Evaporator Core: Service and Repair
EVAPORATOR COREREMOVAL
1. Turn ignition On and select outside air on control head.
2. Disconnect negative battery cable.
3. Remove wiper arm assemblies.
4. Remove cowl retaining nuts and remove cowl screen assembly.
5. Rotate locking tabs outward to release filter assembly.
6. Remove filter by lifting straight up.
7. Remove filter housing attachment bolts and remove filter housing.
8. Remove blower motor housing screws, release locking tabs and remove housing.
9. Disconnect blower motor electrical connector by squeezing bottom of connector and pulling downward.
10. Remove blower motor assembly by lifting straight out.
IMPORTANT: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.
11. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil lost during recovery and record.
NOTE: When removing the TXV, keep dirt and foreign material from getting on or into the O-ring sealing surfaces. Clean tools and a clean work area are important for proper service. The TXV seal area should be cleaned before any repairs are begun. The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non-petroleum based solvent and dried with air. Use only lint free cloths to wipe parts. Do not allow solvent to enter evaporator or hoses.
CAUTION: DO NOT REMOVE HOSES OR LINES BEFORE SYSTEM IS FULLY DISCHARGED.
12. Remove suction/liquid line assembly to TXV retaining bolt.
13. Remove suction/liquid line assembly block from TXV by gently rocking while pulling forward.
14. Install cap on suction/liquid line hose assembly to prevent oil spillage.
15. Remove TXV retaining bolts.
16. Install suction/liquid line assembly to TXV bolt and hand tighten into TXV
17. Using bolt as a handle, remove TXV from evaporator by gently rocking TXV while pulling forward in vehicle.
18. Open glove box door.
19. Remove glove box lamp assembly by pulling on lamp plunger.
20. Disconnect glove box lamp wiring harness from glove box lamp.
21. Remove right side I/P lower dash insulator retainers.
22. Pull insulator rearward to detach from forward insulator retainers.
23. Remove right side heater duet assembly retainer and remove duct.
24. Remove glove box door.
25. Remove glove box bin fasteners.
26. Slowly remove glove box bin tilting bin downward to expose the BCM module residing on top of the glove box.
27. Remove BCM module from glove box by sliding module out of attaching slots.
28. Remove glove box bin.
29. Remove hush panel support from front of dash.
CAUTION: TO AVOID CUTTING INTERNAL COMPONENTS, CUT ONLY INSIDE RAISED BEAD AREA.
NOTE: Do not cut through or damage raised bead, this bead will be used as a sealing surface when completing procedure.
30. Locate evaporator access door location on right side of module. The entire area inside raised lip is to be cut out. Using a sharp utility knife, cut through module wall, following inside of the raised bead as a guide. Several passes may be necessary to accomplish this.
31. From inside of vehicle, slide evaporator core out through access door opening. Use care not to damage core fins or pipes. Install caps on pipes to prevent oil spillage.
32. Carefully clean out any debris that may be inside of module.
INSTALLATION
NOTE: Add 72 ml (2.4 oz) of PAG oil to new evaporator.
1. Lubricate evaporator O-rings with mineral oil.
2. Install evaporator into module. Use care not to bend the pipes or damage foam seals.
3. Inspect module/TXV foam seal to verify proper location.
4. Install suction/liquid line assembly to TXV bolt finger tight into TXV
5. Apply a thin coating of clean mineral oil on TXV to evaporator O-ring surfaces.
CAUTION: BLOWER RESISTOR CARD HAS SHARP EDGES AND MAY BE HOT IF BLOWER WAS USED PRIOR TO SERVICING.
6. Reach down through blower motor opening and locate evaporator pipes and block.
7. Install TXV into foam seal, dome end towards passenger's side of vehicle.
8. While gently lifting evaporator pipes and block with one hand, gently press TXV inward until fully installed onto both pipes. When completely installed, TXV should be almost flush with edge of bevel of TXV foam seal.
9. Remove suction/liquid line assembly to TXV bolt from TXV
NOTE: Improper installation of TXV to evaporator pipes will damage pipes requiring evaporator core replacement.
10. Thread TXV to evaporator core block bolts into block by hand. Bolts should thread in easily. Do not force! If bolts do not thread in easily, verify that TXV is properly installed onto both pipes and fully seated to block.
11. After verifying proper installation, tighten both TXV to block bolts.
Torque: 7 N.m (62 in-lbs)
12. Thoroughly clean the O-ring surfaces of the TXV
13. Install new O-rings to suction/liquid line assembly block.
14. Lubricate the O-rings with clean mineral oil.
15. Install suction/liquid line assembly block to TXV
16. Install suction/liquid line assembly to TXV bolt.
Torque: 7 N.m (62 in-lbs)
NOTE: Proper sealing is important to prevent condensation from leaking into the passenger compartment.
17. Apply provided sealant to service door at tongue and groove location as shown.
18. Install evaporator core service door to module and install screws.
Torque: 1 N.m (9 in-lbs)
19. Install blower motor assembly into module housing. Fan motor assembly rib must be located into channel in module housing.
20. Connect blower motor electrical connector.
21. Install blower motor housing. Housing rib must fit into slot in module case. Snap left and right clip into place and install fan housing to module screws.
Torque: 1 N.m (9 in-lbs)
NOTE: A new filter housing seal must be used whenever the filter housing is removed to prevent water from leaking into module.
22. Remove filter housing seal using a small flat blade screwdriver.
23. Install new filter housing seal.
24. Install filter housing and screws.
Torque: 3.5 N.m (31 in-lbs)
25. Install cabin air filter paying special attention to air flow direction indicator printed on side of filter.
26. Rotate locking tabs on filter housing inward to secure air filter in place.
27. Install cowl screen and fasteners.
Torque: 1 N.m (9 in-lbs)
28. Close the filter access door.
29. Install wiper arm assemblies.
Torque: 20 N.m (15 ft-lbs)
30. Connect negative battery cable.
Torque: 17 N.m (151 in-lbs)
31. Install glove box bin partially into opening.
32. Secure BCM module to glove box bin slots.
33. Route glove box lamp wiring harness through lamp opening.
34. Install glove box bin to I/P with fasteners.
Torque: 2.5 N.m (22 in-lbs)
35. Connect glove box lamp wiring harness to glove box lamp.
36. Snap lamp into glove box bin.
37. Install heater outlet with retainer.
38. Install lower dash insulator support.
39. Install lower dash insulator with retainers.
40. Function glove box lamp and glove box door to ensure proper operation.
41. Install glove box door with fasteners.
Torque: 2 N.m (18 in-lbs)
42. Connect negative battery cable.
43. Evacuate, charge, and leak check the A/C system.
Torque: 17 N.m (151 in-lbs)
44. Turn HVAC blower On with mode set to heater, temperature on hot, recirc on outside air.
45. Use back of hand to check for any air leaks around service door. If any leaks are found door must be removed and resealed.