HVAC Bolt Up:






11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel.
12 Disconnect the HVAC housing wiring harness.
13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle.

Evaporator Core Removal

1. Place HVAC unit assembly on workbench.

Distribution Housing:






2. Remove distribution housing mounting screws.

Blower Motor Cover:






3. Remove blower motor cover.

Blower Motor Grommet:






4. Remove blower motor wiring grommet and feed wiring through blower housing.

Blower Motor Screws:





Blower Motor:






5. Remove blower motor screws. Remove blower motor from housing.

Recirculation Door Cover:






6. Remove recirculation door cover.

Recirculation Door:






7. Remove recirculation door.

HVAC Cover:






8. Remove screws around the perimeter of the upper HVAC housing.

CAUTION: Do not damage the insulation barrier surrounding the evaporator.

Evaporator:






9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new evaporator before installing.

Note: For reassembly of the evaporator housing, reverse the above procedures.
- Perform the HVAC control Calibration Diagnostic and Cool-down test. Refer to: "Testing and Inspection" Testing and Inspection



INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets
2. Evacuate and recharge the A/C system.
3. Perform HVAC control Calibration Diagnostic and Cool-down test.