Evaporator Core: Service and Repair

Fig. 2 Evaporator Core:

On 1994 models equipped with airbags, disable airbag system prior to performing service operation as possible airbag deployment may cause personal injury.

If a leaking evaporator core is suspected, leak test the core before removing it from the vehicle. If the core needs to be replaced, replace the evaporator/blower unit as an assembly, Fig. 4.
1. Disconnect battery ground cable, then discharge A/C system.
2. Using a suitable spring coupling tool, disconnect high-pressure line and accumulator/drier inlet tube from evaporator core at bulkhead and plug ports to prevent entrance of dirt or moisture.
3. Remove glove compartment, then remove trim panel below glove compartment.
4. Disconnect two electrical connectors from resistor assembly, then electrical connector from blower motor.
5. Remove right dash side panel, then right lower dash trim panel and capscrews.
6. Remove support bar and bolts, then support plate and bolts.
7. Disconnect cable from recirc/fresh air cam and retaining clip.
8. Loosen capscrew that secures evaporator to heater clamp, then remove four mounting nuts from evaporator/blower unit.
9. Remove evaporator/blower unit.
10. Reverse procedure to install, adjusting Recirc/Fresh air cable as follows:
a. Move air cable to the FRESH position on climate control assembly.
b. Remove glove compartment.

Fig. 2 Adjusting Recirc/Fresh Air Cable:

c. Insert Cable Locating Key tool No. E7GH-18C408-A or equivalent through the fresh air door cam key slot and recirc door key boss opening to secure cam in its proper position as shown in Fig. 2.
d. Disconnect cable from retaining clip next to Recirc/Fresh air cam, then connect cable to retaining clip.
e. Remove cable locating key, then ensure that Recirc/Fresh air lever moves its full stroke.
f. Leak test, evacuate and charge A/C system.