Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Removal Procedure

1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement (Service and Repair).




2. Remove the center floor air outlet duct screws.
3. Remove the center floor air outlet duct.




4. Drill out the lower HVAC module case heat stakes.
5. Remove the lower HVAC module case screws.
6. Remove the lower HVAC module case.




7. Remove the thermal expansion valve screws.
8. Remove the thermal expansion valve.
9. Remove and discard the sealing washers.




10. Remove the evaporator.

Installation Procedure

1. If replacing the evaporator, add the specific amount of PAG(R) oil directly to the evaporator. Refer to Refrigerant System Capacities ([1][2]Capacity Specifications).




2. Install the evaporator.
3. Install new sealing washers. Refer to Sealing Washer Replacement (Sealing Washer Replacement).




4. Install the thermal expansion valve.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the thermal expansion valve screws and tighten to 7 Nm (62 lb in).




6. Install the lower HVAC module case.
7. Install the lower HVAC module case screws and tighten to 1.5 Nm (13 lb in).




8. Install the center floor air outlet duct.
9. Install the center floor air outlet duct screws and tighten to 1.5 Nm (13 lb in).
10. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement (Service and Repair).