Evaporator Core: Service and Repair

Fig. 3 Service access gauge port valve location:

1. Disconnect both battery cables.
2. Discharge refrigerant from A/C system at service access gauge port valve, Fig. 3, observing all safety measures.
3. Remove engine valve cover as follows:
a. Loosen clamp on PCV hose at the oil separator on valve cover and disconnect hose.
b. Disconnect coolant hoses that passes over rear of valve cover.
c. Remove coolant pipes retaining clip screw from right front side of valve cover.
d. Disconnect air bypass valve electrical connector.
e. Disconnect throttle position sensor connector.
f. Disconnect automatic transmission kickdown cable from throttle linkage.
g. Disconnect accelerator cable from throttle linkage.
h. Loosen clamp and disconnect flexible intake tube from throttle body.
i. Remove two upper attaching screws and two lower attaching nuts and remove throttle body assembly and gasket.
j. Disconnect spark plug wires at spark plugs and at valve cover studs and fold them toward distributor.
k. Remove valve cover retaining screws and studs, then the valve cover and gasket.
4. Remove cowl insulator cover.
5. Pull water valve out of retaining clip and remove clip.
6. Remove battery shield attaching screws and the battery shield.
7. Disconnect vacuum hose from EGR valve, then disconnect EGR valve by removing bolt attaching valve to manifold and moving valve forward to provide clearance.
8. Remove two nuts retaining air conditioning hose plate and seal at partition between engine compartment and evaporator, then remove plate and seal.
9. Disconnect wiring harness from partition, pulling harness forward to disconnect the tabs connecting the harness to the partition.

Fig. 4 Disconnecting refrigerant lines at expansion valve:

10. Remove No. 30 torx bolt retaining refrigerant lines to expansion valve, Fig. 4.
11. Disconnect suction and liquid lines at expansion valve.
12. Remove weather seal from upper end of partition.

Fig. 5 Partition retaining bolt location:

13. Remove seven retaining screws attaching partition, Fig. 5. If screws are damaged during removal, replace with 10mm hex head screws and washers.
14. Remove left and right drainage valves, then the partition, by pulling partition up and out.
15. Disconnect deicer wire at connector, then the ground wire on the evaporator.
16. Remove evaporator to firewall attaching bolts.
17. Remove cowl grille panel, then disconnect windshield wiper to windshield wiper motor arm.
18. Slide evaporator case assembly upward and forward out of engine compartment, checking and replacing seal as necessary.
19. Reverse procedure to install.