Complete replacement of the AC evaporator core, requiring dashboard removal and refrigerant system evacuation and recharge.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• AC expansion valve × 1 — Use OEM specification
• AC O-ring kit × 1 — Use OEM refrigerant system O-rings
• PAG 46 oil × 1 — Use OEM PAG oil for R-134a systems
• R-134a refrigerant × 1 — Approximately 1.75 lbs
• Dashboard mounting clips × 5 — Have extras on hand

Preparation

1. Park vehicle on level surface and set parking brake
2. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge
3. Recover AC refrigerant using certified recovery equipment and measure oil removed
4. Remove both front seats completely to access dash mounting bolts
5. Remove steering wheel (mark position before removal)
6. Remove instrument cluster and trim panels
7. Disconnect all electrical connectors from dashboard components, labeling each connection

Procedure

1. 1

   Remove dashboard upper trim and components
   Remove A-pillar trim panels on both sides. Remove upper dashboard trim panel by releasing clips starting from passenger side. Remove defroster grilles. Disconnect ambient temperature sensor and any electrical connectors from upper dash area.
2. 2

   Disconnect AC lines at firewall
   Locate AC liquid and suction lines at firewall on passenger side. Use flare nut wrench to disconnect both lines from evaporator connections. Immediately cap all openings to prevent moisture and debris entry. Note orientation of lines for reinstallation.
   ⚠Small amount of residual refrigerant may escape. Wear safety glasses and gloves.
3. 3

   Lower steering column
   Remove lower steering column covers. Locate and remove four steering column mounting bolts. Carefully lower column and support with a padded surface or mechanics wire. Do not let column hang unsupported as this can damage clockspring or steering shaft.
4. 4

   Remove center console and floor components
   Remove center console entirely including all trim, cupholders, and storage compartments. Remove transmission shifter bezel and boot. Disconnect all electrical connections including USB ports, power outlets, and shift position sensor. Remove floor duct work from both driver and passenger sides.
5. 5

   Disconnect remaining dashboard connections
   Disconnect all remaining electrical connectors including HVAC controls, radio antenna, navigation/radio harness, and HVAC blend door actuators. Disconnect vacuum lines if equipped. Remove ground straps from dashboard mounting points. Take photos of every connection.
6. 6

   Remove dashboard mounting bolts and extract dashboard
   Locate all dashboard mounting bolts (typically 8-10 total) including those at A-pillars, center tunnel, and below windshield. Remove all mounting bolts. With assistance, carefully slide dashboard rearward and upward to disengage locating pins. Lift dashboard assembly out of vehicle. This is a two-person operation.
   ⚠Dashboard is bulky and heavy. Use two people to prevent damage to dash or windshield.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Remove HVAC case upper housing
   With dashboard removed, HVAC case is now accessible. Remove screws securing upper HVAC case half to lower half. Carefully separate upper case half to expose evaporator core. Note position of any foam seals or insulation.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
8. 8

   Remove expansion valve
   Locate expansion valve (thermostatic expansion valve) attached to evaporator inlet. Remove mounting bolt securing expansion valve. Carefully separate valve from evaporator, noting orientation of valve and capillary tube position. Discard old O-rings.
   ℹ️Do not bend or kink the capillary tube sensing bulb as this will require valve replacement.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
9. 9

   Remove evaporator core
   Remove screws securing evaporator core to HVAC case. Carefully lift evaporator core out of case, noting orientation and position. Drain any residual oil from old evaporator into graduated container to measure quantity. Inspect case for debris, leaves, or moisture damage.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
10. 10

    Prepare and install new evaporator
    Add measured quantity of PAG 46 oil (plus any lost during recovery) to new evaporator core. Install new evaporator into HVAC case in same orientation as original. Secure with evaporator case screws. Ensure all foam seals are properly positioned around evaporator.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)
11. 11

    Install expansion valve with new O-rings
    Lubricate new O-rings with PAG oil and install on expansion valve connections. Position expansion valve onto evaporator inlet with capillary bulb in correct location against evaporator outlet. Install and torque mounting bolt. Ensure capillary tube is not kinked or damaged.
    ⚠Use only refrigerant-compatible PAG oil on O-rings. Do not use petroleum-based lubricants.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
12. 12

    Reassemble HVAC case
    Align upper HVAC case half with lower half, ensuring all blend door actuator linkages are properly engaged. Install all case screws and torque to specification. Verify all doors move freely by manually operating actuator connections before proceeding.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
13. 13

    Reinstall dashboard assembly
    With assistance, carefully position dashboard assembly into vehicle, aligning all locating pins. Install all mounting bolts finger-tight first, then torque to specification working from center outward. Reconnect all electrical connectors, ground straps, and vacuum lines using photos as reference.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
14. 14

    Reconnect AC lines at firewall
    Install new O-rings on AC line fittings, lubricating with PAG oil. Connect liquid and suction lines to evaporator fittings at firewall. Torque fittings to specification using flare nut wrench. Ensure lines are not kinked and have proper clearance.
    Torque spec

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

    Evacuate and recharge AC system
    Connect AC service equipment to service ports. Pull vacuum on system for minimum 45 minutes. System should hold vacuum without loss for 30 minutes. If vacuum holds, recharge system with specified amount of R-134a refrigerant (approximately 1.75 lbs). Add UV dye if desired for future leak detection.
    ⚠️If system will not hold vacuum, there is a leak. Do not charge system until leak is located and repaired.

Reassembly

1. Reinstall steering column and torque mounting bolts to specification
2. Reinstall instrument cluster and all dashboard trim panels
3. Reinstall center console, shifter components, and floor duct work
4. Reinstall steering wheel, aligning marks made during disassembly
5. Reinstall both front seats and torque mounting bolts
6. Reconnect battery negative terminal
7. Perform steering angle sensor calibration if equipped with electronic stability control

Verification

• Start engine and turn AC to maximum cold with fan on high
• Check for cold air from all vents within 2-3 minutes
• Verify AC compressor cycles on and off normally
• Check all AC line connections for leaks using leak detector
• Verify both high and low side pressures are within specification (approximately 200-250 psi high side, 25-35 psi low side at idle, 85°F ambient)
• Check for proper operation of blend doors and temperature control
• Verify no refrigerant odor in cabin and no oily residue at vents
• Test all dashboard functions including instrument cluster, radio, HVAC controls, and airbag light (should illuminate then extinguish)
• Road test vehicle and verify AC performance under load

More procedures for this vehicle