This procedure involves removing the dashboard and HVAC housing to replace the AC evaporator core, requiring refrigerant recovery, complete dash removal, and system recharge.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — Use OEM specification
• AC Line O-ring Kit × 1 — Use OEM specification
• Expansion Valve (if equipped) × 1 — Use OEM specification
• PAG-46 Oil × 1 — Use OEM specification
• R-134a Refrigerant × 1 — Use OEM specification
• Dashboard trim clips × 1 — Assorted sizes
• Evaporator case seal/gasket × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait minimum 2 minutes for airbag system deactivation
3. Recover all AC refrigerant using approved recovery machine and document amount removed
4. Remove front seats (4 bolts per seat, 8mm socket) to provide workspace and protect upholstery
5. Cover steering wheel and seats with protective material
6. Take detailed photos of dashboard, wiring connections, and trim before disassembly
7. Prepare labeled containers or bags for storing fasteners by location

Procedure

1. 1

   Disconnect AC Lines at Firewall
   From engine compartment, locate AC line connections at firewall near passenger side. Remove bolt holding both liquid and suction line fittings at thermal expansion valve. Cap all openings immediately with plugs or tape to prevent moisture entry and debris contamination. Discard old O-rings.
   ⚠Ensure all refrigerant has been recovered. Even small amounts can cause injury when released.
2. 2

   Remove Lower Dash Trim and Panels
   Remove lower steering column cover (2 screws). Remove driver side lower dash panel (push clips and screws). Remove passenger side lower dash panel and glove box (open glove box, squeeze sides inward to release stops, then pull out completely). Remove center console side panels and lower trim pieces. Disconnect all electrical connectors encountered and label them.
3. 3

   Remove Steering Column and Instrument Cluster
   Remove steering column shrouds (screws). Lower steering column by removing 4 nuts at column bracket (13mm). Support column with padding. Remove instrument cluster by removing upper dash trim panel, then 4 cluster mounting screws. Disconnect electrical connectors from rear of cluster and remove cluster from vehicle.
4. 4

   Disconnect Dashboard Wiring and HVAC Controls
   Disconnect main wiring harness connectors behind center stack (minimum 6 large connectors - BCM, radio, HVAC, accessory power). Remove climate control head unit and radio. Disconnect blend door actuators and temperature sensors accessible from front of HVAC case. Label all connectors with tape and marker.
   ℹ️Take photos of each connector before disconnection. Some connectors have secondary locks that must be released.
5. 5

   Remove Dashboard Mounting Bolts
   Locate and remove all dashboard mounting bolts: 2 bolts at each A-pillar (inside weatherstrip area), 4 bolts across top of dashboard (visible with hood open at cowl), 2 bolts at center support bracket, and 2 bolts at passenger side bracket. Remove ground wire connections. There are typically 10-12 mounting bolts total.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Extract Dashboard Assembly
   With assistant support, carefully pull dashboard rearward off mounting points. Watch for any remaining wire connections or clips. Lift dashboard up and rearward, maneuvering around steering column. Remove dashboard completely from vehicle and place on protected surface. This is a large, awkward assembly requiring two people.
   ⚠Dashboard weighs approximately 60-80 lbs and is fragile. Use two people and avoid placing stress on mounting brackets.
7. 7

   Remove HVAC Case Cover and Actuators
   With dashboard removed, HVAC plenum is now accessible. Remove remaining blend door actuators (typically 3-4 actuators with 2-3 screws each). Disconnect evaporator temperature sensor. Remove recirculation door actuator. Remove blower motor assembly (3 screws) from case.
8. 8

   Separate HVAC Case Halves
   Remove all screws joining upper and lower HVAC case halves (approximately 12-15 screws around perimeter). Carefully separate case halves, noting position of blend doors and linkage. The evaporator core is housed in the lower section near the firewall.
   Torque spec

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

   Remove Expansion Valve and Old Evaporator
   If equipped with external expansion valve (TXV), disconnect it from evaporator inlet. Remove evaporator mounting bracket or clips. Carefully lift old evaporator core out of case, tilting as needed to clear foam seals. Note orientation and position of any foam seals, drain tubes, or insulators for reinstallation.
   ℹ️Old evaporator may contain residual oil and refrigerant. Drain into approved container and measure oil quantity for replacement.
   Torque spec

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

    Install New Evaporator Core
    Add correct amount of fresh PAG oil to new evaporator (typically 3-4 oz, or replace measured amount from old evaporator). Install new evaporator into case in same orientation as original, ensuring all foam seals are properly positioned. Install evaporator mounting brackets. Install new expansion valve with new O-rings lubricated with PAG oil.
    ⚠Use only new evaporator from sealed packaging. Exposure to atmosphere for more than 15 minutes can cause moisture absorption.
    Torque spec

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

    Reassemble HVAC Case
    Verify all blend door linkages are properly positioned and move freely. Install new case seal gasket if equipped. Carefully mate upper and lower case halves, ensuring no wires or linkages are pinched. Install all case screws and torque evenly in cross pattern. Install blower motor assembly. Reinstall all blend door actuators and sensors.
    Torque spec

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

    Reinstall Dashboard Assembly
    With assistant, position dashboard assembly over HVAC case and guide into position around steering column. Align all mounting points. Install all dashboard mounting bolts finger-tight first, then torque to specification. Reconnect all ground wires. Reconnect all electrical connectors using photos/labels as reference.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reinstall Interior Components
    Install instrument cluster and reconnect electrical connectors. Raise and secure steering column. Install climate control head unit and radio. Install all dashboard trim panels, glove box, center console pieces, and lower panels. Install front seats and torque seat bolts. Verify all trim pieces are secure and gaps are even.
14. 14

    Connect AC Lines at Firewall
    Install new O-rings on AC line fittings, lubricate with PAG oil. Route lines to thermal expansion valve connections at firewall. Hand-thread fittings first to ensure proper alignment, then torque AC line fittings to specification. Verify lines are not kinked or stressed.
    ⚠Cross-threading aluminum AC fittings will destroy threads. Always start by hand and verify smooth threading before using tools.
    Torque spec

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

    Evacuate and Recharge AC System
    Reconnect battery. Using approved AC service equipment, vacuum system to 29+ inches Hg for minimum 45 minutes to remove all moisture. System should hold vacuum for 15 minutes without decay. Charge system with R-134a refrigerant to specification (typically 1.75-2.0 lbs, verify on underhood label). Add any additional PAG oil if required per service machine readings. Perform leak test on all connections using electronic leak detector.
    ⚠️Insufficient vacuum time will leave moisture in system, causing compressor failure and corrosion. Do not skip or shorten vacuum procedure.

Reassembly

1. Verify all electrical connectors are fully seated with locking tabs engaged
2. Test operation of all blend door actuators using climate control before final trim installation
3. Ensure no dashboard rattles or loose trim before returning vehicle to service
4. Check that all airbag warning lights extinguish after battery reconnection (may require drive cycle)
5. Verify heater and AC operation in all modes and temperature ranges

Verification

• Start engine and set AC to maximum cold, recirculation mode, high blower
• AC system should produce vent temperatures of 38-45°F within 5 minutes at idle
• Verify no refrigerant leaks at firewall connections using leak detector
• Check for proper airflow from all vents with no restrictions or whistling
• Verify no musty odors from vents indicating moisture or incomplete seal
• Test blend door operation through full hot-to-cold range for smooth transition
• Confirm all dashboard functions work: gauges, lights, radio, climate controls, airbag light off
• Inspect evaporator drain tube under vehicle for proper condensate drainage during operation

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