Evaporator Core: Service and Repair

Heater/Evaporator Module:

SPECIAL TOOL REQUIRED (or equivalent)
- J-38100-D, A/C refrigerant recovery and recycling station.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Recover refrigerant and drain cooling system.
3. Raise and support vehicle.
4. Heater hoses from heater core.
5. Evaporator block fitting from the evaporator and discard "O" ring seals.
6. Moisture drain tube from heater-A/C module and lower vehicle.
7. Right and left sound insulators and steering column opening filler.
8. Floor air outlet duct and heater core cover.

CAUTION: To avoid breaking the drain tube, carefully pull the heater core cover straight rearward when removing.

9. Heater core mounting clamps and remove heater core.
10. Screws holding the defroster vacuum actuator to the module case.
11. Evaporator cover and evaporator core.

INSTALL OR CONNECT
1. Evaporator and evaporator cover. Add 90 ml (3 oz.) of 525 viscosity refrigerant oil to the system if installing a new evaporator.
2. Defroster vacuum actuator to the module case with attaching screws.
3. Heater core and heater core mounting clamps.
4. Heater core cover and floor air outlet duct.
5. Steering column opening filler, right and left sound insulators.
6. Raise and support vehicle. Connect moisture drain tube to heater-A/C module.
7. Heater hoses to heater core.
8. Evaporator block fitting to evaporator using new "O" ring seals lubricated in clean 525 viscosity refrigerant oil.
9. Lower vehicle, evacuate and recharge A/C system.
10. Negative battery cable.
11. Fill cooling system and check for leaks.
12. Leak test evaporator block fitting and performance test A/C system.