Evaporator Case: Service and Repair

REMOVAL




1. Disconnect battery ground cable.
2. Discharge the refrigerant from the A/C system while observing all safety precautions. Discharging and Recovery
3. Remove heater blower motor switch resistor. Service and Repair
4. Disconnect the evaporator to compressor suction line from the suction accumulator/drier using Spring Lock Coupling Disconnect Tool and plug the openings to prevent dirt and excessive moisture from entering. Position the hose away from suction accumulator/drier assembly.

NOTE: Whenever the A/C evaporator core housing is replaced, it will be necessary to replace the suction accumulator/drier.

5. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube using Spring Lock Coupling Disconnect Tool and plug the openings. Position the condenser to evaporator tube away from the A/C evaporator core housing assembly.
6. Drain coolant from radiator. Save coolant for reuse.





7. Loosen the hose clamps and disconnect the heater water hoses from the heater core tubes.
8. Remove the two nuts retaining purge valve mounting bracket to the cowl top extension. Position purge valve and bracket away from A/C evaporator core housing.
9. Remove radiator coolant recovery reservoir. Position radiator coolant recovery reservoir forward, away from A/C evaporator core housing.





10. Disconnect A/C blower motor lead assembly from the main wiring harness and remove the hard-shell connector from the A/C blower motor speed control and the A/C cycling switch.
11. Disconnect the main wire harness (which crosses the A/C evaporator core housing) at the hard shell connecting point and position it away from the A/C evaporator core housing.
12. Remove instrument panel lower insulator from bottom of instrument panel on passenger side by disengaging four push pins and disconnecting power point electrical connector.
13. Fold carpeting back on the RH side of the floor. Remove the bottom LH screw that supports the A/C recirculating air duct.
14. Remove RH front wheel and tire.
15. Remove retaining bolts from rear of RH fender apron. Position apron down in rear to improve access to A/C evaporator core housing.
16. From the engine side of the dash panel, remove the three nuts (one upper and two lower) from the three evaporator assembly mounting studs. Also remove the two screws (one drill point and one sheet metal) from the top of the A/C evaporator core housing.
17. Pull the bottom of the A/C evaporator core housing assembly away from the dash panel to disengage the two bottom studs. Move the top of the A/C evaporator core housing assembly away from the dash panel, disengaging it from the top stud, and maneuver the case up and over the fender apron.

INSTALLATION
1. Position the A/C evaporator core housing assembly next to the dash panel by maneuvering it down past the tender apron.
2. Engage the two bottom dash panel studs into the A/C evaporator core housing assembly stud holes. Move the top of the A/C evaporator core housing assembly toward the dash panel while engaging the top dash panel stud into the A/C evaporator core housing assembly stud hole.
3. Install, but do not tighten, the three stud nuts.
4. Install the two screws (one drill point and one sheet metal) and tighten to 2.5-3.2 N.m (23-28 lb-in). Be careful to return the drill point screw to the correct hole located on top of the A/C evaporator core housing and to the right of the blower motor. Tighten the three stud nuts previously installed to 2.5-3.2 N.m (23-28 lb-in).
5. Position the wire harness connector across the A/C evaporator core housing assembly and attach the various connectors.
6. Install A/C blower motor speed control.
7. Connect wire harness connectors to the blower motor and A/C blower motor speed control.
8. Install RH fender apron.
9. Install tire and wheel assembly.
10. Install radiator coolant recovery reservoir to fender apron with two retaining nuts tightened to 5.5-7.0 N.m (49-61 lb-in).
11. Place the hose clamps onto the heater water hoses and carefully connect the hoses to the inlet and outlet heater core tubes. Refill coolant system.
12. Install purge valve mounting bracket to the cowl top extension with two retaining nuts.
13. Remove the plugs from the evaporator inlet tube and the condenser to evaporator tube and install new O-Ring seals dipped in clean refrigerant oil. Connect the condenser to evaporator tube to the evaporator inlet tube.

CAUTION: Make sure correct O-Ring seals are installed whenever an A/C fitting is serviced. Leaks and refrigerant loss may result.

14. Remove the plugs from the suction accumulator/drier outlet and the evaporator to compressor suction line and install new O-Ring seals dipped in clean refrigerant oil. Connect the evaporator to compressor suction line to the suction accumulator/drier.
15. From passenger side of dash panel, install retaining screw through A/C recirculating air duct into A/C evaporator core housing.
16. Connect power point electrical connector and install instrument panel lower insulator to bottom of instrument panel with four push pins.
17. Connect battery ground cable.
18. Leak-test, evacuate and charge the refrigeration system following the recommended procedures and safety precautions.
19. Check the A/C system for proper operation.