Evaporator Core: Service and Repair

1. Obtain audio anti-theft code, if equipped, as outlined under Technician Safety Information.
2. Discharge and recover A/C refrigerant, then disconnect suction tube from cooling unit outlet fitting.

Fig. 11 A/C System Components.:

3. Disconnect liquid tube from cooling unit inlet fitting Fig. 1, then cap open fittings immediately to keep moisture from entering the system.
4. Remove grommets from inlet and outlet fittings.

5. Remove glove box and reinforcement, then disconnect electrical connectors.
6. Remove three nuts and four bolts that attach the cooling unit to the instrument panel and cowl.
7. With cooling unit removed from vehicle, disconnect connectors from upper case unit.

Fig. 12 Cooling Unit.:

8. Remove four clips and four screws that attach upper case to lower case, Fig. 2.
9. Remove thermistor and thermistor holder, then the lower case.
10. Remove packing and heat sensing tube from suction and liquid tubes.
11. Remove expansion valve from evaporator.

12. Reverse procedure to install, noting the following:
a. Torque bolt attaching expansion valve, suction and liquid lines tubes to evaporator core to 48 in. lb. Ensure O-rings are properly positioned on the tube fittings.
b. Torque nut attaching liquid tube to cooling unit inlet fitting to 10 ft. lb.
c. Torque nut attaching suction tube to cooling unit outlet fitting to 24 ft. lb.
d. Add 1.4-1.7 fl. oz. of compressor oil to compressor before recharging system.
e. Reset audio coded anti-theft, if equipped, as outlined under Technician Safety Information.