Evaporator Core: Service and Repair

Evaporator Inlet & Outlet Lines:

1. Discharge and recover refrigerant from system.
2. Drain radiator and cooling system.
3. Remove two bolts from each side of the cross-tower support bracket.
4. Remove two nuts from the cowl relay center bracket, then position relay bracket aside.
5. Disconnect electrical connectors from the power module, blower motor and blower motor resistor.
6. Disconnect both heater core hoses from the heater core.
7. Remove the evaporator line retaining bracket.
8. Remove evaporator core refrigerant lines. Cap all open fittings to prevent contamination of system.
9. Remove heater hose T-connector.
10. Remove two heat shield screws from engine compartment, raise and support vehicle, then the remaining two screws from beneath vehicle. Remove heat shield.
11. Remove two A/C module retaining screws (one 7 mm and one 10 mm).
12. Lower vehicle, then remove the MAP sensor bracket.
13. Remove diverter valve from righthand side valve cover.
14. Remove two harness hold-down brackets from valve cover.
15. Remove power module, blower motor, then the sound insulator.
16. Remove the A/C module cover screws, module cover, sound insulator, then the seal.
17. Remove the evaporator retaining clamp, then pull evaporator core from evaporator case.
18. Reverse procedure to install, noting the following:
a. Torque module cover retaining screws to 27 inch lbs.
b. Torque line fitting bolt to 18 ft. lbs.
c. Leak test all refrigerant connections.