AC Evaporator

Replace the AC evaporator core located inside the HVAC housing under the dashboard, requiring extensive dash disassembly and AC system recovery.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• Expansion valve (if integrated) × 1 — Use OEM specification
• AC line O-rings kit × 1 — Use OEM specification
• HVAC case foam seal × 1 — Use OEM specification
• Receiver/drier or accumulator × 1 — Replace when system is opened
• PAG oil for compressor × 1 — ND-8 or ND-12 PAG
• R-134a refrigerant × 1 — 2-3 lbs typical capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
3. Use certified AC recovery machine to fully recover refrigerant from system
4. Remove engine cover if present to access AC line connections at firewall
5. Place protective covers over seats and floor to prevent damage during extensive interior work
6. Have a camera or smartphone ready to photograph electrical connector locations before disconnection

Procedure

1. 1

   Disconnect AC lines at firewall
   Locate AC lines entering firewall from engine bay. Use two wrenches to disconnect liquid line and suction line fittings at expansion valve or evaporator. Cap all open fittings immediately to prevent moisture and debris entry. Remove and discard old O-rings.
   ⚠Verify system is fully recovered before loosening fittings. Small amounts of residual refrigerant may remain.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
2. 2

   Remove instrument panel components
   Remove instrument cluster bezel by releasing clips. Remove instrument cluster screws and disconnect electrical connectors. Remove radio and climate control head unit. Remove glove box by releasing stops and removing hinge screws. Remove lower dash panels on both driver and passenger sides. Remove center console if equipped. Document all electrical connections with photos.
   ℹ️Keep all fasteners organized by location. Use small labeled containers or bags for each section.
3. 3

   Remove steering column and supports
   Remove steering column shroud screws. Disconnect all electrical connectors from steering column switches. Remove steering column mounting nuts/bolts and carefully lower column, supporting its weight. Remove instrument panel support braces and mounting bolts along driver side. On some models, the brake pedal assembly may need partial disassembly for clearance. Steering column is heavy and, on airbag-equipped models, contains supplemental restraint components. Handle carefully and support properly when lowering.
   ⚠Steering column is heavy and contains airbag components. Handle carefully and support properly when lowering.
4. 4

   Disconnect HVAC electrical and vacuum connections
   Locate and disconnect blower motor electrical connector. Disconnect blend door actuator connectors and mode door actuator connectors (typically 2-3 actuators). Disconnect vacuum harness from engine side of firewall if equipped with vacuum-operated controls. Disconnect any remaining wiring from HVAC housing.
5. 5

   Remove instrument panel main beam
   Disconnect all remaining electrical connections to instrument panel. Remove instrument panel mounting bolts at each end (typically at A-pillars) and center support bolts. With assistance, carefully pull instrument panel back and away from firewall. This may require 2-3 people due to size and weight. Set panel aside in safe location.
   ⚠Instrument panel is large and awkward. Use at least two people to prevent damage and injury.
6. 6

   Remove blower motor assembly
   Locate blower motor housing on passenger side of HVAC unit. Remove blower motor mounting screws and carefully extract blower motor and fan assembly from housing. This provides access and working room for evaporator housing removal.
7. 7

   Remove HVAC housing mounting
   Remove HVAC housing mounting bracket bolts securing unit to firewall and support structures. Remove any remaining duct clips connecting housing to defroster or floor ducts. Support HVAC housing weight as you remove final fasteners.
   ℹ️HVAC housing is bulky. May need to rotate and maneuver carefully to extract from vehicle.
   Torque spec

   Mounting Bracket Bolts24 Nm (18 lb-ft)

   Duct Clips3 Nm (2 lb-ft)
8. 8

   Separate and open evaporator housing
   Place HVAC housing on clean workbench. Remove evaporator case screws around perimeter of housing. Carefully separate upper and lower housing halves. Note position of foam seals and any blend door linkages before removal.
   ℹ️Take photos of actuator arm positions and linkage connections for accurate reassembly.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
9. 9

