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 third, fourth and fifth bench seats, if equipped.
2. Remove left center bolster trim panel, left lower front trim panel, left rear lower trim panel and upper trim panels, if equipped.
3. Drain cooling system and discharge air conditioning system.
4. Raise and support vehicle, then disconnect heater hoses from underbody heater tubes and plug hoses.
5. On models equipped with air conditioning, using suitable backup wrench, disconnect and cap liquid and suction line from underbody A/C lines.
6. On all models, disconnect auxiliary heater and A/C assembly electrical connectors and vacuum lines.
7. Remove assembly vertical duct attaching screw, then lift dust into headliner, then pull down and away from headliner to remove, if equipped.
8. Remove assembly attaching screws, then pull assembly rearward to clear dowel alignment pin.
9. Lift heater and A/C assembly from vehicle while guiding heater hoses from below underbody.
10. Remove evaporator cover attaching screws, then remove cover.
11. Remove evaporator core and seal.
12. Reverse procedure to install.