Evaporator Core: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39500-B R-134a Refrigerant Recovery, Recycling and Recharging (ACR4) System

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Use the J 39500-B in order to recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
3. Drain the cooling system.
4. Raise and support the vehicle.
5. Disconnect the heater hoses from the heater core.
6. Remove the evaporator fitting from the evaporator. Discard the O-ring seals.
7. Remove the moisture drain tube from the HVAC module.
8. Lower the vehicle.
9. Remove the instrument panel and console.
10. Remove the heater outlet cover.
11. Remove the heater core cover. The heater core cover mounting screw is located in a recess in the center of the cover.
12. Remove the following components:
^ The heater core mounting clamps
^ The heater core
13. Remove the following components:
^ The heater core shroud
^ The evaporator core
14. Remove the evaporator core.

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.

1. Install the evaporator. If you are installing a new evaporator, refer to Refrigerant Oil Distribution.

Tighten
Tighten the screws to 1 N.m (9 lb in).

2. Install the following components:
^ The heater core shroud
^ The heater core
^ The heater core mounting clamp

Tighten
Tighten the screws to 1 N.m (9 lb in).

3. Install the heater core cover.

Tighten
Tighten the screws to 1 N.m (9 lb in).

4. Install the heater core outlet cover.

Tighten
Tighten the screws to 1 N.m (9 lb in).

5. Install the instrument panel and console.
6. Raise and support the vehicle.
7. Install the moisture drain tube to the HVAC module.
8. Install the evaporator fittings to the evaporator.
Use the new O-ring seals. Lubricate the seals using a clean 525 viscosity refrigerant oil.

Tighten
Tighten the screws to 24 N.m (18 lb in).

9. Connect the heater hoses to the heater core.
10. Lower the vehicle.
11. Fill the cooling system. Inspect for leaks. Refer to Leak Testing.
12. Evacuate and charge the A/C system. Refer to Refrigerant Recovery and Recharging.
13. Connect the negative battery cable.

Tighten
Tighten the bolt to 16 N.m (12 lb ft).