Evaporator Core: Service and Repair

REMOVAL
1. Discharge and recover refrigerant from system.
2. Remove right side sound insulator.
3. Disconnect electrical connectors from power module and blower motor.
4. Disconnect electrical connectors, vacuum connector and powertrain control module.
5. Remove bolt securing evaporator core housing to front of dash (bolt is located above carpet directly behind left side of console.)
6. Remove two bolts securing harness pass-through to front of dash.
7. Remove cross car brace.
8. Disconnect electrical connectors: four at the 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 and A/C low pressure switch.
9. Remove ignition control module.
10. Remove air cleaner.
11. Disconnect vapor (evaporator/accumulator) line.
12. Raise vehicle.
13. Remove left front wheel.
14. Remove 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 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. Disconnect RSS position sensors right and left side.
16. Remove exhaust Y-pipe at catalytic converter and two lower heat shield bolts.
17. Disconnect electrical connectors at power steering pressure switch, vehicle speed sensor and knock sensor.
18. Remove four rear bolts securing frame to body.
19. Lower vehicle.
20. Lower powertrain.
21. Raise vehicle.
22. Remove two upper exhaust heat shield bolts and four lower HEBA bolts.
23. Cut lower portion of rubber HEBA insulator bit guides.
24. Lower vehicle.
25. Remove two ground wires attached to engine head.
26. Remove electrical harness from camshaft cover (conduit and clip.)
27. Move loose electrical harness to left side of vehicle.
28. Cut upper portion of rubber HEBA insulator bolts.
29. Disconnect evaporator core from liquid line.
30. Remove four upper HEBA insulator bolts.
31. Remove rubber insulator covering evaporator core housing (engine may need to be repositioned to allow for removal of evaporator core housing.)
32. Remove evaporator core.

INSTALLATION
1. Install evaporator core.
2. Install evaporator core housing.
3. Install rubber insulator covering evaporator core housing.
4. Secure four upper HEBA insulator bolts.
5. Install blower motor and power module.
6. Connect evaporator inlet bracket to HEBA.
7. Seal upper portion of rubber HEBA insulator.
8. Reposition loose electrical harness along rear of powertrain and raise vehicle.
9. Connect 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. Secure four lower HEBA bolts.
12. Seal lower portion of rubber HEBA insulator.
13. Secure two upper bolts of exhaust heat shield and lower vehicle.
14. Raise powertrain, then vehicle.
15. Tighten four rear bolts securing frame to body.
16. Tighten two lower bolts on exhaust heat shield and exhaust Y-pipe.
17. Connect electrical connectors at power steering pressure switch, vehicle speed sensor and knock sensor.
18. Connect intermediate shaft pinch bolt from rack and pinion gear.
19. Reinstall RSS position sensors on both sides.
20. Install left front wheel and lower vehicle.
21. Tighten two bolts securing harness pass-through to front of dash.
22. Install ignition control module.
23. Connect electrical connectors: four at Ignition Control Module, blower motor, rear heated oxygen sensor, A/C low and high side temperature sensors and two connectors at the HVAC power module and A/C refrigerant pressure switch.
24. Connect RSS Accelerometer located on right side of strut tower.
25. Tighten interior bolt securing evaporator core housing to front of dash.
26. Connect powertrain control module,vacuum connector and electrical connectors.
27. Install right side sound insulator.
28. Connect vapor (evaporator/accumulator) line.
29. Connect evaporator to A/C liquid line.
30. Tighten bolt securing liquid line to bracket.
31. Install cross car brace.
32. Install air cleaner.
33. Charge the system and test all refrigerant connections for leaks.