Evaporator Case: Service and Repair

REMOVAL

NOTE:
- The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly.
- If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle.
- Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

1. Recover the refrigerant.
2. Remove the suction accumulator.
3. Remove the A/C compressor.
4. Remove the engine oil indicator and tube.







5. Disconnect the blower motor and blower motor resistor electrical connectors.







6. Disconnect the heater hoses.
1 Using suitable tools, clamp-off the heater hoses.
2 Release the clamps and disconnect the heater hoses.







7. Detach the pin-type retainer and position aside the windshield washer hose.
8. Disconnect and detach the heater control valve vacuum hose.







9. Disconnect the vacuum supply hose near the evaporator core housing.

NOTE: 2.3L engine shown, others are similar.







10. Disconnect the condenser to evaporator line spring lock coupling from the evaporator core inlet.
- Discard the O-ring seals.







11. Disconnect the vacuum hose connector and remove the nut.

NOTE: This step is performed at the lower passenger side dash panel, inside the passenger compartment.







12. Remove the nuts and the evaporator core housing.

INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent.
- Install new O-ring seals lubricated in clean PAG oil or equivalent.
- Lubricate the coolant hoses with coolant hose lubricant or plain water only, if needed.

2. Evacuate, leak test, and charge the refrigerant system.