Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Remove HVAC module. Service and Repair





2. Remove TXV to backing plate attachment bolts and remove TXV and backing plate.
3. Remove O-rings from evaporator pipes and caps to prevent system contamination.
4. Remove HVAC module front of dash seal.





5. Remove heater duct.





6. Disconnect HVAC module harness from all three mode actuators.
7. Remove panel, defrost and floor mode actuators. If blower case assembly is being replaced, mode actuators do not need to be removed.





8. Remove heater core cover.





9. Remove heater core pipe cover.
10. Remove heater core pipe seal.





11. Grasp heater core at end tanks and remove. Spraying perimeter of heater core seal with a soap and water mixture will ease removal.





12. Remove evaporator cover assembly.





13. Remove evaporator pipe retainer.





14. Remove evaporator. Spraying perimeter of evaporator core seal with a soap and water mixture will ease removal.

Installation Procedure





1. Inspect seal around evaporator. Make sure seal is in correct position and retained properly.
2. Spray seal with a soap and water mixture to ease the installation of evaporator.
3. Install evaporator.





4. Install evaporator cover assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install evaporator cover assembly screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





6. Install evaporator pipe retainer.
7. Install evaporator pipe retainer screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





8. Install heater core. Spraying perimeter of heater core seal with a soap and water mixture will ease installation.
9. Install heater core pipe seal.





10. Install heater core pipe cover.
11. Install heater core pipe cover screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





12. Install heater core cover.
13. Install heater core cover screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





14. Install panel, defrost and floor mode actuators.
15. Install actuator screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





16. Install heater duct.
17. Install heater duct screws.

Tighten
Tighten the screws to 1 N.m (9 lb in).





18. Install HVAC module front of dash seal. Inspect and if damaged, replace.

Important: Use only R-12 refrigerant oil (mineral) to lubricate O-rings. Use of R-134a PAG oil will cause premature corrosion of fitting joints.

Use only clean lint free cloths with non-petroleum based solvents to clean refrigerant system sealing surfaces. Allow solvent to dry with air. Do not allow solvents to enter refrigerant system.

19. Remove evaporator pipe caps and insure seal areas are clean, dry and lint free.
20. Install new O-rings to evaporator lubricating with mineral oil. Refer to O-Ring Replacement.
21. Remove shipping caps and install TXV to evaporator pipes with backing plate and bolts.

Tighten
Tighten the bolts to 9 N.m (80 lb in).

22. Install the HVAC module. Refer to HVAC Module Assembly Replacement.