Evaporator Core Housing

EVAPORATOR CORE HOUSING







Removal and Installation

NOTE:
- The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Housing Assembly HVAC
- If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. Component Tests and General Diagnostics
- Installation of a new suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. Service and Repair

All vehicles
1. Drain the cooling system. Service and Repair
2. Recover the refrigerant. Component Tests and General Diagnostics
3. Remove the air cleaner outlet pipe.
4. Remove the suction accumulator.

Vehicles with 2.3L engine
5. Remove the A/C compressor. Service and Repair
6. Remove the engine oil indicator and tube.

Vehicles with 3.0L and 4.0L engines
7. Position the coolant reservoir and windshield washer reservoir aside.
1 Remove the 2 screws and 2 nuts.
2 Position the reservoirs aside.







Vehicles with speed control
8. Disconnect the speed control actuator electrical connector.







9. Remove the speed control actuator bolt and position the actuator aside.
- Detach the speed control cable from the evaporator core housing.







All vehicles
10. Disconnect the blower motor electrical connector.
11. Disconnect the blower motor resistor electrical connector.
12. Release the 2 heater hose clamps and disconnect the heater hoses from the heater core.
13. Detach the pin-type retainer and position the windshield washer hose aside.







14. Disconnect and detach the heater control valve vacuum hose.

15. NOTE: 2.3L engine shown, others are similar.

Disconnect the vacuum supply hose near the evaporator core housing.







16. Disconnect the evaporator inlet fitting.
- Discard the O-ring seals.

17. NOTE: The following step is carried out at the lower passenger side dash panel, inside the passenger compartment.

Disconnect the vacuum hose connector and remove the nut.







Vehicles with 4.0L engine
18. If equipped, remove the wheel splash guard. Service and Repair
19. Remove the RH fender splash shield.
20. Remove the 2 evaporator core housing nuts.
- To install, tighten to 4 Nm (35 lb-in).

21. Remove the evaporator core housing.
22. To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent. Refrigerant Oil
- Install new O-ring seals.
- Lubricate the coolant hoses with plain water only, if needed.

23. Evacuate, leak test and charge the refrigerant system. Component Tests and General Diagnostics