Evaporator Case: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Drain coolant from radiator into a clean container.
3. Discharge A/C system, please refer to Heating and Air Conditioning/Service and Repair/ Service and Repair
4. Disconnect heater water hoses from heater core . Plug heater core tubes or blow any coolant from heater core with low pressure air.
5. Disconnect vacuum supply hose (black) from A/C vacuum check valve in engine compartment.
6. Disconnect condenser to evaporator tube from A/C evaporator core using Spring Lock Coupling Disconnect Tool T81P-19623-G2. Cap refrigerant line and A/C evaporator core to prevent entrance of dirt and excess moisture.
7. Disconnect suction accumulator/drier inlet tube from A/C evaporator core using Spring Lock Coupling Disconnect Tool T85L-19623-A. Cap refrigerant line and A/C evaporator core to prevent entrance of dirt and excess moisture.
8. Remove instrument panel, please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ Service and Repair
9. Remove heater outlet floor duct.
10. Remove three nuts retaining A/C evaporator housing to dash panel in engine compartment.
11. Remove screws retaining support bracket to cowl top panel.
12. Remove nut retaining A/C evaporator housing to PCM mounting bracket.

13. Pull A/C evaporator housing away from cowl panel and remove A/C evaporator housing from vehicle.

INSTALLATION

1. NOTE: Install screw and washer assembly first to properly position housing to cowl.

Position A/C evaporator housing assembly against the dash panel and cowl top panel at air inlet opening. Install screws and nut retaining support bracket to cowl top panel. Tighten to 2.7-6.8 Nm (24-60 lb-in).
2. Install three nuts in engine compartment retaining A/C evaporator housing to cowl panel. Tighten to 4.1-9.5 Nm (37-84 lb-in).
3. Install heater outlet floor duct.
4. Install instrument panel, please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ Service and Repair
5. CAUTION: Make sure correct type O-ring seals are installed on A/C fittings.

Remove caps then connect condenser to evaporator tube and suction accumulator/drier inlet tube to A/C evaporator core.
6. Remove caps then connect heater water hoses to heater core.
7. Connect black vacuum supply hose to A/C vacuum check valve in engine compartment.
8. Fill radiator to correct level with previously removed coolant or specified mixture of coolant and water.
9. Connect battery ground cable.
10. Leak-test, evacuate and charge A/C refrigerant system, please refer to Heating and Air Conditioning/Service and Repair/ Service and Repair
11. Check system for proper operation.