Evaporator Core: Service and Repair

EVAPORATOR CORE REPLACEMENT

REMOVAL PROCEDURE




1. Remove the HVAC module. Service and Repair
2. Remove the evaporator case assembly.
3. Remove the TXV bolts from the backing plate
4. Remove the TXV and the backing plate from the evaporator pipes.
5. Remove the O-rings from evaporator pipes.
6. Install protective caps to the evaporator pipes to prevent system contamination.
7. Remove the HVAC module front of dash seal.




8. Remove the evaporator pipe cover screw from the blower case assembly.
9. Remove the evaporator pipe cover from the blower case assembly.




10. Remove the evaporator core from the blower case assembly. Spraying the perimeter of the evaporator core seal with a soap and water mixture will ease removal.

INSTALLATION PROCEDURE




1. Add the proper of PAG oil to the evaporator core. Refer to Refrigerant System Capacities.
2. Inspect the seal around the evaporator core. Make sure the seal is in correct position and retained properly.
3. Spray the seal with a soap and water mixture to ease the installation of evaporator core.
4. Install the evaporator core to the blower case assembly.




5. Install the evaporator pipe cover.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the evaporator pipe cover screw.

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




7. Install the HVAC module front of dash seal.
8. Remove the protective caps from the evaporator pipes and ensure the seal areas are clean, dry and lint free.
9. Install new O-rings to the evaporator pipes.

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.

10. Instal the TXV and the backing plate to the evaporator pipes.
11. Install the TXV screws to the backing plate.

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

12. Install the evaporator case assembly.
13. Install the HVAC module.