Evaporator Core: Service and Repair

EVAPORATOR CORE

A/C Module/Evaporator Lines:

^ Recover refrigerant.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Right side sound insulator.
3. Electrical connectors from power module and blower motor.
4. Electrical connectors, vacuum connector and powertrain control module.
5. Bolt securing evaporator core housing to front of dash. (bolt is located above carpet directly behind left side of console).
6. Two bolts securing harness pass-through to front of dash.
7. Cross car brace.
8. Electrical connectors: Four connectors at ignition control module, blower motor, rear heated oxygen sensor, A/C high and low side temperature sensors and two connectors at the HVAC power module, A/C low pressure switch.
9. Ignition Control Module.
10. Air cleaner.
11. Vapor (evaporator/accumulator) line.
12. Install engine support tool.
^ Raise vehicle.
13. Left front wheel
14. Intermediate shaft pinch bolt from rack and pinion gear.

CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of steering control which could result in vehicle crash with possible bodily injury.

15. RSS position sensors right and left side.
16. Exhaust y-pipe at catalytic converter and two lower heat shield bolts.
17. Electrical connectors at power steering pressure switch, vehicle speed sensor and knock sensor.
18. Four rear bolts securing frame to body.
^ Lower vehicle.
19. Lower powertrain.

NOTICE: Engine support tool is not designed to raise or lower powertrain. Damage to tool may result from improper usage.

^ Raise vehicle.
20. Two upper exhaust heat shield bolts and four lower Heater, Evaporator, Blower Assembly (HEBA) bolts.
21. Cut lower portion of rubber HEBA insulator at guides.
^ Lower vehicle.
22. Two ground wires attached to engine head.
23. Electrical harness from camshaft cover (conduit and clip).
24. Move loose electrical harness to left side of vehicle.
25. Cut upper portion of rubber HEBA insulator.
26. HVAC power module and blower motor.
27. Four bolts retaining evaporator inlet bracket to HEBA.
28. Bolt securing liquid line to bracket. (above blower motor).
29. Evaporator core from liquid line.
30. Four upper HEBA insulator bolts.
31. Rubber insulator covering evaporator core housing (engine may need to be repositioned to allow for removal of evaporator core housing).
32. Three bolts securing evaporator core housing to front of dash and housing (engine may need to be repositioned to allow for removal of evaporator core housing).
33. Evaporator core.

INSTALL OR CONNECT
1. Evaporator core.
2. Evaporator core housing.
3. Rubber insulator covering evaporator core housing.
4. Four upper HEBA insulator bolts.
5. Blower motor and power module.
6. Evaporator inlet bracket to HEBA.
7. Seal upper portion of rubber HEBA insulator.
8. Reposition loose electrical harness along rear of powertrain.
^ Raise vehicle.
9. Two ground wires attached to engine head.
10. Route power steering pressure switch, vehicle speed sensor and knock sensor behind heater pipes. Do not connect.
11. Four lower HEBA insulator bolts.
12. Seal lower portion of rubber HEBA insulator.
13. Two upper bolts exhaust heat shield.
^ Lower vehicle.
14. Raise powertrain.
^ Raise vehicle.
15. Four rear bolts securing frame to body.
16. Two lower bolts on exhaust heat shield and exhaust Y-pipe.
17. Electrical connectors at power steering pressure switch, vehicle speed sensor and knock sensor.
18. Intermediate shaft pinch bolt from rack and pinion gear.
19. RSS position sensors right and left side.
20. Left front wheel.
^ Lower vehicle.
21. Remove engine support tool.
22. Two bolts securing harness pass-through to front of dash.
23. Ignition Control Module
24. Electrical connectors: Four connectors at Ignition Control Module, blower motor, rear heated oxygen sensor, A/C high and low side temperature sensors and two connectors at the HVAC Power Module, A/C Refrigerant Pressure Switch.
25. RSS Accelerometer located on right side strut tower.
26. Interior bolt securing evaporator core housing to front of dash.
27. Powertrain Control Module, vacuum connector and electrical connectors.
28. Right side sound insulator.
29. Vapor (evaporator/accumulator) line.
30. Evaporator core to A/C liquid line.
31. Bolt securing liquid line to bracket.
32. Cross car brace.
33. Air cleaner.
34. Negative battery cable.
^ Evacuate and charge ECC system.
^ Leak test all refrigerant connections.