Evaporator Case: Service and Repair
SPECIAL SERVICE TOOL(S) REQUIREDDescription Tool Number
Spring Lock coupling Disconnect Tool (1/2 inch) 412-027 (T81P-19623-G2)
Spring Lock coupling Disconnect Tool (3/4 inch) 412-040 (T85L-19623-A)
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 1/2 inch Spring Lock Coupling Disconnect Tool 412-027 (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 3/4 inch Spring Lock Coupling Disconnect Tool 412-040 (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. 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 N.m (24-60 Lb-In).
NOTE: Install screw and washer assembly first to properly position housing to cowl.
2. Install three nuts in engine compartment retaining A/C evaporator housing to cowl panel. Tighten to 4.1-9.5 N.m (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. Remove caps then connect condenser to evaporator tube and suction accumulator/drier inlet tube to A/C evaporator core.
CAUTION: Make sure correct type O-ring seals are installed on A/C fittings.
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.