Evaporator Core: Service and Repair
EVAPORATOR CORE REPLACEMENTTOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the HVAC module assembly. Service and Repair
2. Remove the air inlet housing screws.
3. Remove the air inlet housing from the HVAC module.
4. Remove the right side HVAC module assembly mounting bracket screws.
5. Remove the right side HVAC module assembly mounting bracket.
IMPORTANT: The HVAC module assembly retaining screw is located under the HVAC module assembly mounting bracket.
6. Remove the upper HVAC module assembly retaining screw.
7. Remove the HVAC module assembly to dash panel sound barrier seal.
8. Remove the lower HVAC module assembly retaining screws.
9. Remove the heater core cover screws.
10. Remove the heater core cover.
11. Remove the heater core pipe retaining screw.
12. Remove the heater core.
IMPORTANT: The HVAC module assembly retaining screw is located under the heater core.
13. Remove the HVAC module assembly retaining screw.
14. Separate the upper and tower HVAC module halves.
15. Remove the evaporator core from the upper HVAC module case half.
16. Remove the TXV mounting screws.
17. Remove the TXV from the evaporator core.
INSTALLATION PROCEDURE
IMPORTANT: The evaporator temperature sensor must be located in the same position on the new evaporator core.
1. The evaporator temperature sensor should be approximately 3.5 cm (1.4 in) from the side and 5.0 cm (2.0 in) from he bottom corner of the evaporator core.
2. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant hose and the A/C refrigerant component.
IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new sealing washer to enter the refrigerant system.
3. Lightly coat the sealing washers with mineral base 525 viscosity refrigerant oil.
4. Carefully slide the sealing washers onto the evaporator line until seated.
5. Install the TXV to the evaporator core.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Install the TXV mounting screws.
Tighten
Tighten the screws to 3.2 N.m (28 lb in).
IMPORTANT: Align the evaporator temperature sensor wires with the opening in the upper HVAC module case. Improper alignment will pinch and/or cut the sensor wires.
7. Install the evaporator core into the upper HVAC module case half.
8. Align and install the upper module case to the lower module case.
9. Install the lower HVAC module assembly retaining screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
10. Install the HVAC module assembly retaining screw.
Tighten
Tighten the screw to 0.9 N.m (8 lb in).
11. Install the heater core.
12. Install the heater core pipe retaining screw.
Tighten
Tighten the screw to 0.9 N.m (8 lb in).
13. Install the heater core cover.
14. Install the heater core cover screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
15. Install the HVAC module assembly to dash panel sound barrier seal.
16. Install the upper HVAC module assembly retaining screw.
Tighten
Tighten the screw to 0.9 N.m (8 lb in).
17. Install the right side HVAC module assembly mounting bracket.
18. Install the right side HVAC module assembly mounting bracket screws.
Tighten
Tighten the screws to 1.8 N.m (16 lb in).
19. Install the air inlet housing to the HVAC module.
20. Install the air inlet retaining screws.
Tighten
Tighten the screws to 0.9 N.m (8 lb in).
21. Install the HVAC module assembly.