Evaporator Core: Service and Repair

Evaporator Core Replacement

Tools Required

J39400-A Halogen Leak Detector

Removal Procedure

1. Remove the HVAC module from the vehicle.





2. Remove the heater core cover heat stakes with a small chisel.





3. Remove the heater core.




4. Unsnap and open the passenger compartment filter door.
5. Remove the lower HVAC case screws.




6. Remove the lower HVAC case.




7. Remove the evaporator core.

Installation Procedure

1. If replacing the evaporator core, add polyalkylene glycol (PAG) oil to the evaporator core. Refer to Refrigerant System Capacities.





2. Install new seal washers to the evaporator core fittings.
3. Install the thermal expansion valve (TXV).

Notice: Refer to Fastener Notice.

4. Install the TXV bolts.

Tighten the TXV bolts to 7 N.m (62 lb in).




5. Install the foam seals to the evaporator core.
6. Install the evaporator core into the HVAC module assembly.






Important: Make certain that the orifice plate is correctly positioned in the HVAC module. Make certain that the lower HVAC case is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all lower HVAC case screws.

7. Install the lower HVAC case.




8. Install the lower HVAC case screws.

Tighten the screws to 1.8 N.m (15 lb in).

9. Close and secure the passenger compartment filter door.




10. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
11. Install the heater core into the HVAC module.






Important: Make certain that the heater core cover is properly positioned and is fully seated on the HVAC module before installing the screws. Be sure to install all heater core cover screws.

12. Install the heater core cover.
13. Install the heater core cover screws.

Tighten the screws to 1.8 N.m (15 lb in).

14. Install the HVAC module into the vehicle.
15. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
16. Leak test the fittings using the J39400-A.
17. Connect the negative battery cable.
18. Fill the cooling system. Refer to Draining and Filling Cooling System (2.0L (LSJ)) Draining and Filling Cooling System (2.2L (L61), 2.4L (LE5)) Draining and Filling Cooling System (GE 47716 Fill).