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.
NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. For additional information, refer to Climate Control System - General Information and Diagnostics Climate Control System.
All vehicles
1. Drain the cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.
2. Recover the refrigerant. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.
3. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.
4. Remove the suction accumulator. For additional information, refer to Suction Accumulator Service and Repair.
Vehicles with 2.3L engine
5. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 2.3L Service and Repair.
6. Remove the engine oil indicator and tube.
Vehicles with 4.0L engine
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.
- To install, tighten to 11 Nm (97 lb-in).
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.
19. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels 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. For additional information, refer to Climate Control System - General Information and Diagnostics Refrigerant Oil Adding.
- Install new O-ring seals.
- Lubricate the coolant hoses with plain water only, if needed.
23. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.