Evaporator Core: Service and Repair

REMOVAL

NOTE: The evaporator core is serviced as a core and housing assembly. The evaporator core, internal doors, seals and door linkage are included with the housing. Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and vacuum actuators to the new housing.

All vehicles
1. Remove the heater core and evaporator core housing. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Removal and Installation, Remove and Installation






2. Remove the heater-to-dash panel seal, the air conditioner tubes-to-dash panel seal, and the air conditioner evaporator drain tube seal.

Vehicles with Electronic Automatic Temperature Control (EATC)







3. Remove the Remote Climate Control (RCC) module.
1 Disconnect the electrical connector.
2 Remove the two nuts. Disconnect the vacuum harness.
3 Remove the two screws.
4 Remove the RCC module.

All vehicles







4. Remove the screws and the shield.







5. Remove the temperature blend door actuator.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the temperature blend door actuator.







6. Remove the A/C evaporator case damper door assist spring.







7. Remove the A/C evaporator case damper door lever.
1 While depressing the tab, disconnect the A/C evaporator case damper door lever.
2 Rotate and remove the A/C evaporator case damper door lever.

CAUTION: Do not attempt to bend any part of the A/C evaporator case damper door lever.







8. Remove the metal link.

Vehicles with manual climate control







9. Detach the vacuum harness from the mounting bracket.

All vehicles







10. Remove the heater core cover.
1 Remove the screws.
2 Rotate the temperature blend door.
3 Remove the heater core cover and seal.







11. Remove the heater core.
1 Rotate the temperature blend door.
2 Remove the heater core.

Vehicles with manual climate control







12. Remove the screws and the blower motor. Remove the screws and the blower motor resistor.

Vehicles with electronic automatic temperature control (EATC)







13. Disconnect the vacuum hose. Remove the screws. Remove the blower motor and the blower motor speed control as an assembly.







14. Remove the in-car temperature sensor hose.

All vehicles







15. Remove the bracket.







16. Remove the recirculation air duct.
1 Disconnect the vacuum hose.
2 Remove the three screws.
3 Remove the recirculation air duct.







17. Remove the screws and the shield.







18. Label and disconnect the two vacuum hoses. Remove the screw. Lift, rotate, and remove the vacuum control motor.
19. Note the vacuum harness and wiring harness routing. Remove the vacuum harness and wiring harness.

INSTALLATION

All vehicles
1. Install the vacuum and wiring harness as noted during removal.







2. Install the vacuum control motor and the screw. Connect the vacuum hoses.







3. Install the shield and screws.







4. Install the recirculation air duct.
1 Position the recirculation air duct.
2 Install the three screws.
3 Connect the vacuum hose.







5. Install the bracket.

Vehicles with electronic automatic temperature control (EATC)







6. Install the in-car temperature sensor hose.







7. Install the blower motor and blower motor speed control as an assembly. Install the screws. Connect the vacuum hose.

Vehicles with manual climate control







8. Install the blower motor and the screws. Install the blower motor resistor and the screws.

All vehicles







9. Install the heater core.
1 Rotate the temperature blend door.
2 Install the heater core.







10. Install the heater core cover.
1 Rotate the temperature blend door.
2 Install the heater core cover.
3 Install the screws.

Vehicles with manual climate control







11. Attach the vacuum harness to the mounting bracket.

All vehicles







12. Install the metal link.







13. Install the A/C evaporator case damper door lever.
1 Install the A/C evaporator case damper door lever.
2 Align and insert the A/C evaporator case damper door lever.

CAUTION: Do not attempt to bend any part of the A/C evaporator case damper door lever.







14. Install the A/C evaporator case damper door assist spring.







15. Install the temperature blend door actuator.
1 Install the temperature blend door actuator.
2 Install the screws.
3 Connect the temperature blend door actuator electrical connector.







16. Install the shield and two screws.

Vehicles with electronic automatic temperature control (EATC)







17. Install the RCC module.
1 Install the RCC module.
2 Install the two screws.
3 Connect the vacuum harness. Install the two nuts.
4 Connect the RCC module electrical connector.

All vehicles







18. Install the heater-to-dash panel seal, the air conditioner tubes-to-dash panel seal, and the air conditioner evaporator drain tube seal.
19. Install the heater core and evaporator core housing. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, Removal and Installation, Remove and Installation