Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.




2. Remove and discard 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 and discard all of the O-rings.
10. Disconnect the thermistor electrical connector from the HVAC module retainer.
11. Disconnect the LH and the auxiliary temperature actuator electrical connectors. Reposition the harness.
12. Release the retainers and remove the front duct on the HVAC module
13. Remove the screws that hold the case together.




14. Separate the HVAC module.




15. Remove the evaporator core.

Installation Procedure




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

Important: Do not force the evaporator core into the HVAC module. Damage to the thermistor can occur.

3. Install the evaporator core.






Important: Ensure that all of the temperature and mode doors align to their corresponding slots within the HVAC module.

Do not force the HVAC module case halves together.

4. Slide the HVAC module case halves together.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the screws that hold the case together.

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

6. Install the front duct on the HVAC module. Ensure that the retainers are properly engaged.
7. Reposition the wire harness and connect the LH and the auxiliary temperature actuator electrical connectors.
8. Connect the thermistor electrical connector to the HVAC module retainer.
9. Install new O-rings to the evaporator core and the TXV lines.
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.




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 the TXV.
17. Install the HVAC module.