Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement




1. Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Replacement (Air Conditioning and Heater Module Assembly Replacement).
2. Remove the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement (Service and Repair).
3. Remove the thermal expansion valve (TXV) bolts from the backing plate.
4. Remove the TXV and the backing plate from the evaporator pipes.
5. Remove the seal washers from evaporator pipes. Refer to Air Conditioning System Seal Replacement (Air Conditioning System Seal Replacement).
6. Remove the HVAC module front of dash seal.




7. Remove the screws retaining the two halves of the blower case assembly.
8. Separate the two halves of the blower case assembly.




9. Remove the evaporator core from the blower case assembly.

Installation Procedure




1. Add the proper of polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant System Capacities (With HP5) (Capacity Specifications)Refrigerant System Capacities (Without HP5) (Capacity Specifications).
2. Inspect the seal around the evaporator core. Make sure the seal is in correct position and retained properly.
3. Install the evaporator core to the blower case assembly.




4. Assemble the two halves of the blower case assembly.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the blower case assembly screws.

Tighten the screw to 1.5 Nm (13 lb in).

6. Install the HVAC module front of dash seal.




7. Install new seal washers to the evaporator pipes. Refer to Air Conditioning System Seal Replacement (Air Conditioning System Seal Replacement).
8. Instal the TXV and the backing plate to the evaporator pipes.
9. Install the TXV screws to the backing plate.

Tighten the screws to 3.5 Nm (31 lb in).

10. Install the evaporator case assembly. Refer to Air Conditioning (A/C) Evaporator Case Assembly Replacement (Service and Repair).
11. Install the HVAC module. Refer to Air Conditioning and Heater Module Assembly Replacement (Air Conditioning and Heater Module Assembly Replacement).