   Remove old evaporator and expansion valve
   Lift out old evaporator core from housing. If expansion valve is separate, disconnect it from evaporator using proper wrench on fittings. Inspect housing for debris, leaves, or rodent damage. Clean housing thoroughly with shop vacuum and damp cloth. Check and clean condensate drain tube.
   ⚠Old evaporator may contain residual oil and refrigerant. Handle over drain pan.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
10. 10

    Install new evaporator and expansion valve
    Install new expansion valve to new evaporator using new O-rings lubricated with PAG oil. Torque expansion valve fitting properly. Add manufacturer-specified amount of PAG oil to evaporator (typically 2-3 oz to replace oil lost with old evaporator). Use only PAG oil compatible with R-134a system. Check the compressor label or Chrysler service documentation for the correct PAG viscosity specified for this vehicle's compressor. Install new foam seals on housing mating surfaces. Carefully place new evaporator into lower housing, ensuring proper alignment with case features and tube exit location.
    ℹ️Use only PAG oil compatible with R-134a system. Check compressor label for correct PAG viscosity (ND-8 or ND-12).
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
11. 11

    Reassemble evaporator housing
    Verify all foam seals are properly positioned. Join upper and lower housing halves, ensuring no pinched seals or misaligned doors. Install and torque all evaporator case screws and cover screws in a cross-pattern to ensure even sealing. Verify blend doors and mode doors move freely through full range of motion.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)
12. 12

    Reinstall HVAC housing into vehicle
    With assistance, carefully maneuver HVAC housing back into position against firewall. Align mounting brackets and start mounting bracket bolts. Torque mounting bracket bolts to specification. Reconnect duct clips to defroster and floor ducts.
    Torque spec

    Mounting Bracket Bolts24 Nm (18 lb-ft)

    Duct Clips3 Nm (2 lb-ft)
13. 13

    Reinstall blower motor and reconnect electrical
    Install blower motor assembly into housing and secure with mounting screws torqued to specification. Reconnect all HVAC electrical connectors including blower motor, actuators, and any sensors. Reconnect vacuum harness if equipped.
14. 14

    Reinstall instrument panel assembly
    With assistance, position instrument panel back onto vehicle. Install and torque all mounting bolts at A-pillars and center supports. Reconnect all electrical connections to instrument panel components. Reinstall steering column, torquing mounting fasteners properly. Reinstall all trim panels, console, radio, climate controls, instrument cluster, and glove box in reverse order of removal.
15. 15

    Connect AC lines and install new receiver/drier
    Install new receiver/drier or accumulator in system. Install new O-rings on all AC line fittings, lubricating with PAG oil. Connect liquid line and suction line to evaporator at firewall. Use backup wrench and torque wrench to tighten AC line fittings to specification without over-tightening.
    ⚠Over-torquing AC fittings can damage O-rings and cause leaks. Use torque wrench for all critical AC connections.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
16. 16

    Evacuate and recharge AC system
    Reconnect battery. Connect AC manifold gauges to service ports. Use vacuum pump to evacuate system to minimum 29 inches Hg vacuum for at least 45 minutes. Monitor for vacuum loss indicating leaks. If vacuum holds, close valves and monitor for 10 minutes. If vacuum is maintained, recharge system with the exact amount of R-134a refrigerant specified on the underhood label for this vehicle.
    ⚠Never overcharge AC system. Use refrigerant scale and follow exact specifications on underhood label.

Reassembly

1. Verify all instrument panel components are properly secured and no rattles are present
2. Verify all electrical connectors are fully seated and locked
3. Ensure steering column is properly secured and functions correctly
4. Check that all dashboard trim pieces are flush and properly clipped

Verification

• Start engine and turn AC to maximum cold with fan on high
• Verify cold air is blowing from all vents within 2-3 minutes
• Check AC pressures with gauges: low side should be 25-35 PSI, high side 200-250 PSI at 75°F ambient
• Verify no refrigerant leaks at evaporator connections using leak detector or soap solution
• Test all blend door functions (hot/cold) and mode door functions (defrost, vent, floor)
• Check for proper condensate drainage under vehicle after 10 minutes of operation
• Verify blower motor operates at all speed settings
• Inspect interior for any loose panels or missed fasteners
• Test drive vehicle and verify AC performance under load

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