Evaporator Core: Service and Repair

Fig. 3 Exploded view of evaporator core.:

EVAPORATOR CORE AND / OR EXPANSION VALVE


1. Disconnect battery ground cable and discharge A/C system.
2. Working from engine compartment, disconnect refrigerant lines at evaporator, then plug lines and fittings.
3. Remove glove box, then disconnect thermo switch wire connector.
4. Disconnect defroster hose and position aside.
5. Remove evaporator case attaching nuts and bolts, then the evaporator assembly.
6. Remove insulators, then the thermo switch, Fig. 3.
7. Remove retaining clips, then separate evaporator case upper half from evaporator case lower half.
8. Carefully disconnect thermo switch capillary tube from evaporator case.
9. Remove evaporator core assembly with expansion valve, inlet and outlet fittings attached.
10. Disconnect inlet and outlet fittings from expansion valve, peel tape from thermo bulb, then remove valve.
11. Remove evaporator core.
12. Reverse procedure to install. If core and valve are being replaced, add 1.7 oz. refrigerant oil to replacement core. Use new O-rings lightly lubricated with refrigerant oil when connecting refrigerant lines. Replace tape around thermo bulb and insulating tape around the sensing bulb. Evacuate and discharge system, then check for leaks.