Heater Core Case: Service and Repair

NOTE:
- Whenever an A/C evaporator housing is removed, it will be necessary to replace the suction accumulator/drier.

- If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle.

Spring Lock Coupling Disconnect Tool (1/2 Inch):

Special Service Tool(s) Required

Removal
1. Remove the instrument panel. Place instrument panel on front seat. Service and Repair
2. Recover the refrigerant from the A/C system at the service access gauge port valve located on the suction line. Observe all safety precautions.
3. Remove the high and low-pressure hoses. Cap the hose openings to prevent the entrance of dirt and excessive moisture.
4. Disconnect the liquid line and suction accumulator/drier inlet tube from the A/C evaporator core at the dash panel. Cap refrigerant lines and A/C evaporator core to prevent entrance of dirt and excessive moisture.
5. Remove suction accumulator/drier. Remove suction accumulator/drier bracket.
6. If necessary, remove throttle cable bracket and position out of the way.
7. Disconnect the heater water hoses from the heater core tubes and plug the hoses with suitable 5/8-inch and 3/4-inch plugs. Cap the heater core tubes to prevent coolant loss from the heater core during removal of the A/C evaporator housing.
8. Disconnect the vacuum supply hose (black) from the in-line A/C vacuum check valve in the engine compartment.
9. Working under the hood, remove three nuts retaining the A/C evaporator housing to the dash panel.
10. In the passenger compartment, remove the screw retaining the A/C evaporator housing support bracket to the cowl top panel.
11. Remove one nut retaining the bracket below the A/C evaporator housing to the dash panel and one nut retaining the mounting bracket at the LH end of the A/C evaporator housing to the dash panel.
12. Carefully pull the A/C evaporator housing away from the dash panel and remove the A/C evaporator housing assembly from the vehicle.

Installation
1. Position the A/C evaporator housing assembly in the vehicle and install the screw retaining the A/C evaporator housing support bracket to the cowl top panel.
2. Check the A/C evaporator housing drain tube to make sure it is through the dash panel and is not pinched or kinked.
3. Install one nut retaining the mounting bracket at the LH end of the A/C evaporator housing to the dash panel, and another nut to retain the bracket below the A/C evaporator housing to the dash panel.
4. Working under the hood, install three nuts retaining the A/C evaporator housing to the dash panel. Tighten the four nuts (two in engine compartment and two in the passenger compartment) and the one support bracket retaining screw.
5. Connect the black vacuum supply hose to the A/C vacuum check valve in the engine compartment.
6. Install suction accumulator/drier bracket. Install suction accumulator/drier.
7. Install throttle cable bracket, if removed.
8. Using new O-ring seals lubricated with clean refrigerant oil, connect liquid line and suction accumulator/drier inlet tube to A/C evaporator core.
9. Connect the high and low-pressure refrigerant hoses using new O-ring seals dipped in specified refrigerant oil.
10. Install the instrument panel.
11. Connect the heater water hoses to the heater core and fill the cooling system.
12. Leak test, evacuate and charge the refrigeration system following the recommended procedures and safety precautions.