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Removal & Installation

  1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove air cleaner and air distribution duct from engine.
  2. Drain engine coolant. Disconnect heater hoses at engine compartment firewall. Cap heater core tube openings. Disconnect refrigerant lines from expansion valve. remove expansion valve. See Figure. Cap expansion valve and refrigerant line openings.
  3. Remove HVAC control panel. See HVAC CONTROL PANEL . Remove radio. Remove upper instrument panel bezel. Remove right and left instrument panel end caps. Disconnect lower left knee bolster.
  4. Disconnect mode door motor wiring. Remove right and left door post kick panels. Remove lower right side silencer/duct. Remove glove box. Remove right and left side vertical support struts.
  5. Remove lower center distribution housing. Remove bolts attaching heater/evaporator housing to instrument panel frame. Remove upper instrument panel cowl trim cover. Detach steering column from instrument panel, and lower steering column.
  6. Remove instrument panel bolts at cowl fence. Remove instrument panel bolts at lower "A" pillars. Remove instrument panel frame and wiring. Remove bolts attaching heater/evaporator housing to cowl. Remove heater/evaporator housing from vehicle.
  7. Remove recirculated air door inlet cover. Remove evaporator temperature probe. Remove clips, and separate heater housing from evaporator housing. Remove seal around evaporator tube inlet. Remove evaporator housing upper cover. Carefully remove evaporator core from housing.
  8. To install, reverse removal procedure. Transfer evaporator sensor to replacement evaporator core. If installing a new evaporator, add 2 ounces of refrigerant oil to system. Tighten intake manifold plenum bolts to 13 ft. lbs. (18 N.m).
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