Evaporator Core: Service and Repair

REMOVAL

Heater/Evaporator Housing:

1. Disconnect battery cables and remove battery.
2. Discharge refrigerant system.
3. Remove center vent/control panel.
4. Remove instrument panel, refer to Service and Repair

Heater/Evaporator Housing Coolant Hoses:

5. Clamp heater hoses A and B to prevent excess engine coolant loss.
- A = return to water pump.
- B = feed to cylinder head.
6. Loosen clamps and remove hoses from fittings.
7. Cap hoses.






8. Remove A/C refrigerant lines from evaporator.
16 Nm (11.8 ft lb)

Note: Be sure there is no tension on refrigerant lines during installation.

Air Plenum Cover:

9. Remove right side air plenum cover
10. Remove outside temperature sensor B.
11. Remove mounting bolts A.
12. Remove air intake.

Note: Be sure gasket around air intake seals correctly during installation

Heater/Evaporator Connections:

13. Remove nuts A on firewall.

Note: Be sure rubber grommet -B- seals properly during installation.

Fuel Injection Control Unit:

14. Remove vacuum hose from two way valve.
15. Remove water drain hose from heater/evaporator housing.
16. Remove fuel injection control unit (see arrow).
17. Remove heater/evaporator housing.

Note: Check Bowden cables for kinks and ease of movement before reinstalling heater/evaporator housing. Replace cables if necessary.

Heater/Evaporator Assembly:

18. Remove heater plenum chamber retaining clips.
19. Carefully pry the heater plenum chamber from the evaporator housing.






20. Unlatch air intake duct clips, remove air duct.
21. Remove evaporator housing case half retaining clips.
22. Carefully pry the evaporator case halves apart.
23. Remove evaporator.

INSTALLATION
- Installation is the reverse of removal.
NOTE:
- Be sure evaporator case halves seal properly during installation. Use silicone sealer during assembly.
- Intake ring is keyed in lower evaporator case to prevent turning.