Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly.




2. Remove the 4 bolts (1) and the 2 air ducts (2).




3. Remove the 2 bolts (2) and the air outlet lever (1).
4. Remove the 4 bolts and the blower motor upper case.




5. Remove the bolts and the evaporator case cover.
6. Remove the evaporator.
7. Remove the 2 bolts and expansion valve from the evaporator.

Installation Procedure

Important: If the evaporator was replaced add 60 ml (2.0 fl oz) of compressor oil.

Install new O-rings lubricated with 525 viscosity mineral oil.

Notice: Refer to Fastener Notice.

1. Install the expansion valve to the evaporator. Secure with the 2 bolts.

Tighten the bolts to 5.4 N.m (48 lb in).

2. Install the evaporator to the HVAC module assembly




3. Install the evaporator case cover to the HVAC module assembly. Secure with the bolts.

Tighten the bolts to 10N.m (89 lb in).

4. Install the 4 bolts and the blower motor upper case.

Tighten the bolts to 10N.m (89 lb in).




5. Install the air outlet lever (1). Secure the lever with the 2 bolts (2).

Tighten the bolts (2) to 10N.m (89 lb in).




6. Install the 2 air ducts (2). Secure the air ducts with the 4 bolts (1).

Tighten the bolts (1) to 10N.m (89 lb in).

7. Install the HVAC module assembly.