Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

1. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement Instrument Panel Assembly Replacement.




2. Remove instrument panel wiring harness (2) from instrument panel tie bar (1).
Disconnect electrical connectors.




3. Remove instrument panel tie bar (2).

1. Remove 4 instrument panel tie bar bolts (3, 4).
2. Remove 2 instrument panel tie bar nuts (1).




4. Remove air conditioning module wiring harness (1).
Disconnect electrical connectors.
5. Remove heater core. Refer to Heater Core Replacement Service and Repair.
6. Remove blower motor. Refer to Blower Motor Replacement (Left Hand Drive) Service and Repair.
7. Remove heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) HVAC - Automatic or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) HVAC - Manual.
8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.




9. Remove heater and air conditioning evaporator case (2) from heater and blower and air conditioning control module (1).
10. Remove 10 heater and air conditioning evaporator case bolts (3).
11. Remove air conditioning evaporator core from heater and blower and air conditioning control module.

Installation Procedure

1. Install air conditioning evaporator core to heater and blower and air conditioning control module.




2. Install heater and air conditioning evaporator case (2) to heater and blower and air conditioning control module (1).

Caution: Refer to Fastener Caution Fastener Caution.

3. Install 10 heater and air conditioning evaporator case bolts (3) and tighten to 2.5 Nm (22 lb in).
4. Refrigerant recovery and recharging. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.
5. Install heater and blower and air conditioning control module. Refer to Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) HVAC - Automatic or Heater and Blower and Air Conditioning Control Module Replacement (Left Hand Drive) HVAC - Manual.
6. Install blower motor. Refer to Blower Motor Replacement (Left Hand Drive) Service and Repair.
7. Install heater core. Refer to Heater Core Replacement Service and Repair.




8. Install air conditioning module wiring harness (1).
Connect electrical connectors.




9. Install instrument panel tie bar (2).

1. Install 4 instrument panel tie bar bolts (3, 4) and tighten to 22 Nm (17 lb ft).
2. Install 2 instrument panel tie bar nuts (1) and tighten to 6 Nm (53 lb in).




10. Install instrument panel wiring harness (2) from instrument panel tie bar (1).
Connect electrical connectors.
11. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement Instrument Panel Assembly Replacement.