Evaporator Core: Service and Repair

NOTE: If an A/C evaporator core leak is suspected, the A/C evaporator core should be leak tested before it is removed from the vehicle.

REMOVAL
1. Remove A/C evaporator housing. Evaporator Case
2. Remove foam seals from evaporator core tubes.
3. Remove two retaining screws and metal cover from A/C evaporator housing.







4. Remove three remaining screws and A/C electronic blend door actuator from A/C evaporator housing.







5. Disengage spring from heater core cover and remove spring from lever.







6. Gently depress locking ramp and remove lever from secondary A/C air temperature control door end.

NOTE: Do not attempt to bend any part of the lever. It is brittle and will break.

7. Rotate primary A/C air temperature control door shaft down; then swing metal link and remove from pin.
8. Remove retaining screws from around flange joint of A/C evaporator housing.
9. With side cutters (or equivalent), cut all snap loops around flange joint of A/C evaporator housing.
10. Remove upper evaporator case housing from lower evaporator case housing.







11. Remove A/C evaporator core from lower evaporator case housing.

INSTALLATION
1. Transfer two foam seals to new A/C evaporator core.
2. Position A/C evaporator core in lower evaporator case housing.
3. Install upper evaporator case housing to lower evaporator case housing, making sure heater air damper door lower post is positioned in pivot hole in lower evaporator case housing.
4. Install retaining screws around flange joint of A/C evaporator housing.
5. Install metal link over pin on primary A/C air temperature control door shaft.
6. Install secondary A/C air temperature control door lever on metal link.
7. Install secondary A/C air temperature control door lever to secondary A/C air temperature control door end.
8. Engage spring to heater core cover and secondary A/C air temperature control door lever.
9. Install A/C electronic blend door actuator to A/C evaporator housing with three retaining screws.
10. Install metal cover to A/C evaporator housing with two retaining screws.
11. Install foam seals over evaporator tubes.
12. Install A/C evaporator housing assembly.