With Manual A/C

REMOVAL
1. Remove the refrigerant from the A/C system, using an approved recovery unit, while observing all safety precautions.

NOTE: Whenever the evaporator case is removed, it will be necessary to replace the suction accumulator/drier.

2. Disconnect the suction hose from the suction accumulator/drier using the Spring Lock Coupling Tool T81P-19623-G1 or G2 or equivalent, and plug the openings to prevent dirt and excessive moisture from entering. Position the hose away from the evaporator assembly.
3. Disconnect the liquid line from the evaporator inlet tube using the Spring Lock Coupling Tool T81P-19623-G1 and G2 or equivalent, and plug the openings. Position the liquid line away from the evaporator assembly.
4. Disconnect the two 2-wire connector plug from the pressure control de-ice switch on the suction accumulator/drier.
5. Drain the coolant from the radiator. Save the coolant for reuse.
6. Loosen the heater hose clamps and disconnect the heater hoses from the heater core tubes.
7. Remove the six screws holding the RH side of the hood seal bracket assembly. Remove the copper hood ground clip from underneath the hood seal and fold the hood seal assembly to the LH side of the vehicle.
8. Loosen the retaining clamp and disconnect the emission hose that passes over the top of the evaporator case assembly. Position the emission hose, all vacuum hoses, and movable wires away from the evaporator case assembly.
9. Disconnect the blower motor lead assembly from the main wiring harness and remove the hard-shell connector from the blower motor resistor assembly.
10. Disconnect the two large wiring harnesses (which cross the evaporator assembly) at the various hard shell connecting points and position them away from the evaporator assembly.
11. From the passenger side of the dash panel, fold the carpeting back on the RH side of the floor. Remove the bottom LH screw of the two screws that support the inlet recirculation air duct assembly.
12. From the engine side of the dash panel, remove the three nuts (one upper and two lower) from the three evaporator assembly mounting studs. Also remove the two screws (one drill point and one sheet metal) from the blower motor and wheel assembly portion of the case assembly.
13. Pull the bottom of the evaporator case assembly away from the dash panel to disengage the two bottom studs. Move the top of the case assembly away from the dash panel disengaging it from the top stud and maneuver the case up and over the wheel well splash panel.

INSTALLATION
1. Position the evaporator assembly next to the dash panel by maneuvering it down past the wheel well splash panel.

Plenum/Evaporator Case And Evaporator Assembly:

2. Engage the two bottom dash panel studs into the evaporator assembly stud holes. Move the top of the case assembly toward the dash panel while engaging the top dash panel stud into the evaporator assembly stud hole.
3. Replace, but do not tighten, the three stud nuts.
4. Replace the two screws (one drill point and one sheet metal) and tighten. Be careful to return the drill point screw to the correct hole which is located on top of the case and to the right of the blower motor and wheel assembly. Tighten the three stud nuts previously installed.
5. Position the two large wiring harnesses across the evaporator case assembly and connect the various connectors.
6. Connect the blower motor lead assembly to the main wiring harness.
7. Place the emission hose clamp on the hose, tighten the clamp and position it over the evaporator case assembly along with the vacuum hoses and wires previously moved.
8. Unfold the hood seal bracket assembly and insert the copper hood ground clip underneath the hood seal. Install the four screws that secure the RH side of the hood seal bracket assembly. Secure the copper ground clip under one of these screws.
9. Place the heater core hose clamps onto the heater hoses and carefully connect the hoses to the inlet and outlet heater core tubes. Position the clamps and tighten. Refill the coolant system.
10. Remove the plugs from the evaporator inlet tube and the liquid line and install new 0-rings dipped in clean refrigerant oil. Connect the liquid line to the evaporator inlet tube.
11. Remove the plugs from the suction accumulator-drier outlet and the suction hose and install new 0-rings dipped in clean refrigerant oil. Connect the suction hose to the accumulator-drier and tighten.
12. Leak test, evacuate, and charge the refrigeration system following the recommended procedures and safety precautions.
13. From the passenger compartment, install the inlet air duct assembly screw.
14. Check the A/C system for proper operation.