Evaporator Core: Service and Repair
EVAPORATOR CORERemoval Procedure
CAUTION: Refer to Battery Disconnect Caution in Cautions and notes.
1. Disconnect the battery negative cable.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Remove the right fender. Refer to Fender Replacement - Front in Body Front End.
4. Remove the right wheel panel. Refer to Wheelhouse Panel Replacement in Body Front End.
5. Remove the evaporator tube from the evaporator. Refer to Evaporator Tube Replacement.
6. Remove the accumulator. Refer to Accumulator Replacement (2.2L) or Accumulator Replacement (4.3L).
7. Remove the evaporator core assembly heat shield.
8. Remove the electrical connectors/harnesses, as necessary.
9. Remove the blower motor resistor. Refer to Blower Motor Resistor Replacement.
10. Remove the heater core case to the bulkhead mounting bolt.
11. Remove the evaporator and the blower module screws and the nuts.
12. Remove the acoustic barrier, if equipped.
13. Remove the lower right heater core case mounting bolts.
The bolts are located on the lower right side of the instrument panel on the 4.3L engine only.
14. With the aid of an assistant, lightly pull the lower right corner of the heater case away from the bulkhead (4.3L engine only).
15. Remove the evaporator core assembly from the vehicle.
16. Disassemble the evaporator core case sections.
17. Remove the evaporator core.
Installation Procedure
1. Install the evaporator core.
2. Assemble the evaporator core case sections.
With the aid of an assistant, pull the lower right corner of the heater case away from the bulkhead.
3. Install the evaporator core assembly into the vehicle.
4. Install the lower right heater core case mounting bolts (4.3L engine only).
The bolts are located in the lower right side of the instrument panel.
5. Install the acoustic barrier, if equipped.
NOTE: Refer to Fastener note in Cautions and notes.
6. Install the evaporator core assembly screws and the nuts.
Tighten
Tighten the bolts and the stud to 4.5 N.m (40 lb in).
Tighten the screw and the nuts to 2.5 N.m (22 lb in).
7. Install the heater core case to the bulkhead mounting bolt.
8. Install the blower motor resistor. Refer to Blower Motor Resistor Replacement.
9. Connect the electrical connectors/harnesses, as necessary.
10. Install the evaporator core assembly heat shield.
11. Install the accumulator. Refer to Accumulator Replacement (2.2L) or Accumulator Replacement (4.3L).
12. Install the evaporator tube to the evaporator. Refer to Evaporator Tube Replacement.
13. Install the right front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
14. Install the right fender. Refer to Fender Replacement - Front in Body Front End.
15. Install the hood. Refer to Hood Replacement in Body Front End.
16. Add refrigerant to the system. Refer to Refrigerant Recovery and Recharging.
17. Connect the battery negative cable.
18. Inspect the system for leaks.