Evaporator Core: Service and Repair

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

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.

NOTE: Refer to TSB 94-2-12 if water drips from the floor ducts.

1. Disconnect battery ground cable.
2. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw Left Hand side and pull to disengage five (5) snap-in retainers across top).
3. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel.
4. Remove steering column upper and lower shrouds.
5. Disconnect wiring from steering column.
6. Remove shift interlock switch.
7. Disconnect steering column lower universal joint.
8. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle.
9. Remove one (1) nut retaining Left Hand side of instrument panel to parking brake bracket.
10. Remove Right Hand and Left Hand side cowl trim panels.
11. Disconnect electrical connections at Right Hand cowl side.
12. Remove two (2) instrument panel-to-floor tunnel nuts.
13. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor.
14. Disconnect wiring, heater and Air Conditioning (A/C) vacuum lines and control cables through glove compartment opening.
15. Remove two (2) screws at Right Hand side retaining instrument panel to cowl side.
16. Remove two (2) screws at Left Hand side retaining instrument panel to cowl side.
17. Remove Right Hand and Left Hand finish panel by pulling up to disengage snap-in retainers, three (3) on Right Hand side and four (4) on Left Hand side.
18. Remove Right Hand and Left Hand roof rail trim panels.
19. Remove four (4) screws retaining instrument panel to cowl top.
20. Gently pull instrument panel away from Right Hand side of cowl panel.
21. Place a drain pan or suitable container under heater hose connections at the cowl panel.
22. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure.

CAUTION: Observe all safety precautions.

23. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
24. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core.
25. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment.
26. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel.
27. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel.
28. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel.
29. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench.
30. With a small saw, cut the top of the evaporator case between the dotted lines.
31. Remove the old evaporator core from the case.
32. Be sure all burrs are removed from the sawed edges of the evaporator case.
33. Hold the cover against the case firmly and drill five 3/16 inch diameter holes for the retaining screws.
34. Install the new evaporator in the evaporator case.
35. Install the service cover to the evaporator case.
36. Install the five retaining screws.
37. Run a bead of Caulking Cord Rope Sealer between the service cover and the evaporator case.
38. Install the evaporator case in the vehicle by reversing the removal procedure.

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