Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.




2. Remove the center floor air outlet duct screws.
3. Remove the center floor air outlet duct.




4. Drill out the lower HVAC module case heat stakes.
5. Remove the lower HVAC module case screws.
6. Remove the lower HVAC module case.




7. Remove the thermal expansion valve screws.
8. Remove the thermal expansion valve.
9. Remove and discard the sealing washers.




10. 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.

Notice: Refer to Fastener Notice.

5. Install the thermal expansion valve screws.

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 center floor air outlet duct.
9. Install the center floor air outlet duct screws.

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

10. Install the HVAC module assembly.