Evaporator Core: Service and Repair

Front A/C Evaporator


Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury.


Review the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury.

• The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

Removing

- Remove the HVAC housing and place it on a workbench. Refer to => [ Front HVAC Housing ] Front HVAC Housing.

- Disassemble the HVAC housing as necessary to gain access to the A/C evaporator. Refer to => [ Front HVAC Housing ] Overhaul.

- Carefully lift the A/C evaporator (2) out of the lower half of the HVAC housing (3).

- If required, remove the evaporator insulator (2) from around the A/C evaporator.

Installing


Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Refer to => [ A/C Compressor Refrigerant Oil Charge ] A/C Compressor Refrigerant Oil Charge. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

• When replacing multiple A/C system components, refer to the refrigerant oil capacities chart to determine how much oil should be added to the refrigerant system. Refer to => [ A/C Compressor Refrigerant Oil Charge ] A/C Compressor Refrigerant Oil Charge.

• If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

• Replacement of the seals is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber and metal dual-plane seals may result in a refrigerant system leak.








- Install the A/C evaporator (2) into the lower half of the HVAC housing (3). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator (2) is properly installed.

- Assemble the HVAC housing. Refer to => [ Front HVAC Housing ] Overhaul.

- Install the HVAC housing. Refer to => [ Front HVAC Housing ] Front HVAC Housing.

- If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the refrigerant oil capacities chart to determine how much oil should be added to the refrigerant system. Refer to => [ A/C Compressor Refrigerant Oil Charge ] A/C Compressor Refrigerant Oil Charge. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.