Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

Tools Required
^ J 38042 Dual O-Ring Joint Separator
^ J 39500-B A/C Refrigerant Recovery, Recycling, and Recharging (ACR4) System
^ J 39400 Electronic Halogen Leak Detector

1. Recover the refrigerant.
2. Remove the cross car support brace.





3. Remove the fuse block cover.
4. Remove the accumulator.





5. Remove the positive booster cable from the multi-use relay center.
6. Position the under hood fuse block out of the way.





7. Remove the evaporator tube from the evaporator.
8. Remove the wire harness clip from the HVAC module.
9. Remove the accumulator bracket.
10. Remove the heat shield of the HVAC module.
11. Following the cut line, cut the top side of the HVAC module cover.
12. Raise and support the vehicle.





13. Following the cut line, cut the bottom side of the HVAC module cover.
14. Lower the vehicle.
15. Remove the fuel line clip from the HVAC module.
16. Remove the insulator from the module.
17. Remove the bolt that attaches the heater and A/C module assembly to the inside of the vehicle.

^ Remove the blower module from the HVAC module assembly.





18. Remove the evaporator core.

Installation Procedure





1. Install the evaporator core.
2. Install the blower module to the HVAC module assembly.

Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the bolts.

Tighten
Tighten the bolts to 5 Nm (44 lb in).

4. Install the bolt to attach the heater and A/C module assembly to the inside of the vehicle.

Tighten
Tighten the bolt to 5 Nm (44 lb in).

5. Install the insulator to the module.
6. Install the fuel line clip to the HVAC module.
7. Install the HVAC module heat shield.
8. Install the bolts.

Tighten
Tighten the bolts to 5 Nm (44 lb in).

9. Install the accumulator bracket.
10. Install the screws.

Tighten
Tighten the screws to 6 Nm (53 lb in).

11. Install the wire harness clip to the HVAC module.





12. Install the evaporator tube to the evaporator.

Tighten
Tighten the evaporator tube connection to 24 Nm (18 lb ft).

13. Reposition the under hood fuse block to the original position.
14. Install the booster cable from the multi-use relay center.
15. Install the accumulator.





16. Install the fuse block cover.
17. Install the cross car support.
18. Recharge the A/C system.
19. Leak test the system.