Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

REMOVAL PROCEDURE
1. Remove the HVAC module assembly.
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.




5. Remove the air inlet assembly screws.
6. Remove the air inlet assembly.







7. Remove the air temperature actuator screws.
8. Remove the air temperature actuator.
9. Remove the mode actuator screws.




10. Remove the mode actuator.
11. Drill out the mode valve assembly heat stakes.




12. Remove the mode valve assembly screws.
13. Remove the mode valve assembly.
14. Drill out the lower HVAC module case heat stakes.
15. Remove the lower HVAC module case screws.




16. Remove the lower HVAC module case.
17. Remove the thermal expansion valve screws.
18. Remove the thermal expansion valve.




19. Remove and discard the sealing washers




20. Remove the evaporator.

INSTALLATION PROCEDURE
1. If replacing the evaporator, add the specific amount of PAG(r) oil directly to the evaporator. Refer to Refrigerant System Capacities




2. Install the evaporator.
3. Install new sealing washers.




4. Install the thermal expansion valve.
5. Install the thermal expansion valve screws.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the screws to 7 N.m (62 lb in).




6. Install the lower HVAC module case.
7. Install the lower HVAC module case screws.

Tighten the screws to 1.5 N.m (13 lb in).

8. Install the mode valve assembly.




Install the mode valve assembly screws.

Tighten the screws to 1.5 N.m (13 lb in).

9. Install the mode actuator.




10. Install the mode actuator screws.

Tighten the screws to 1.5 N.m (13 lb in).

11. Install the air temperature actuator.




12. Install the air temperature actuator screws.

Tighten the screws to 1.5 N.m (13 lb in).

13. Install the air inlet assembly.




14. Install the air inlet assembly screws.

Tighten the screws to 1.5 N.m (13 lb in).

15. Install the upper center floor air outlet duct.




16. Install the upper center floor air outlet duct screws.

Tighten the screws to 1.5 N.m (13 lb in).

17. Install the lower center floor air outlet duct.
18. Install the HVAC module assembly.