Heater-Evaporator Unit Replacement

Evaporator case removal

1. Recover the refrigerant with a Recovery/Recycling/Charging System.
2. Remove the dashboard lower cover, the knee bolster and the glove box. Refer to Body and Frame - Interior Trim - Dash Board - Service and Repair - Procedures

3. Remove the ECM. Refer to Powertrain Management - Computers and Control Systems - Engine Control Module - Locations - Components Component Locations

4. Remove the ABS control unit and the radiator fan control module together with the bracket, then remove the TCM. Remove the security control unit. Refer to Brakes and Traction Control : Relays and Modules - Brakes and Traction Control : Electronic Brake Control Module : Service and Repair : Procedures Service and Repair






5. Disconnect the connectors from the power transistor, blower motor high relay, evaporator temperature sensor, blower motor and the heater sub-harness, then remove the blower motor and heater subharness connectors from the brackets. Disconnect the passenger's airbag harness clip.






6. Remove the wire harness clips, the three self-tap- ping screws and the pipe cover.






7. Remove the expansion valve covers, then disconnect the suction line and unbolt the expansion valve from the evaporator.

NOTE: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.






8. Disconnect the drain hose, and remove the seven self-tapping screws. Then pull the evaporator out of the front passengers side to remove it.

NOTE: Be careful not to damage the evaporator fins when removing the evaporator.

9. Install in the reverse order of removal. Make note of the following items.
If you're installing a new evaporator, add refrigerant oil (ND-OIL 8).
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil (ND-OIL 8) before installing them.

NOTE: Be sure to use the right O-rings for HFC134a (R-134a) to avoid leakage.

Be careful not to damage the evaporator fins when installing the evaporator.
Install the expansion valve capillary tube with the capillary tube in contact with the suction line directly, and wrap it with tape.

NOTE: Make sure there is no foreign matter stuck between the capillary tube and the suction line.

Make sure that there is no air leakage.
Charge the system, and test its performance.