Evaporator Core: Service and Repair

Right-Side Instrument Panel Center Support:

Evaporator Case Retaining Clips:

Upper/Lower Evaporator Case Halves:

Evaporator And Expansion Valve:

Remove or Disconnect

1. Discharge and recover refrigerant. Refer to Discharging, Adding Oil, Evacuating and Charging the Refrigeration System.
2. Disable the SIR.
3. Negative (-) battery cable.
4. Blower case.
5. Evaporator inlet and outlet pipes at bulkhead by loosening pipe nuts.
6. Evaporator case mounting nut on engine side of bulkhead (near refrigerant pipes).
7. Two bolts and right-side instrument panel center support.
8. Passenger-side SIR inflator module.
9. Loosen evaporator-to-heater connector band; slide band on to heater case.
10. Drain hose from evaporator case.
11. A/C amplifier and evaporator temperature sensor electrical connectors.
12. SIR harness loop around evaporator case.
13. Two upper bolts and evaporator case from vehicle.
14. Separate upper and lower case halves by disengaging five retaining clips and one screw.
15. Evaporator pipe retaining clamp from lower case.
16. Evaporator from lower case.
17. Expansion valve from evaporator by removing two nuts.
18. Evaporator thermistor from evaporator.

Install or Connect

1. Evaporator thermistor to evaporator.
2. Expansion valve to evaporator; secure with two nuts.

Tighten

^ Expansion valve pipe (larger nut) to 35 N.m. (26 lb. ft.).

^ Expansion valve pipe (smaller nut) to 13 N.m. (115 lb. in.).

3. Evaporator attaching screws and evaporator to lower case.
4. Evaporator pipe retaining clamp to lower case.
5. Evaporator case; secure upper and lower halves with five retaining clips and one screw.
6. Evaporator case to vehicle; secure with two bolts and one nut.

Tighten

^ Evaporator case mounting bolts and nut to 15 N.m. (11 lb. ft.).

7. SIR harness loop to evaporator case.
8. A/C amplifier and evaporator thermistor electrical connectors.
9. Evaporator case drain hose.
10. Evaporator case-to-heater case connector band; slide band on from heater case and tighten.
11. Blower case.
12. Passenger-side SIR inflator module.
13. Right-side instrument panel center support; secure with two bolts.
14. Install new O-rings to evaporator pipe fittings. Coat new O-rings with clean refrigerant oil.
15. Evaporator inlet and outlet pipes at bulkhead; secure with pipe nuts.

Tighten

^ Evaporator inlet pipe nut to 35 N.m. (26 lb. ft.).

^ Evaporator outlet pipe nut to 45 N.m. (33 lb. ft.).

16. Enable the SIR.
17. Negative (-) battery cable. Refer to Battery.
18. Evacuate and recharge air conditioning system. Refer to Discharging, Adding Oil, Evacuating and Charging the Refrigeration System.
19. Operate A/C system and check for refrigerant leaks. Refer to Refrigerant Leak Testing.