Evaporator Core: Service and Repair

NOTE: If the evaporator core is replaced, the suction accumulator/drier must also be replaced.

Removal
1. Disconnect the cable from the battery negative (ground) terminal.
2. Discharge the refrigerant from the Air Conditioning (A/C) system. Observe all safety precautions.
3. Disconnect the electrical connector from the pressure switch located on top of the accumulator/drier.





4. Remove the pressure switch from the accumulator/drier.





5. Disconnect the suction hose from the accumulator/drier, using the Spring Lock Coupling Tool, and cap openings to prevents dirt and/or moisture from entering.
6. Disconnect the liquid line from the evaporator core inlet tube using a backup wrench to loosen the fitting. Cap the openings to prevent dirt and/or moisture from entering.
7. Remove the screws holding the evaporator case service cover and vacuum reservoir to the evaporator case assembly.
8. Store the vacuum reservoir in a secure position to avoid vacuum line damage.
9. Remove two dash panel mounting nuts.
10. Remove the evaporator case service cover from the evaporator case assembly.
11. Remove the evaporator core and suction accumulator/drier assembly from the vehicle.

Installation
1. Position the evaporator core and accumulator/drier assembly into the evaporator case outboard half.
2. Position the evaporator case service cover into place on the evaporator case assembly.
3. Install the two dash panel mounting nuts.
4. Install the screws holding the evaporator service case half to the evaporator case assembly.
5. Place the vacuum reservoir in it's installed position. Attach the reservoir to the case with two screws.
6. Connect the liquid line to the evaporator inlet tube using a backup wrench to tighten the fitting to specification. (Install a new lubricated O-ring.)
7. Connect the suction hose to the suction accumulator/drier after checking for a missing or damaged spring lock coupling garter spring and/or repairing or replacing the spring. Install two new specified (special material) O-rings, lubricated with clean refrigerant oil, onto the spring lock coupling male fitting.
8. Install (SCREW) the pressure switch to the accumulator/drier and tighten finger tight.

CAUTION: DO NOT use a wrench to tighten the pressure switch.

9. Connect the electrical connector to the pressure switch.
10. Charge the A/C system. Observe all safety precautions.
11. Connect the cable to the battery negative (ground) terminal.
12. Check the A/C system for refrigerant leaks and proper operation.