Evaporator Core: Service and Repair

Fig. 4 A/C System Components:

Fig. 5 Exploded View Of Cooling Unit:

1. Disconnect battery ground cable and recover refrigerant from system.
2. Disconnect refrigerant lines at cooling unit, Fig. 4, and cap openings.
3. Remove grommets from inlet and outlet fittings.
4. Remove glove compartment, lower instrument panel cover and the side air duct.
5. Disconnect electrical connectors.
6. Remove two nuts and four screws securing cooling unit, then remove cooling unit.
7. Remove A/C wiring harness from cooling unit.
8. Remove three clips and four screws securing lower case, then remove lower case, Fig. 5.
9. Remove screws and separate upper case from evaporator.
10. Remove heat insulator and the clamp from the outlet tube.
11. Disconnect liquid line tube from inlet fitting of expansion valve.
12. Disconnect expansion valve from inlet fitting of evaporator.
13. Reverse procedure to install, then evacuate and charge system and check for leaks. If evaporator is replaced, add 1.4 to 1.7 oz. of new refrigerant oil to compressor.