Evaporator Core: Service and Repair

Air Conditioning Evaporator Core Replacement

Special Tools

J 39400-A - Halogen Leak Detector

Removal Procedure




1. Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation Service and Repair.

2. Remove and discard the HVAC module assembly foam seal.




3. Remove the thermal expansion valve (TXV) mounting bolts.

4. Remove the TXV from the evaporator core.

5. Remove and discard the sealing washers.




6. Disconnect the discharge temperature management (DTM) sensor electrical connectors.

7. Disconnect the HVAC module wiring harness retainer pin (2) from the HVAC module.

8. Disconnect the wiring harness from the heater core cover wire harness retainer (1) and reposition the wiring harness aside.

9. Disconnect the wiring harness from the heater core cover wire harness retainer (3) and reposition the wiring harness aside.




10. Remove the heater cover screws.

11. Remove the heater cover from the HVAC module.




12. Remove the heater core from the HVAC module.




13. Remove the HVAC module case retaining screws.




14. Separate the HVAC module upper case from the HVAC module lower case.




15. Remove the evaporator core from the HVAC module.

Installation Procedure

1. If replacing the evaporator core, add the specified amount of polyalkylene glycol (PAG) oil directly to the evaporator core.

Note: Line the evaporator core side seal up with the corners of the evaporator core.




2. Install a new side seal to the evaporator core.




3. Install a new upper seal to the evaporator core.





Note: Locate the seals at the outer corners of the evaporator core.

4. Install two new lower seals to the evaporator core.




5. Install the evaporator core to the HVAC module.




6. Install the HVAC module upper case to the HVAC module lower case.





Caution: Refer to Fastener Caution Fastener Caution.

7. Install the HVAC module case retaining screws.

Tighten the screws to 1.6 Nm (14 lb in).




8. Install a new foam seal to the heater core.




9. Install the heater core to the HVAC module.

10. Install the heater cover to the HVAC module.




11. Install the heater cover screws.

Tighten the screws to 1.6 Nm (14 lb in).




12. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (1).

13. Reposition the HVAC wiring harness and connect the wiring harness to the heater core cover wiring harness retainer (3).

14. Connect the HVAC module wiring harness retainer pin (2) to the HVAC module.

15. Connect the discharge temperature management (DTM) sensor electrical connectors.




16. Install new sealing washers to the evaporator core. Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.

17. Install the TXV to the evaporator core.

18. Install the TXV to mounting bolts.

Tighten the bolts to 7 Nm (62 lb in).

19. Install the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation Service and Repair.