Evaporator Core: Service and Repair

***THIS ARTICLE INCLUDES UPDATES MADE BY TSB #94-8-8, DATED APRIL 1994***

NOTE: Whenever an evaporator core is removed, it must be leak tested to reduce the possibility of replacing a non-leaking core.

NOTE: A procedure has been developed for replacing the evaporator core without removing the instrument panel from the vehicle. Following this procedure will reduce the time required to replace an evaporator core.

NOTE: Loosen the instrument panel from the cowl by pulling the right end of the instrument panel rearward. This provides enough clearance to remove the evaporator case from the vehicle. A service procedure for each of the vehicles listed above is presented in this article. Refer to the following procedures for service details.

1. Disconnect battery ground cable.
2. Raise vehicle.
3. Disconnect speedometer cable at transaxle.
4. Lower vehicle.
5. Remove two (2) cover retaining screws at bottom of steering column opening and snap cover out.
6. Remove snap in lower cluster finish panel(s) (Topaz LS is one piece, all others, two pieces) to expose two (2) screws and two (2) bolts.
7. Remove four (4) cluster opening finish panel retaining screws and pull panel rearward.
8. Remove speed control module, if so equipped (two (2) screws).
9. Remove lower steering column shroud (five (5) screws).
10. Disconnect all steering column electrical connections: ignition, washer/wiper, turn signal, key warning buzzer and speed control. On console automatic transmission shift, remove interlock cable retaining screw and disconnect cable from steering column.
11. Loosen, but do not remove, two (2) nuts and two (2) bolts retaining steering column to support bracket and remove upper shroud.
12. Loosen steering column to intermediate shaft clamp connection and remove bolt or nut.
13. Remove two (2) nuts and two (2) bolts retaining steering column to support bracket.
14. Pry open steering column shaft in area of clamp on each side of bolt groove with steering column locked. Open enough to disengage shafts with minimal effort. Remove column.
15. Inspect two (2) steering column bracket clips for damage. If clips have been bent or excessively distorted, they must be replaced.
16. Remove four (4) screws retaining cluster and carefully pull rearward enough to disengage speedometer cable. Loosely install two (2) screws to retain instrument cluster during instrument panel removal.
17. Remove left A-pillar garnish molding (five (5) screws).
18. Remove right A-pillar garnish molding (five (5) screws)
19. Remove left kick panel.
20. Remove one (1) instrument panel-to-steering column support bracket retaining nut, accessible through steering column opening.
21. Remove two (2) lower instrument panel-to-cowl side retaining screws (Right Hand and Left Hand side).
22. Remove two (2) instrument panel vertical brace retaining nuts located on the Left Hand side of glove compartment.
23. Gently pull instrument panel away from Right Hand side of cowl panel.
24. Drain the coolant from the radiator into a clean container.
25. Discharge the refrigerant from the Air Conditioning (A/C) system, following the recovery procedure.

CAUTION: Observe all safety precautions.

26. Disconnect the heater hoses from the heater core. Plug the heater core tubes or blow any coolant from the heater core with low pressure air.
27. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the dash panel. Cap the refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
28. Disconnect the wire harness connector from the blower motor resistor.
29. Remove one (1) screw retaining the bottom of the evaporator case to the cowl panel.
30. Remove the instrument panel brace from the cowl top panel.
31. In the engine compartment, remove two (2) nuts retaining the evaporator case to the cowl panel.
32. Loosen the sound insulator from the cowl top panel in the area around the air inlet opening.
33. Remove the two (2) screws retaining the support bracket and the brace to the cowl top panel.
34. Pull the right end of the instrument panel away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench.
35. Remove the evaporator-to-cowl seals from the evaporator core tubes.
36. Using a small saw blade or hot knife, cut the top out of the case completely, between the raised outlines.
37. Remove the cover from the base and lift the evaporator core from the case.
38. Use a coarse file or a rasp to remove any rough edges from the case that may have been caused by the cutting.
39. Install the new core and cover following the instructions in the new evaporator core kit.
40. Install the evaporator case in the vehicle by reversing the removal procedure.

NOTE: Check the operation of all components after assembly is completed.