Evaporator Case: Service and Repair

NOTE: Whenever an evaporator case is removed, it will be necessary to replace the suction accumulator/drier.

Removal
1. Disconnect battery ground cable.
2. Drain the coolant from the radiator into a clean container.
3. Discharge the refrigerant from the Air Conditioning (A/C) system. Observe all safety precautions.
4. Disconnect the heater hoses from the heater core. Plug the heater core tubes or blow any coolant from the heater core with low pressure air.
5. Disconnect the liquid line and the accumulator/drier inlet tube from the evaporator core at the dash panel. Cap the refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
6. Remove the instrument panel and lay it on the front seat.
7. Disconnect the wire harness connector from the blower motor resistor.





8. Remove one screw attaching the bottom of the evaporator case to the dash panel (see illustration).
9. Remove the instrument panel brace from the cowl top panel.
10. Remove two nuts attaching the evaporator case to the dash panel in the engine compartment (see illustration).
11. Loosen the sound insulation from the cowl top panel in the area around the air inlet opening.
12. Remove the two screws attaching the support bracket and the brace to the cowl top panel (see illustration).

Installation
1. Position the evaporator case assembly to the dash panel and the cowl top panel at the air inlet opening. Install the two screws to attach the support bracket and brace to the cowl top panel (see illustration).
2. Install the two nuts in the engine compartment to attach the evaporator case to the dash panel. Inspect the evaporator drain tube for a good seal and that the drain tube is through the opening and not obstructed.
3. Position the sound insulation around the air inlet duct on the cowl top panel.
4. Install the instrument panel.
5. Install one screw to attach the bottom of the evaporator assembly to the dash panel (see illustration).
6. Connect the heater hoses to the heater core.
7. Using new 0-rings lubricated with clean refrigerant oil connect the liquid line and the suction accumulator inlet tube to the evaporator core. Tighten each connection to specification using a backup wrench to prevent component damage.
8. Fill the radiator to the correct level with the removed coolant or the specified mixture of coolant and water.
9. Connect battery ground cable.
10. Leak test, evacuate and charge the A/C refrigerant system.
11. Check the system for proper operation.