Evaporator Core: Service and Repair

Evaporator Inlet & Outlet Lines:

Remove or Disconnect

^ Recover refrigerant.
^ Drain radiator.
1. Cross-tower support bracket (two bolts each side).
2. Cowl relay center bracket (two nuts); position aside.
3. Electrical connectors from power module and blower motor.
4. Electrical connector from blower motor resistor.
5. Heater hose lines (two) at core.
6. Evaporator line retaining bracket.
7. Evaporator core refrigerant inlet and outlet lines. Cap all open lines.
8. Heater hose T-connector.
9. Heat shield.
A. Remove two screws in engine compartment.
B. Raise and suitably support vehicle.
C. Remove two screws from beneath vehicle.
10. Two A/C module retaining screws (one 10 mm and one 7 mm).
^ Lower vehicle.
11. MAP sensor bracket.
12. Diverter valve from right valve cover.
13. Two harness hold-down brackets from valve cover.
14. Retaining clips from sound insulator.
15. Power module and blower motor.
16. Sound insulator.
17. A/C module cover screws.
18. Module cover, sound insulator and seal.
19. Evaporator retaining clamp.
^ Pull evaporator core from evaporator case.

Install or Connect

1. Evaporator core to case.
2. Evaporator retaining clamp.
3. Module cover, retaining screws and seal.

Tighten
^ Module cover retaining screws to 3 N.m (27 lb. in.).

4. Sound insulator.
5. Power module and blower motor.
6. Retaining clips to sound insulator.
7. Two harness hold-down brackets from valve cover.
8. Diverter valve from right valve cover.

9. MAP sensor bracket.
10. Heat shield.
A. Raise and suitably support vehicle.
B. Instal] two A/C module retaining screws (one 10 mm and one 7 mm).
C. Install two screws from beneath vehicle.
D. Lower vehicle.
E. Install two screws in engine compartment.
11. Heater hose T-connector.
12. Evaporator core inlet and outlet lines; install new dual O-rings.

Tighten
^ Line fitting bolt to 24 N.m (18 lb. ft.).

NOTICE: When making line connections use care to avoid nicking the dual O-rings or cross threading the connections.

13. Evaporator line retaining bracket.
14. Heater hose lines (two) at core.
15. Cowl relay center bracket (two nuts).
16. Cross-tower support bracket (two bolts each side).
^ Refill radiator.
^ Evacuate and charge ECC system.
^ Leak test all refrigerant connections.