With Manual A/C

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

NOTE: 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.

REMOVAL
1. Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ Service and Repair
2. Remove the foam seals from the evaporator core tubes.






3. Remove the four screws retaining the A/C electronic door actuator motor to the A/C evaporator housing and remove the A/C electronic door actuator motor from the A/C air temperature control door.






4. Disengage the spring from the heater core cover and remove the spring from the lever.

NOTE: Do not attempt to bend any part of the lever; it is brittle and will break.

5. Gently depress the locking ramp and remove the lever from the secondary A/C air temperature control door end.






6. Rotate the primary A/C air temperature control door shaft down;
then swing the metal link and remove it from the pin.






7. Remove the retaining screws from around the flange joint of the A/C evaporator housing.
6. With side cutters (or equivalent), cut all snap loops around the flange joint of the A/C evaporator housing.
9. Remove the upper evaporator housing case from the lower evaporator case housing.
10. Remove the A/C evaporator core from the lower evaporator case housing.

INSTALLATION
1. Transfer the two foam seals to the new A/C evaporator core.
2. Position the A/C evaporator core in the lower evaporator case housing.
3. Install the upper evaporator case housing to the lower evaporator case housing, making sure the heater air damper door lower post is positioned in the pivot hole in the lower evaporator case housing.
4. Install the retaining screws around the flange joint of the A/C evaporator housing.
5. Install the metal link over the pin on the primary A/C air temperature control door shaft.
6. Install the secondary A/C air temperature control door lever on the metal link.
7. Install the secondary A/C air temperature control door lever to the secondary A/C air temperature control door end.
8. Engage the spring to the heater core cover and the secondary A/C air temperature control door lever.
9. Instal the A/C electronic door actuator motor to the A/C evaporator housing with the four retaining screws.
10. Install the foam seals over the evaporator tubes.
11. Instal the A/C evaporator housing assembly, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ Service and Repair