Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.




2. Remove the air inlet housing screws.
3. Remove the air inlet housing from the HVAC module.




4. Remove the right side HVAC module assembly mounting bracket screws.
5. Remove the right side HVAC module assembly mounting bracket.

Important: The HVAC module assembly upper retaining screw is located under the right side HVAC module assembly mounting bracket.

6. Remove the HVAC module upper retaining screw.




7. Remove the HVAC module assembly to dash panel sound barrier seal.




8. Remove the screws retaining the heater outlet duct.
9. Remove the heater outlet duct.




10. Remove the heater core cover screws.
11. Remove the heater core cover.




12. Remove the heater core pipe retaining screw.
13. Remove the heater core.

Important: The lower HVAC module assembly retaining screw is located under the heater core.

14. Remove the lower HVAC module assembly retaining screw.




15. Remove the lower HVAC module assembly retaining screws.
16. Separate the upper and lower HVAC module halves.




17. Remove the evaporator core from the upper HVAC module case half.




18. Remove the evaporator temperature sensor.




19. Remove the thermal expansion valve (TXV) mounting screws.
20. Remove the TXV from the evaporator core.

Installation Procedure

1. If replacing the evaporator core, add the specified amount of PAG oil directly to the evaporator core. Refer to Refrigerant System Capacities.
2. Install the new sealing washers onto the evaporator line.




3. Install the TXV to the evaporator core.

Notice: Refer to Fastener Notice.

4. Install the TXV mounting screws.

Tighten the screws to 3.2 N.m (28 lb in).






Important: The evaporator temperature sensor must be located in the same position on the new evaporator core.

5. The evaporator temperature sensor should be approximately 3.5 cm (1.4 in) from the side and 5 cm (2 in) from the bottom corner of the evaporator core.
6. Install the evaporator temperature sensor.






Important: Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. Improper alignment will pinch and/or cut the sensor wires.

7. Install the evaporator core into the upper HVAC module case half.




8. Align and install the upper module case to the lower module case.
9. Install the lower HVAC module assembly retaining screws.

Tighten the screws to 0.9 N.m (8 lb in).

10. Install the lower HVAC module assembly retaining screw.

Tighten the screw to 0.9 N.m (8 lb in).




11. Install the heater core.
12. Install the heater core pipe retaining screw.

Tighten the screw to 0.9 N.m (8 lb in).




13. Install the heater core cover.
14. Install the heater core cover screws.

Tighten the screws to 0.9 N.m (8 lb in).




15. Install the heater outlet duct.
16. Install the heater outlet duct screws.

Tighten the screws to 0.9 N.m (8 lb in).




17. Install the HVAC module assembly to dash panel sound barrier seal.




18. Install the HVAC module upper retaining screw.

Tighten the screw to 0.9 N.m (8 lb in).

19. Install the right side HVAC module assembly mounting bracket.
20. Install the right side HVAC module assembly mounting bracket screws.

Tighten the screws to 1.8 N.m (16 lb in).




21. Install the air inlet housing to the HVAC module.
22. Install the air inlet retaining screws.

Tighten the screws to 0.9 N.m (8 lb in).

23. Install the HVAC module assembly.