Evaporator Core: Service and Repair

1. Disarm airbag system.
2. Disconnect battery ground cable, then discharge air conditioning system.
3. Remove air cleaner assembly, then remove front mounting bracket.
4. Disconnect and plug A/C lines from evaporator assembly.
5. Remove glove compartment assembly and upper panel.
6. Remove upper panel bracket.
7. Remove evaporator assembly electrical connectors, then release harness retainers.
8. Remove defroster tube, then remove air duct bands.
9. Remove evaporator assembly drain hose.
10. Remove evaporator assembly attaching nuts and bolts, then remove evaporator assembly.
11. Remove evaporator cover attaching clips, then separate case halves and remove evaporator.
12. Remove de-ice thermostat, then disconnect liquid tube from expansion valve inlet fitting.
13. Remove capillary tube from evaporator outlet, then remove expansion valve from evaporator inlet fitting.
14. Remove evaporator core.
15. Reverse procedure to install. Torque expansion valve to inlet fitting and liquid tube to expansion valve inlet fitting to 9-11 ft lb. Torque suction line to evaporator outlet fitting to 22-25 ft lb.
16. Reactivate airbag system.