Evaporator Case: Service and Repair

Evaporator Case Assembly

Removal

NOTE: Evaporator case removal should only be required in unusual circumstances because all major components of the case assembly are serviceable without removing the case.






1. Disconnect the ground cable.
2. Discharge the refrigerant system following the recommended service procedures. Observe all safety precautions. Please refer to Heating and Air Conditioning/Service and Repair/ Service and Repair
3. Disconnect the electrical hardshell connectors from the blower motor, the blower motor resistor and the pressure switch.
4. Disconnect the vacuum line from the check valve.
5. Disconnect the vacuum line from the vacuum source on the engine intake manifold; then, remove the line from the routing channel.
6. Disconnect the liquid line from the evaporator core inlet tube and cap the openings to prevent the entry of dirt and moisture.
7. Disconnect the suction line from the accumulator/drier with a Spring Lock Coupling Tool and cap the openings to prevent the entry of dirt and moisture, please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ Service and Repair

NOTE: Please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ Service and Repair

8. Disconnect the heater hoses from the heater core tubes and plug the hoses with suitable 15.975mm (5/8 in.) plugs. Observe all safety precautions.
9. Remove the solenoid box cover, if so equipped, by removing the three bolts fastened through the fender liner. Remove the air cleaner and vacuum reservoir, if so equipped.
10. Remove three nuts from the engine compartment side of the evaporator assembly and one nut from the passenger compartment side of the assembly.
11. Remove the evaporator case assembly from the vehicle

Installation

1. Position the evaporator case assembly to the dash panel and install the two retaining nuts in the middle top and inboard top of the assembly.
2. In stall the two nuts along the bottom of the case assembly. (One nut is located on the engine compartment side of the case. The other is on the passenger compartment side.)
3. Install the emission solenoid box cover with the three retaining bolts. Install the air cleaner and vacuum reservoir.
4. Using a new 0-ring lubricated with clean refrigerant oil, connect the liquid line to the evaporator core inlet tube. Tighten the connector to 21-27 Nm (15-20 ft-lb) using a backup wrench.
5. Connect the suction line to the suction accumulator outlet tube after checking for a missing or damaged spring lock coupling garter spring and/or repairing or replacing the spring. Install two new specified (special material) 0-rings, lubricated with clean refrigerant oil onto the spring lock coupling male fitting.
6. Connect the heater hoses to the heater core. Tighten the clamps to 1.8-2.5 Nm (16-22 in-lb).
7. Connect the vacuum line to the check valve.
8. Connect the vacuum line (part of vacuum reservoir assembly) to the source on the engine intake manifold and route it as illustrated.
9. Connect the electrical hardshell connectors to the blower motor resistor, the pressure switch, and the blower motor.
10. Fill the cooling system following the recommended procedures.
11. Leak test, evacuate and charge the system following the recommended procedures. Observe all safety precautions. Please refer to Heating and Air Conditioning/Service and Repair/ Service and Repair
12. Connect battery ground cable.
13. Check the A/C-Heater system for proper operation.