Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Replacement (Air Conditioning and Heater Module Assembly Replacement).




2. Remove the four screws (1).




3. Disengage the four clips (1) and remove the lower heater case (2).




4. Disengage the clamp (2).
5. Remove the evaporator (1).
6. Remove the two bolts and the expansion valve from the evaporator.

Installation Procedure

Caution: Refer to Fastener Caution (Fastener Caution).

Note: If the evaporator was replaced add 400 ml (1.35 fl oz) of compressor oil.

Install new O-rings lubricated with 525 viscosity mineral oil.

1. Install the expansion valve to the evaporator. Secure with the 2 bolts.

Tighten the bolts to 3.5 Nm (31 lb in).




2. Engage the clamp (2) and install the evaporator (1) to the HVAC module assembly.




3. Engage the four clips (1) and install the lower heater case (2).




4. Install the four screws (1).
5. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Replacement (Air Conditioning and Heater Module Assembly Replacement).