Evaporator Core: Service and Repair

Fig. 13 Standard evaporator core removal:

Standard Evaporator
1. Partially drain engine coolant and disconnect heater hoses from heater core.
2. Remove battery from vehicle. Discharge refrigerant from system.
3. Disconnect electrical connectors from blower resistor and pressure switch, Fig. 13.
4. Disconnect EEC-IV Harness.
5. Disconnect suction line from accumulator/drier, liquid line from evaporator core and the discharge line. Plug all open connections to prevent entry of dirt and moisture into system.
6. Remove drain tube from bottom of evaporator case assembly.
7. Remove five nuts retaining evaporator assembly to dash and remove evaporator assembly.
8. Remove screws retaining accumulator to case and remove accumulator.
9. Remove evaporator core and seal assembly by pulling back retaining tab in housing.
10. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
11. Evacuate, charge and leak test system. Check for proper operation.

Fig. 15 Auxiliary evaporator core removal:

Auxiliary Evaporator
1. Remove first bench seat, if equipped.
2. Remove cover assembly, Fig. 15.
3. Discharge refrigerant from system.
4. Disconnect refrigerant lines from evaporator core. Plug all open connections to prevent entry of dirt and moisture into system.
5. On models equipped with an auxiliary heater, disconnect and plug heater hoses from auxiliary heater core.
6. On all models, remove four screws securing evaporator core and mounting bracket to auxiliary case assembly.
7. Remove evaporator core, expansion valve and core mounting plate from case.
8. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
9. Evacuate, charge and leak test system. Check for proper operation.