REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6, 7 and 8
The evaporator core can be removed only after the entire heater/air conditioning unit is removed from the vehicle.
- Take the vehicle to a certified A/C shop to have the system discharged properly.
- Disconnect negative battery cable. Disarm the air bag system.
- Remove the air cleaner hose and the air distribution duct from the engine.
- Drain the cooling system.
- Disconnect the heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to prevent antifreeze from leaking inside of the vehicle.
- Remove both air conditioning lines from the expansion valve using tool 7193 or equivalent, to disengage the quick-connectors. After removing the lines, cap the expansion valve openings to prevent system contamination.
The lubricant used in this air conditioning system absorbs moisture readily. Do not leave any portion of the system open to the atmosphere for any extended period of time.
- Remove the instrument panel. Refer to Body & Trim .
- Remove the three attaching bolts which hold the heater housing to the dash panel. Carefully roll the heater housing out of the vehicle.
- Remove the drain tube from the heater housing.
- Remove the recirculation door actuator.
- Remove the recirculation door and housing.
- Remove the upper housing retaining screws.
- Remove the upper half of the heater housing.
- Lift the evaporator out of the lower housing.
- Transfer the expansion valve to the NEW evaporator. Always use a NEW gasket when transferring the expansion valve. Also transfer the evaporator sensor. Place the sensor in the same location as the old evaporator.
- Place the evaporator into the housing and install the upper half of the housing, securing with the mounting screws.
- Install the recirculation door, housing and door actuator.
- Install the housing into the vehicle and secure using the three attaching bolts.
- Install the drain tube from underneath of the vehicle.
- Install the instrument panel. Refer to Body & Trim .
- Install both air conditioning lines to the expansion valve using new O-rings at the connections.
The O-rings used in this system are made of a special type of rubber that is not affected by R-134a refrigerant. Do not substitute an O-ring not manufactured for R-134a refrigerant type system or leakage will occur within a short period of time.
- Connect the heater hoses at the dash panel and refill the cooling system.
- Install the air cleaner hose and the air distribution duct to the engine.
- Connect the negative battery cable.
- Properly charge the refrigerant system.
- Refill and bleed the cooling system.