Evaporator Core: Service and Repair

Fig. 11 Heater Case Assembly.:

Fig. 13 Evaporator Case Assembly.:

1. Disconnect battery ground cable.
2. Discharge and recover refrigerant.
3. Verify that SIR system is disabled.

WARNING: Refer to Air Bags and Seat Belts / Air Bags (Supplemental Restraint Systems) / Service and Repair / Air Bag System Disarming & Arming. Air Bag(s) Arming and Disarming

4. Disconnect inlet and outlet pipes at bulkhead by loosening pipe nuts.
5. Remove evaporator case mounting nut on engine side of bulkhead.
6. Pull out instrument panel compartment while pushing its stopper from both left and right sides.
7. Remove instrument panel compartment by removing two hinge pins.
8. Remove two bolts and right-side instrument panel center support.
9. Remove blower motor and resistor electrical connectors.
10. Disconnect Fresh / Recirc air control cable from blower motor case, Fig. 11.
11. Remove wiring harness from guide brackets on blower case.
12. Remove three bolts, two screws and passenger-side SIR module.
13. Remove blower case from vehicle by removing two upper retaining bolts and one lower nut.
14. Loosen evaporator-to-heater connector band, then slide band on to heater case.
15. Remove evaporator case drain hose.
16. Remove A/C amplifier and evaporator temperature sensor electrical connectors.
17. Remove SIR harness loop.
18. Remove two evaporator case upper mounting bolts.
19. Remove evaporator case from vehicle.
20. Separate upper and lower case halves by disengaging five retaining clips and one screw, Fig. 13.
21. Remove evaporator pipe retaining clamp from lower case.
22. Remove evaporator from lower case.
23. Remove two attaching nuts and expansion valve from evaporator case.
24. Remove evaporator temperature sensor from evaporator and A/C amplifier from out side of lower case.
25. Reverse procedure to install.