Main Climate Control

HEATER CORE AND EVAPORATOR CORE HOUSING

REMOVAL

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

All Vehicles
1. Recover the refrigerant.
2. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, Removal and Installation

3. Drain the engine coolant.







4. Fold back the carpet and remove the LH instrument panel support bracket.







5. Fold back the carpet and remove the RH instrument panel support bracket.







6. Remove the screws and remove the snow shield.

Vehicles with DATC







7. Detach and disconnect the vacuum line connector.

4x4 vehicles







8. Remove the screws and detach the 4x4 control module.

All vehicles







10. Compress the clamps and disconnect the heater hoses from the heater core.







11. Disconnect the evaporator core inlet and outlet spring lock couplings.
- Discard the O-ring seals.







12. Disconnect the vacuum line connectors in the engine compartment.







13. Push the vacuum lines into the passenger compartment.
- Detach the vacuum line seal from the dash panel and pull it into the passenger compartment.
- Working from outside the vehicle, push the vacuum lines into the vehicle.







14. Detach the electrical connectors.
1 Disconnect the electrical connectors.
2 Detach the electrical connector from the housing.







15. Disconnect the electrical connector from the LH temperature blend door actuator.







16. Pull the wiring harness through the opening and free from the heater core and evaporator core housing.

Vehicles with DATC







17. Disconnect the RH temperature blend door actuator electrical connector.







18. Detach the wiring harness from the heater core and evaporator core housing.

All vehicles







19. Remove the nuts at the dash panel.







20. Remove the remaining nuts at the dash panel.







21. Remove the heater core and evaporator core housing.

INSTALLATION
1. To install, reverse the removal procedure.
- If a new evaporator core is to be installed, lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent.
- Install new O-ring seals lubricated with clean PAG oil or equivalent.
- Clean and lubricate the coolant hoses with coolant hose lubricant or plain water only if needed.

2. Top-off the engine cooling system.
3. Evacuate, leak test, and charge the refrigerant system.