AC Evaporator

Complete removal and replacement of the AC evaporator core, requiring full dashboard and HVAC system disassembly with refrigerant recovery and recharge.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — Use OEM specification
• Expansion Valve × 1 — Use OEM specification
• AC Line O-Ring Kit × 1 — Use OEM specification
• Evaporator Case Foam Seals × 1 — Use OEM specification
• Refrigerant R-134a × 1 — Approximately 1.5 lbs
• PAG 46 Compressor Oil × 1 — 50ml
• Cabin Air Filter × 1 — Replace during service
• Dashboard mounting clips (assorted) × 1 — Keep spares for breakage

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect battery negative terminal and wait minimum 15 minutes for airbag system discharge
3. Recover all refrigerant from AC system using certified recovery machine and document amount recovered
4. Remove both front seats to provide dashboard access (four bolts per seat, retain torque specifications from seat manual)
5. Remove center console completely including trim panels and shifter surround
6. Remove lower dashboard panels on both driver and passenger sides
7. Cover steering wheel and seats with protective material to prevent damage during dashboard removal
8. Take detailed photographs of all connector locations and routing before disconnection

Procedure

1. 1

   Disconnect AC Lines at Firewall
   Locate AC line connections at firewall behind engine bay. Remove insulation wrap from liquid and suction lines. Using appropriate flare nut wrench, disconnect both AC lines from evaporator connections at firewall. Immediately cap all open fittings to prevent contamination and moisture entry. Remove and discard all O-rings.
   ⚠Even after recovery, residual refrigerant may remain. Work in well-ventilated area and wear safety glasses.
   Torque spec

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

   Remove Steering Column and Instrument Cluster
   Lower steering column to lowest position. Remove steering column shroud (upper and lower). Disconnect all electrical connectors from column switches. Remove four steering column mounting bolts and carefully lower column, supporting weight. Remove instrument cluster bezel and disconnect cluster electrical connections. Remove cluster mounting screws and withdraw cluster.
   ⚠Steering column contains clockspring for airbag. Do not rotate steering wheel with column disconnected or clockspring damage will occur.
3. 3

   Disconnect Dashboard Electrical and Mounting
   Working from both sides, disconnect all dashboard electrical connectors including: main body control module harness, HVAC control module, passenger airbag connector (yellow), audio system connections, and all other visible connectors. Label each connection. Locate and remove all dashboard mounting bolts (typically 8-10 bolts along top edge, sides, and center tunnel). Remove side cover panels to access side mounting points.
   ⚠️Passenger airbag connector must be handled carefully. Ensure battery has been disconnected for minimum 15 minutes before touching yellow airbag connectors.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
4. 4

   Remove Dashboard Assembly
   With assistant supporting passenger side, carefully pull dashboard assembly rearward from firewall. Work slowly, checking for any remaining electrical connections or mounting points. Lift dashboard up and back to clear steering column opening. Remove dashboard from vehicle and place on protected surface. This exposes the HVAC housing assembly.
5. 5

   Remove Blower Motor and Ducts
   Disconnect blower motor electrical connector. Remove blower motor mounting screws and withdraw blower motor from HVAC housing. Remove all accessible air distribution ducts connected to HVAC housing, noting routing for reassembly. Disconnect any remaining duct clips.
   Torque spec

   Blower Motor Screws7 Nm (5 lb-ft)

   Duct Clips3 Nm (2 lb-ft)
6. 6

   Separate HVAC Housing
   Remove all HVAC housing mounting brackets from firewall. Disconnect heater hoses at firewall (coolant will drain, have drain pan ready). Remove HVAC housing mounting bolts securing it to firewall and body. Carefully withdraw entire HVAC housing assembly from vehicle. Place on clean workbench.
   ⚠Approximately 1 quart of coolant will drain from heater core connections. Have drain pan positioned.
   Torque spec

   Mounting Bracket Bolts26 Nm (19 lb-ft)
7. 7

   Disassemble HVAC Case
   With HVAC housing on bench, remove all case cover screws around perimeter. Carefully separate upper and lower case halves. Note position of all blend doors, linkages, and actuators before removal. Remove expansion valve from evaporator inlet, discarding O-rings. Document actuator positions with photographs.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)

   Evaporator Case Screws5 Nm (4 lb-ft)
8. 8

   Remove Old Evaporator Core
   Lift old evaporator core from lower HVAC case half. Note orientation and position of inlet/outlet tubes. Remove all old foam seals and insulation from case. Inspect case for debris, leaves, or water damage. Clean case thoroughly with compressed air and lint-free cloths. Check heater core for leaks while case is open.
9. 9

