Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.
2. Remove the screws that secure the recirculation housing to the HVAC module assembly.




3. Remove the recirculation housing from the HVAC module assembly.
4. Remove the screws that secure the mode actuator to the HVAC module assembly.
5. Remove the mode actuator from the HVAC module assembly.
6. Remove the bolts that secure the TXV to the evaporator core.
7. Remove the TXV from the evaporator core.
8. Discard the old seal rings from the evaporator core.
9. Remove the screws that secure HVAC module assembly upper case to the HVAC module assembly lower case.
10. Remove the heat stakes that secure the HVAC module assembly upper case to the HVAC module lower case using a small chisel.




11. Separate the HVAC module assembly case (1).




12. Remove the evaporator core.

Installation Procedure

1. If replacing the evaporator, add refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information.




2. Install a new side seal to the evaporator core.




3. Install a new upper seal to the evaporator core.




4. Install 2 new lower seals to the evaporator core.




5. Install the evaporator core into the HVAC module assembly lower case.
6. From the inside of the upper case, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.




7. Align and attach the upper and lower HVAC module assembly case.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the removed screws that secure the HVAC module assembly upper case to the HVAC module assembly lower case to their original position.

Tighten the screws to 1.5 N.m (13 lb in).

9. Install new screws that will secure the HVAC module assembly upper case to the HVAC module assembly lower case in the predrilled holes adjacent to the heat stakes.

Tighten the screws to 1.5 N.m (13 lb in).

10. Install the mode actuator.
11. Install the screws that secure the mode actuator to the HVAC module assembly.

Tighten the screws to 1.5 N.m (13 lb in).




12. Install the recirculation housing to the HVAC module assembly.
13. Install the screws that secure the recirculation housing to the HVAC module assembly.

Tighten the screws to 1.5 N.m (13 lb in).

14. Install new sealing washers on the evaporator core.
15. Install the TXV to the evaporator core.
16. Install the bolts that secure the TXV to evaporator core.

Tighten the bolts to 7 N.m (62 lb in).

17. Install the HVAC module assembly.