Chevrolet Full Size Cars 1979-1989

Evaporator Core

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REMOVAL & INSTALLATION




CAUTION
Please refer to before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Properly discharge and recover the refrigerant in the A/C system using a suitable recovery station.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If applicable, remove the diagnostic connector plug-to-heater case screws.
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  7. Tag and disengage the connectors from the blower motor, resistor, blower relay and the thermostatic switch, as applicable. Remove the air conditioner wiring harness from the blower case shroud.
  8.  
  9. If necessary, remove the accumulator bracket screws.
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  11. Remove the module rubber seal, then loosen the leaf screen assembly screws and remove the screen from the top of the module.
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  13. Loosen the retainers and remove the module's top cover. Be careful, on most models there are hard to find screws such as those located inside the air intake near the case separation points. The cover is sealed to the module and this seal must be broken before the cover can be removed. Be absolutely sure that all cover fasteners are removed before attempting to break the seal or cover damage will result. Take your time and be careful not to force and crack or otherwise damage the cover.
  14.  
  15. Disconnect the refrigerant lines and immediately cover or plug all openings to prevent system contamination.
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  17. Remove the evaporator core.
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To install:

  1. Thoroughly clean the mating surfaces of the cover and the module of all old sealer.
  2.  

When connecting the refrigerant lines, use new O-rings dipped in clean refrigerant oil.

  1. Install the evaporator core, then remove the caps and connect the refrigerant lines.
  2.  
  3. Apply a coating of sealant to the cover, then install the cover and tighten the fasteners.
  4.  
  5. If applicable, install the accumulator bracket screws.
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  7. Install the module screen and rubber seal.
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  9. Engage and secure the electrical connectors and components to the module cover, as noted during removal.
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  11. Connect the negative battery cable.
  12.  
  13. After checking that all the refrigerant lines are properly tightened, evacuate, leak test and charge the system.
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