Evaporator Core: Service and Repair

1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
2. Disconnect both ground and positive battery cables, then remove battery.
3. Discharge A/C system.
4. Remove bolts and disconnect receiver and suction lines from evaporator and plug lines.
5. Remove glove compartment and frame.
6. Disconnect electrical connector from A/C thermostat, then remove clips or clamps from evaporator.

Fig. 24 Evaporator Housing Removal:

7. Remove self-tapping screws, bolts and nut, Fig. 24.
8. Disconnect drain hose and remove evaporator.
9. Pull evaporator sensor from evaporator fins.
10. Remove self-tapping screws and clips from housing.
11. Separate housings, then remove evaporator covers.
12. Remove expansion valve, if necessary. When loosening expansion valve nuts, use second wrench to hold valve or evaporator pipe to avoid damaging them.
13. Reverse procedure to install, noting the following:
a. Use new O-rings when installing expansion valve and connecting refrigerant lines.
b. Install expansion valve and secure valve sensor against suction line with tape.
c. Reinstall evaporator sensor in its original location.
d. Ensure there is no air leakage in evaporator housing.
14. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.