   Install New Expansion Valve
   Install new O-rings on expansion valve, lubricating with fresh PAG 46 oil. Thread expansion valve into inlet of new evaporator core by hand until seated. Torque expansion valve to specification. Add 20ml of fresh PAG 46 oil into evaporator inlet to replace oil lost during service.
   ⚠Use only fresh PAG 46 oil suitable for R-134a systems. Do not overfill with oil as this reduces cooling capacity.
   Torque spec

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

    Install New Evaporator and Reassemble Case
    Apply new foam seals to lower case half per factory positions. Carefully position new evaporator core in lower case, ensuring inlet/outlet tubes align with case openings and orientation matches original. Verify all blend door linkages are correctly positioned. Join upper case half, ensuring no wiring or linkages are pinched. Install all case screws to specification in crisscross pattern.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws11 Nm (8 lb-ft)
11. 11

    Reinstall HVAC Housing Assembly
    Guide HVAC housing back into position at firewall, carefully threading evaporator tubes and heater hoses through firewall. Install all mounting brackets and secure housing mounting bolts to specification. Reconnect heater hoses at firewall with new clamps. Install blower motor with new mounting screws to specification. Reconnect all air distribution ducts using duct clips.
    Torque spec

    Mounting Bracket Bolts26 Nm (19 lb-ft)

    Blower Motor Screws7 Nm (5 lb-ft)

    Duct Clips3 Nm (2 lb-ft)
12. 12

    Reconnect AC Lines
    Install new O-rings on all AC line fittings, lubricating with fresh PAG 46 oil. Connect liquid and suction lines to evaporator tubes at firewall. Thread fittings by hand first to ensure proper engagement. Torque AC line fittings to specification using flare nut wrench. Do not overtighten.
    ℹ️O-rings must be new and properly lubricated to prevent leaks. Old O-rings will not seal correctly even if undamaged.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
13. 13

    Reinstall Dashboard
    With assistant, carefully position dashboard assembly back into vehicle, guiding over steering column opening. Align all mounting points and install mounting bolts finger tight first. Verify proper seating before torquing bolts to specification. Reconnect all electrical connectors including body control module, HVAC controls, passenger airbag (yellow connector last), instrument cluster, and all other labeled connections.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
14. 14

    Complete Interior Reassembly
    Reinstall instrument cluster and secure with mounting screws. Reconnect cluster electrical connections. Reinstall steering column, torquing mounting bolts per specification, and reconnect all column switch connectors. Install column shrouds. Reinstall all dashboard trim panels, center console, and lower panels. Reinstall front seats, ensuring all airbag connectors are properly secured.
15. 15

    Evacuate and Recharge AC System
    Reconnect battery negative terminal. Using AC service machine, pull vacuum on system for minimum 45 minutes to remove all moisture and air. Monitor vacuum decay for 15 minutes to verify no leaks exist. If vacuum holds, recharge system with R-134a to specification (typically 1.3-1.5 lbs, verify on underhood label). Add UV dye if desired for future leak detection. Monitor pressures during initial operation.

Reassembly

1. Refill cooling system to proper level after heater core reconnection and bleed air from system
2. Verify all dashboard electrical functions operate correctly including airbag warning light proper operation (light should illuminate then extinguish)
3. Check that all HVAC blend doors and mode selections operate properly through full range
4. Verify cabin air filter is installed in correct orientation
5. Confirm all dashboard mounting points are secure with no squeaks or rattles
6. Test all steering column functions including turn signals, wipers, and cruise control

Verification

• Start engine and verify AC compressor engages when AC is activated
• Monitor AC pressures: low side should be 25-35 PSI, high side 200-250 PSI at idle with 75°F ambient temperature
• Verify cold air output at all vents with temperature at coldest setting within 5 minutes of operation
• Use refrigerant leak detector to check all connections at firewall for leaks
• Verify evaporator drain tube drips condensation after 10 minutes of AC operation
• Check blower motor operates at all speed settings without noise
• Confirm no refrigerant odor in cabin during operation
• Verify airbag warning light extinguishes after startup (indicates proper passenger airbag reconnection)
• Test all mode selections (defrost, floor, panel, bi-level) for proper airflow direction
• Road test vehicle and verify AC performance under load and confirm no interior squeaks or rattles from dashboard

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