Evaporator Core: Service and Repair

Evaporator
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

NOTE:
The removal of this component involves cutting an aperture in the evaporator housing wall and cutting through the high and low pressure A/C lines. A service repair kit is supplied to cover this procedure.
1 Disconnect the battery ground cable.
For additional information, refer to Specifications Specifications
2 Recover the A/C refrigerant.
For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair
3 Remove the plenum chamber panel.
For additional information, refer to Plenum Chamber Plenum Chamber




4 If installed, remove the anti-theft alarm horn with integral battery.





CAUTION: Make sure that all openings are sealed. Use new blanking caps.
5 Disconnect the A/C pipes from the TXV.








6 Remove the RH floor console extension.
7 Remove the glove compartment.
For additional information, refer to Glove Compartment Service and Repair
























8 Remove the CJB bracket.




Remove the 3 spring clips.
Release the 4 plastic clips.




Remove the lower cover.
Position the upper cover aside for access.




9 Cut the A/C pipes at the marked position.









10 Guide the cut evaporator pipes through the bulkhead so that approximately 20mm is visible in the engine compartment.





11 Remove the evaporator pipes.













12 Remove the evaporator core.

13 Remove any debris from the heater core and evaporator core housing.

Installation





1 Apply the foam strips from the service kit to the
evaporator core.
2 Install the evaporator core.




Install the service door.
Secure the 4 clips.
Install the 4 screws.
3 Install the pollen filter cover.




4 Apply the asphalt tape from the service kit to the service replacement evaporator pipes.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.
5 Remove the TXV assembly from the service replacement evaporator pipes.
6 Guide the service replacement evaporator pipes through the bulkhead so that approximately 20mm is visible in the engine compartment.
7 Install the TXV captive clamping plate.





NOTE:
Install new O-ring seals.
8 Install the service replacement evaporator pipes to the evaporator.
Torque to: 5 Nm
9 Install the CJB bracket.
Torque to: 10 Nm

10 Secure the wiring harnesses to the CJB bracket.

11 Install the CJB.

12 Connect the 5 electrical connectors to the CJB and secure the front carpet.

13 Install the CJB lower access cover.

14 Install the passenger side footwell duct.

15 Install the glove compartment.
For additional information, refer to Glove Compartment Service and Repair

16 Install the RH floor console extension.

NOTE:
Install new O-ring seals.

17 Install the TXV assembly.
Torque to: 4 Nm

NOTE:
Install new O-ring seals.

18 Connect the A/C pipes to the TXV and tighten the M6 nut.
Torque to: 9 Nm

19 Install the anti-theft alarm horn with integral battery.

20 Install the plenum chamber panel.
For additional information, refer to Plenum Chamber Plenum Chamber

21 Recharge the A/C system.
For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair

22 Connect the battery ground cable.
For additional information, refer to Specifications Specifications