Evaporator Core: Service and Repair

Fig. 21 Evaporator Core Replacement:

1. Discharge refrigerant into a recovery station, then drain coolant.
2. Remove righthand instrument panel sound insulator panel assembly, then disconnect heater hoses at heater core assembly.
3. Remove instrument panel compartment, then the heater core.
4. Remove evaporator temperature sensor assembly, Fig. 21, then disconnect temperature control cable assembly at temperature valve case assembly.
5. Remove bolts (located in engine compartment) from temperature valve case assembly, then the temperature valve case assembly by sliding case assembly downward to disengage upper case clip.
6. Remove thermostatic expansion valve assembly.
7. Using a small hand saw, remove perforated section of evaporator module assembly as one piece and retain for reuse.
8. Remove bolts retaining evaporator, then the evaporator from module assembly by sliding evaporator to left and pulling out through opening cut in module.
9. Reverse procedure to install, noting the following:
a. If replacing evaporator, transfer condensate screen to new evaporator.
b. If replacing evaporator, add 3 fluid ounces of polyalkalene glycol (PAG), synthetic refrigerant oil to new evaporator.
c. Apply sealer No. 3012078, or equivalent, between evaporator upper and lower case just behind thermostatic expansion valve assembly to prevent air entry from engine compartment.
d. Use epoxy glue to adhere perforated section of module assembly to module assembly.
e. Fill radiator and bleed cooling system.
f. Partially charge system and perform a leak test, then recover refrigerant and evacuate and charge system.