Evaporator Case: Service and Repair

REMOVAL

NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle.

1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ Accumulator HVAC






2. Disconnect the blower motor and the blower motor resistor electrical connectors.






3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the heater hoses.






4. Detach the heater control valve vacuum hose.
5. Disconnect the heater control valve vacuum hose and the vacuum supply hose.






6. Disconnect the condenser to evaporator tube spring lock coupling.






7. Disconnect the vacuum harness connector. Remove the nut.






8. Remove two nuts, one bolt, and the A/C evaporator housing.
- Remove the nut located at the bottom of the A/C evaporator housing first.
- To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise. Then tip the evaporator core end towards the front of the vehicle.

INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition.
- Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
- Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed.