Evaporator Core: Service and Repair

Fig. 14 Instrument Panel Assembly:

Fig. 17 Evaporator Case Assembly:

1. Remove instrument panel Fig. 14, as outlined in INSTRUMENT PANELS AND CLUSTERS/
INSTRUMENT CLUSTER.
2. Disconnect battery ground cable.
3. Discharge refrigerant from system, then remove carbon canister from vehicle.
4. Disconnect A/C lines from evaporator, then plug ends to prevent dirt and moisture from entering system, Fig. 17.
5. Fit spring lock coupling tools No. T81P-19623-G2 1/2 inch or tool No. T83P-19623-C 5/8 inch to coupling.
6. Close tool and push into open side of cage to expand garter spring and release female fitting. Garter spring may not release if tool is cocked while pushing into cage opening.
7. After garter spring is expanded, pull fitting apart and remove tool from coupling.
8. Disconnect electrical connectors from [1][2]A/C relays at top of evaporator core.
9. Remove air duct bands and drain hose.
10. Remove evaporator case attaching nuts, then the evaporator case from vehicle.
11. Carefully remove evaporator case from vehicle.
12. Remove foam seals at inlet and outlet of the cooling unit by peeling them away from evaporator case.
13. Remove seven retaining clips from housing, then separate case halves and remove evaporator.