Complete replacement of the AC evaporator core, requiring full dashboard removal, AC system evacuation and recharge, and replacement of associated seals and O-rings.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• Expansion valve × 1 — Use OEM specification
• AC line O-rings (assorted sizes) × 1 — Use OEM specification
• PAG oil for AC system × 1 — Use OEM specification
• R-134a refrigerant × 1 — Approximately 3.0 lbs
• Receiver-drier/accumulator × 1 — Replace when system is opened
• Foam evaporator case seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery terminal and wait minimum 2 minutes for airbag system capacitors to discharge
3. Recover all refrigerant from AC system using approved recovery equipment
4. Document or photograph all electrical connector locations before disconnection
5. Remove both front seats to provide working space and prevent damage
6. Cover steering wheel, seats, and carpet with protective material
7. Ensure all necessary replacement parts and O-rings are available before beginning

Procedure

1. 1

   Remove instrument panel top cover and defroster grilles
   Remove all screws securing the instrument panel top cover. Carefully lift the cover from the rear and work forward to release clips. Remove defroster grille panels by releasing clips and lifting upward. Disconnect ambient light sensor connector if equipped.
2. 2

   Remove steering column and knee bolster
   Lower steering column to lowest position. Remove knee bolster panel below steering column. Disconnect all electrical connectors from steering column switches. Remove steering column mounting bolts and carefully lower column, supporting its weight. Do not allow column to hang by wiring.
3. 3

   Disconnect and remove center console and floor components
   Remove center console by removing all mounting screws and disconnecting electrical connectors for power outlets, heated seat switches, and transfer case shifter if equipped. Remove floor duct work and any trim panels blocking access to instrument panel mounting bolts.
4. 4

   Disconnect instrument panel electrical and data connections
   Disconnect all electrical connectors from instrument cluster, HVAC controls, radio, and accessory switches. Disconnect antenna cable from radio. Disconnect all body harness connectors that pass through instrument panel. Label all connections for reassembly. Disconnect OBD-II connector and any other data connections.
5. 5

   Remove instrument panel mounting bolts and carrier
   Locate and remove all instrument panel mounting bolts (typically 8-10 bolts along the cowl and sides). With assistance, carefully pull instrument panel rearward to disengage from cowl. Lift and remove entire instrument panel assembly from vehicle. Place on protected surface to prevent damage.
   ⚠Instrument panel weighs over 100 lbs. Requires two people to remove safely without damage to vehicle or injury.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
6. 6

   Access and disconnect AC lines at evaporator
   With dashboard removed, locate AC line connections at firewall entering evaporator housing. Clean area around fittings thoroughly. Disconnect liquid line and suction line from evaporator core using proper line wrenches. Cap all open lines immediately to prevent moisture and contamination entry.
   ⚠Even after recovery, residual refrigerant may remain. Work in well-ventilated area.
7. 7

   Remove HVAC housing assembly
   Disconnect blower motor electrical connector. Remove all screws and bolts securing HVAC housing to firewall and mounting brackets. Disconnect any remaining vacuum lines or electrical connections. Carefully remove entire HVAC housing assembly from vehicle.
   ℹ️Note position and routing of all vacuum lines and drain tubes for proper reassembly.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
8. 8

   Disassemble HVAC case and remove evaporator
   Place HVAC housing on clean work surface. Remove case screws securing upper and lower housing halves. Carefully separate housing halves. Remove expansion valve from evaporator inlet, noting orientation. Lift evaporator core from housing. Remove and discard all foam seals and gaskets.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)

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

   Install new evaporator and expansion valve
   Clean evaporator housing thoroughly, removing all debris and old foam seal material. Install new foam seals in housing. Install new expansion valve to new evaporator core with new O-rings lubricated with PAG oil, torque to specification. Place new evaporator into lower housing, ensuring proper seating and drain tube alignment.
   ℹ️Add specified amount of PAG oil to evaporator core before installation per vehicle specifications (typically 3 oz).
   Torque spec

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

    Reassemble HVAC housing
    Carefully align and join upper and lower HVAC housing halves, ensuring evaporator core remains properly seated and all seals align correctly. Install and tighten case screws in cross pattern to ensure even sealing. Verify blend door and mode door operation is not obstructed.
    Torque spec

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

    Reinstall HVAC housing to vehicle
    Position HVAC housing assembly back into vehicle, aligning mounting points and ensuring proper firewall seal engagement. Install mounting bolts and tighten to specification. Reconnect blower motor electrical connector. Reconnect all vacuum lines and verify drain tube is properly routed.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
12. 12

    Connect AC lines with new O-rings
    Install new O-rings on all AC line fittings, lubricating with appropriate PAG oil. Connect liquid line and suction line to evaporator fittings, ensuring proper alignment. Tighten AC line fittings to specification using proper line wrenches.
    ⚠Use only new O-rings and ensure proper lubrication. Over-tightening can damage fittings and cause leaks.
    Torque spec

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

    Reinstall instrument panel assembly
    With assistance, carefully position instrument panel assembly back into vehicle. Align all mounting points and guide wiring harnesses through proper openings. Install and tighten all mounting bolts to specification. Reconnect all electrical connectors, data connections, and antenna cable in reverse order of removal.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
14. 14

    Reinstall steering column and interior components
    Raise and secure steering column, installing mounting bolts. Reconnect all steering column electrical connectors. Install knee bolster panel. Reinstall center console, floor duct work, and all trim panels removed during disassembly. Reinstall front seats and torque mounting bolts properly.
15. 15

    Evacuate and recharge AC system
    Connect vacuum pump to AC system and evacuate for minimum 45 minutes to remove all moisture and air. Monitor vacuum gauge for proper vacuum hold (system should hold 29+ inHg for 10 minutes). Recharge system with correct amount of R-134a refrigerant per specifications. Add UV dye for future leak detection if desired.
    ⚠Proper evacuation is critical to prevent moisture contamination which can damage AC components and reduce cooling performance.

Reassembly

1. Reconnect negative battery terminal and clear any stored airbag codes using scan tool
2. Verify all electrical components function properly including instrument cluster, HVAC controls, radio, and accessory switches
3. Test all airbag indicator lights illuminate and extinguish properly during startup sequence
4. Ensure steering column is properly secured and all functions operate correctly
5. Verify floor ducts and console components are properly secured

Verification

• Start engine and verify AC system operates properly with no unusual noises from evaporator area
• Check for cold air from all vents in MAX AC mode with recirculation on
• Monitor AC pressures with manifold gauges: low side should be 25-35 PSI, high side 175-250 PSI at 75°F ambient
• Perform leak detection using electronic leak detector at all AC line connections and evaporator drain area
• Verify proper condensate drainage from evaporator drain tube under vehicle during operation
• Check for any refrigerant odor inside cabin or signs of oil residue at vents
• Test all blend door and mode door functions operate correctly with smooth airflow transitions
• Verify instrument panel has no squeaks or rattles and all mounting points are secure
• Test drive vehicle and verify AC performance remains consistent and no odors develop

More procedures for this vehicle