Evaporator Core: Service and Repair

A/C Evaporator

Removal

WARNING:
- On Vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury.
- Review the warnings in the front of this section before performing the following operation.

The HVAC housing must be removed from the vehicle when replacing the evaporator.

1. Open the hood and disconnect the negative battery cable remote terminal from the remote battery post.
2. Remove the HVAC housing from vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, HVAC Housing Removal and Installation,

3. Remove the recirculation door actuator.
4. Remove the recirculation door and housing.
5. Remove the upper HVAC housing retaining screws.
6. At the center of the HVAC housing, locate the evaporator probe access plate. Using a flat blade pry tool, pull back on the locking tab. Twist the access plate counter clockwise one-quarter turn, and push the plate inside the HVAC housing.
7. Remove the upper half of the HVAC housing.
8. Lift the evaporator out of the lower housing.

Installation

WARNING: Review the warnings in the front of this section before performing the following operation.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

1. Transfer the evaporator probe to the new evaporator. Place the evaporator probe in the same location as on the previous evaporator.
2. Place the evaporator in the lower HVAC housing.
3. Insert the access plate inside the HVAC housing and orientate it so that the locking tab is one-quarter turn clockwise to where the tab snaps into the HVAC case detent. Note that the plate will be flush with the outside of the HVAC housing.
4. Turn the plate one-quarter turn counter-clockwise to seat the locking tab in the HVAC case detent.
5. Place the top half of the HVAC housing on the lower half. Tighten fasteners to 2.2 Nm (20 in. lbs.). Refer to HVAC Housing / Assembly.
6. Install the recirculation door and housing on the HVAC Housing and tighten the screws to 2.2 Nm (20 in. lbs.).
7. Install the recirculation door actuator.
8. Install the HVAC housing in the vehicle. Refer to: Heating and Air Conditioning, Housing Assembly HVAC, Service and Repair, HVAC Housing Removal and Installation,

9. Evacuate the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, Refrigerant System Evacuate

10. Charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, Refrigerant System Charge