Evaporator Core: Service and Repair

NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to 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.

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






3. Remove four screws retaining A/C electronic blend door actuator housing and remove A/C electronic blend door actuator from A/C air temperature control door.






4. Remove metal cover then disengage spring from heater core cover and remove spring from lever.






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

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

6. Rotate primary A/C air temperature control door shaft down, then swing metal link and remove from pin.
7. Remove retaining screws from around flange joint of A/C evaporator housing.
8. With side cutters (or equivalent), cut all snap loops around flange joint of A/C evaporator housing.
9. Remove upper evaporator housing case from lower evaporator case housing.






10. Remove A/C evaporator core from lower evaporator case housing.

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