Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.




2. Remove the insulation (1) from the thermal expansion valve (TXV).




3. Remove the HVAC line clamp screw.




4. Remove the HVAC line clamp.




5. Remove the TXV to evaporator bolts (1).




6. Remove the TXV line bracket.




7. Remove the TXV from the evaporator core.
8. Separate the TXV from the A/C lines by pulling straight out.
9. Remove the TXV.
10. Remove the screws that hold the case together.




11. Remove the clips that hold the case together.




12. Disconnect the thermistor electrical connector.




13. Separate the HVAC module.




14. Remove the thermistor from the evaporator core.




15. Remove the evaporator core.

Installation Procedure

1. Add refrigerant oil. Refer to Refrigerant System Capacities.
2. Install new evaporator core seals to evaporator.




3. Install the evaporator core.




4. Install the thermistor to the evaporator into the same position as removed.




5. Slide the HVAC module together.

Notice: Refer to Fastener Notice.

6. Install the screws that hold the case together.

Tighten the screws to 1 N.m (8 lb in).

7. Install the clips that hold the case together.




8. Connect the thermistor electrical connector.
9. Lube A/C lines with refrigerant oil before installing. Refer to O-Ring Replacement.
10. Install the A/C lines into the TXV.




11. Carefully slide the TXV onto the evaporator core until seated.




12. Install the TXV line bracket.






Notice: Refer to Fastener Notice.

13. Install the TXV to evaporator bolts (1).

Tighten the bolts to 3.5 N.m (31 lb in).




14. Install the HVAC line clamp.




15. Install the HVAC line clamp screw.

Tighten the screw to 1 N.m (8 lb in).




16. Install the insulation (1) onto the lines and TXV.
17. Install the HVAC module.