Evaporator Core: Service and Repair

Standard Evaporator
1. Partially drain engine coolant and disconnect heater hoses from heater core.
2. Remove battery from vehicle. Discharge refrigerant from system.

Fig. 13 Standard evaporator core removal:

3. Disconnect electrical connectors from blower resistor and pressure switch, Fig. 13.
4. Disconnect EEC-IV Harness.

Fig. 2 Spring lock coupling disconnect & connect:

5. Disconnect suction line from accumulator/drier, Fig. 2, liquid line from evaporator core and the discharge line. Plug all open connections to prevent entry of dirt and moisture into system.
6. Remove drain tube from bottom of evaporator case assembly.
7. Remove five nuts retaining evaporator assembly to dash and remove evaporator assembly.
8. Remove screws retaining accumulator to case and remove accumulator.
9. Remove evaporator core and seal assembly by pulling back retaining tab in housing.
10. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
11. Evacuate, charge and leak test system. Check for proper operation.

Auxiliary Evaporator
1. Remove first bench seat, if equipped.

Fig. 15 Auxiliary evaporator core removal:

2. Remove cover assembly, Fig. 15.
3. Discharge refrigerant from system.
4. Disconnect suction line from evaporator core, Fig. 2, and liquid line from expansion valve. Cap refrigerant lines to prevent dirt and moisture contamination.
5. On models equipped with an auxiliary heater, disconnect and plug heater hoses from auxiliary heater core.
6. On all models, remove four screws securing evaporator core and mounting bracket to auxiliary case assembly.
7. Remove evaporator core, expansion valve and core mounting plate from case.
8. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
9. Evacuate, charge and leak test system.