Evaporator Core: Service and Repair

Fig. 17 Evaporator assembly:

1. Disconnect battery ground cable.
2. Discharge refrigerant from system.
3. Disconnect suction hose from accumulator/dryer and cap both openings. Position hose away from evaporator assembly, Fig. 17.
4. Disconnect liquid line from evaporator inlet tube and cap both openings. Position liquid line away from assembly.
5. Disconnect two electrical connectors from pressure control de-ice switch on accumulator/dryer.
6. Drain coolant from radiator, then disconnect heater hose from inlet and outlet heater core tubes.
7. On models equipped with Automatic Temperature Control System, turn steering wheel to the left far enough to gain access to right wheelwell splash panel support.
8. On models equipped with Automatic Temperature Control System, remove screw and splash panel support bracket from back portion of wheelwell. This will allow splash panel to be depressed slightly for extra clearance when removing evaporator.
9. On all models, remove six screws holding right side of hood seal bracket assembly. Remove copper hood ground clip from underhood seal and move bracket assembly to right side of vehicle.
10. Disconnect emission hose which passes over top of evaporator case assembly, and position aside. Also, position aside any other vacuum hoses or movable wires that pass over top of evaporator case.
11. Disconnect blower motor ground from body frame.
12. Disconnect blower motor wiring connector from harness hard shell connector.
13. Disconnect two large wire harnesses, which cross evaporator assembly, at the various connecting points and position harnesses aside.
14. Fold back carpeting from passenger side of dash panel. On right side of floor remove bottom left screw of the two supporting inlet recirculation air duct assembly.
15. On models equipped with Automatic Temperature Control System, disconnect ambient sensor air tube from evaporator sensor air tube port.
16. On all models, from engine side of dash panel, remove three nuts from three evaporator assembly mounting studs. Also remove two screws from blower motor and wheel portion of case assembly.
17. Pull bottom of evaporator case assembly away from dash panel to disengage evaporator ambient sensor air tube port, if equipped, and two bottom studs. Move top of evaporator assembly away from dash panel, disengaging it from top stud, and work case up over wheelwell splash panel.
18. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
19. Leak test, evacuate and charge system. Check system for proper operation.