Heater-Evaporator Unit Replacement

Evaporator Removal and Installation

1. Make sure you have the anti-theft code for the radio and the navigation system, then write down the frequencies for the radio's preset buttons.
2. Disconnect the negative cable from the battery.
3. Remove the under-hood fuse/relay box, but do not disconnect the connectors.
4. Recover the refrigerant with a recovery/recycling/charging station.




5. Disconnect the suction line (A) and the receiver line (B) from the evaporator. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6. Remove the glove box and the glove box cover.




7. Remove the wire harness connectors (A) from the evaporator. Disconnect the connector (B) from the evaporator temperature sensor.




8. Remove the self-tapping screws, the mounting nut, the mounting bolts and the evaporator.
9. Install the evaporator in the reverse order of removal, and note these items.

- If you're installing a new evaporator, add refrigerant oil (DENSO ND-OIL 8)
- Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for HFC-134a (R-134a) to avoid leakage.
- Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
- Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
- Make sure that there is no air leakage.
- Charge the system.
- Enter the anti-theft code for the radio and the navigation system, then enter the customer's radio station presets.
- For '03 models: Perform the engine control module (ECM)/powertrain control module (PCM) idle learn procedure, and the power window control unit reset procedure.