Evaporator Case: Service and Repair

Automatic Climate Control System Components:

REMOVAL

1. Disconnect the negative battery cable.
2. Evacuate the A/C system.
3. Drain the engine coolant.
4. Disconnect the hoses to the heater core.

Removing Underhood A/C And Heater Lines:

5. Loosen the clamp (2) on the refrigerant line.
6. Remove the mount for the check valves (3).
7. Unscrew the mount nut (1) and disconnect the pipes to the expansion valve.
8. Disconnect the 2-pole connector from the dropping resistor network (R14) and pull out the lead to the fan motor.
9. Remove the instrument panel. Service and Repair
10. Remove the center console. Service and Repair

Removing The Air Ducts And Mounting Hardware:

11. Pull the left and right air ducts (6 and 7) off of the heater and air conditioner box.
12. Remove the cross member (10) and brace (11).
13. Remove the mount (13).
14. Remove the steering wheel lock:

a. Loosen the screw (a)
b. Turn the ignition key to position 1
c. Press in retainer (arrow)
d. Pull out the steering wheel lock

15. Remove the connector for the heater core temperature sensor (B10/1) and the lead for the evaporator temperature sensor (B10/6).
16. Remove the vacuum lines, 2-lead connector, and the switch-over valve (Y13/1).
17. Remove the left and right air ducts for the side nozzles.
18. Remove the 4 mount nuts (15), remove the outside temperature sensor (B10/5), and pull the heater and A/C box downward and out.

INSTALLATION:

Applying Sealant To The Heater-A/C Box:

5. Check the gasket on the bulkhead and replace if necessary. Apply sealant (arrow) to sealing surface of the A/C box.
6. At this point, reverse the removal procedure to install.
7. After the installation is complete (including instrument panel and center console installation), fill the engine with coolant and check for leaks.
8. Evacuate and recharge the A/C system.
9. Check for leaks and proper operation of the A/C system, only allow the engine to run at idle speed for the first 4 minutes.