Evaporator Core: Service and Repair

Evaporator Core Replacement

Removal Procedure




1. Remove the HVAC module.
2. Remove the evaporator case assembly.
3. Remove the thermal expansion valve (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. Disconnect the thermal expansion valve (TXV) temperature sensor from the engine harness.
8. Remove the temperature sensor screw from the evaporator pipe.
9. Remove the temperature sensor from the evaporator pipe.
10. Remove the HVAC module front of dash seal.




11. Remove the evaporator pipe cover screw from the blower case assembly.
12. Remove the evaporator pipe cover from the blower case assembly.




13. 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 amount of polyalkylene glycol (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.

Notice: Refer to Fastener Notice.

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.

Important: The TXV cavity for temperature sensor must be packed with thermal grease to ensure functionality.

8. Fill the temperature sensor housing in the TXV with the thermal grease included with the service kit.
9. Install the temperature sensor and wipe away the excess grease.
10. Install the temperature sensor screw.

Tighten the screw to 8.5 N.m (75 lb in).

11. Connect the temperature sensor to the engine harness.




12. Remove the protective caps from the evaporator pipes and ensure the seal areas are clean, dry and lint free.

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.

13. Install new O-rings to the evaporator pipes.
14. Instal the TXV and the backing plate to the evaporator pipes.




15. Install the TXV screws to the backing plate.

Tighten the screws to 8 N.m (71 lb in).

16. Install the evaporator case assembly.
17. Install the HVAC module.