Evaporator Core: Service and Repair

REMOVAL




1. Turn ignition On and select outside air on control head.
2. Disconnect negative battery cable.
3. Remove thermal expansion valve (TXV).




4. Open glove compartment door.
5. Remove glove compartment lamp assembly by pulling on lamp plunger.
6. Disconnect glove compartment lamp wiring harness from glove compartment lamp.




7. Remove right side I/P lower dash insulator retainers.
8. Pull insulator rearward to detach from forward insulator support.
9. Remove insulator support from front of dash studs by pulling rearward.




10. Remove right side heater duct assembly retainer and remove duct.




11. Remove glove compartment door.




12. Remove glove compartment bin fasteners.
13. Slowly remove glove compartment bin tilting bin downward to expose the BCM module residing on top of glove compartment.
14. Remove BCM module from glove compartment by sliding module out of attaching slots.
15. Remove glove compartment bin.




16. Locate evaporator access door location on right side of module. The entire area inside raised I/P is to be cut out.

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.




17. 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.




18. 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.
19. Carefully clean out any debris that may be inside of module.

INSTALLATION

IMPORTANT: 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 thermal expansion valve (TXV).

NOTE: Proper sealing is important to prevent condensation from leaking into the passenger compartment.




5. Apply provided sealant to service door at tongue and groove location as shown.




6. Install evaporator core service door to module and install screws.

Torque:
Evaporator Core Service Door-to-HVAC Module Fasteners: 1 N.m (9 lb in)




7. Install glove compartment bin partially into opening.
8. Secure BCM module to glove compartment bin slots.
9. Route glove compartment lamp wiring harness through lamp opening.
10. Install glove compartment bin to I/P with fasteners.

Torque:
Glove Compartment-to-I/P Fasteners: 2.5 N.m (22 lb in)




11. Connect glove compartment lamp wiring harness to glove compartment lamp.
12. Snap lamp into glove compartment bin.




13. Install heater outlet with retainer.




14. Install lower dash insulator support.
15. Install lower dash insulator with retainers.




16. Install glove compartment door with fasteners.

Torque:
Glove Compartment Door Fasteners: 2 N.m (18 lb in)

17. Function glove compartment lamp and glove compartment door to ensure proper operation.




18. Connect negative battery cable.

Torque:
Battery Terminal Bolts: 17 N.m (13 lb ft)

19. Evacuate, charge, and leak check the A/C system.
20. Turn HVAC blower On with mode set to heater, temperature on hot, recirc on outside air.
21. Use the back of hand to check for any air leaks around service door. If any leaks are found door must be removed and resealed.