AC Evaporator

Replace the AC evaporator core by removing the entire HVAC housing assembly from inside the cab, requiring dashboard and instrument panel removal.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• Evaporator expansion valve × 1 — Use OEM specification
• AC orifice tube or expansion valve × 1 — Replace if contaminated
• Receiver/drier or accumulator × 1 — Must replace when opening system
• HVAC housing foam seals × 1 — Use OEM specification
• AC line O-rings × 4 — Use proper R-134a compatible O-rings
• PAG oil for compressor × 1 — Match compressor type
• Dashboard fastener clips × 10 — Replace broken clips

Fluids

• R-134a refrigerant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait minimum 2 minutes for airbag system capacitor discharge
3. Using certified AC recovery machine, recover all refrigerant from system and record amount removed
4. Drain engine coolant to level below heater core (approximately 1 gallon into drain pan)
5. Remove driver and passenger seats for access and to protect upholstery during dashboard removal
6. Take photos of all electrical connector locations and routing before disconnection
7. Cover steering column and remaining interior surfaces with protective material

Procedure

1. 1

   Disconnect AC lines and heater hoses
   Under hood, disconnect AC liquid line and suction line at firewall connections. Remove retaining bolts and cap all openings immediately to prevent contamination. Disconnect heater hoses at firewall and drain residual coolant into pan. Plug heater core tubes.
2. 2

   Remove steering column components
   Remove lower steering column shroud by removing Torx screws. Remove upper shroud. Disconnect all electrical connectors on column including clockspring connector. Remove steering column mounting nuts (do not remove column completely, just lower it down and rest on floor). Note: a steering wheel puller is not required for this procedure.
3. 3

   Remove instrument cluster and bezel
   Remove instrument cluster bezel by carefully prying with trim tools. Remove four screws securing instrument cluster. Pull cluster forward and disconnect electrical connectors behind cluster. Remove cluster completely. Disconnect and remove radio and HVAC control panel.
4. 4

   Remove center console and floor components
   Remove center console by removing all mounting screws and bolts. Disconnect shift indicator cable if automatic transmission. Remove floor air duct sections connecting to HVAC housing. Remove any kick panel trim pieces on both driver and passenger sides.
5. 5

   Disconnect dashboard electrical connections
   Working from both driver and passenger sides, disconnect all electrical connectors attached to dashboard harness. This includes: ignition switch, light switches, power window/lock switches, airbag connectors, blower motor connector, HVAC control connectors, and all other dash-mounted components. Label each connector.
6. 6

   Remove dashboard mounting fasteners
   Remove dashboard mounting bolts at both A-pillars (approximately 4 bolts per side). Remove center support bracket bolts underneath dashboard. Remove passenger side support bracket bolts. Remove cowl side bolts connecting dashboard to firewall. Total of approximately 12-16 mounting points.
7. 7

   Remove instrument panel from vehicle
   With an assistant, carefully lift and pull dashboard assembly rearward to disengage from cowl. Watch for any missed electrical connections or fasteners. Maneuver dashboard out through driver door opening. This is heavy and awkward - requires two people minimum.
8. 8

   Remove HVAC housing assembly
   With dashboard removed, HVAC housing is now accessible. Disconnect blower motor connector if not already done. Remove HVAC housing mounting nuts at firewall (approximately 4 nuts). Remove housing support brackets inside cab. Carefully pull housing away from firewall studs and remove from vehicle.
9. 9

   Disassemble HVAC housing
   Place HVAC housing on clean work surface. Remove housing retaining screws and clips (approximately 12-15 fasteners around perimeter). Carefully separate housing halves. Note position of all foam seals, blend doors, and mounting hardware. Remove evaporator core and expansion valve from housing.
10. 10

    Inspect and clean housing
    Inspect housing halves for cracks or damage. Check blend door operation and foam seals for deterioration. Clean housing interior thoroughly, removing any debris, old leaves, or corrosion. Replace any damaged foam seals. Inspect heater core for leaks while housing is apart.
11. 11

    Install new evaporator and expansion valve
    Install new expansion valve onto new evaporator core. Apply thin coat of refrigerant oil to all O-rings. Position new evaporator into housing half, ensuring foam seals are properly positioned. Verify evaporator tubes align correctly with housing openings for firewall penetration.
12. 12

    Reassemble HVAC housing
    Carefully align housing halves, ensuring blend doors and actuator linkages engage properly. Install all housing screws and clips, working around perimeter in alternating pattern to ensure even sealing. Verify blend door moves freely through full range before final installation.
13. 13

    Install HVAC housing into vehicle
    Position HVAC housing to firewall, aligning evaporator tubes and heater core tubes through firewall openings. Install mounting nuts at firewall studs. Install support brackets inside cab. Reconnect blower motor electrical connector. Verify housing is secure and properly sealed at firewall.
14. 14

    Reinstall dashboard assembly
    With assistant, position dashboard assembly into vehicle through driver door. Align dashboard to mounting points at A-pillars, center support, and firewall. Install all mounting bolts and tighten securely. Reconnect all electrical connectors using photos and labels as reference. Reinstall steering column to proper position.
15. 15

    Complete interior reassembly and AC connections
    Reinstall instrument cluster, bezels, center console, floor ducts, and all trim pieces. Under hood, install new O-rings on AC line fittings (lubricated with refrigerant oil). Connect AC lines to evaporator at firewall and tighten securely. Connect heater hoses and secure with clamps. Install new receiver/drier at its mounting location (typically integrated with/near the condenser - verify exact location against the FSM). Reconnect battery negative cable.

Reassembly

1. Refill cooling system with HOAT 50/50 coolant and bleed air from system
2. Verify all electrical connections are secure and all dashboard functions operate correctly
3. Check that all HVAC blend doors operate through full range using controls
4. Reinstall driver and passenger seats to original positions
5. Verify steering column operation and proper airbag clockspring connection

Verification

• Evacuate AC system with vacuum pump for minimum 45 minutes, verify system holds 29+ inches vacuum for 30 minutes
• Recharge AC system with proper amount of R-134a refrigerant (typically 42-46 oz, verify on underhood label)
• Add proper amount of PAG oil to match what was removed during recovery
• Start engine and verify AC produces cold air at all vents
• Check for refrigerant leaks at all connections using leak detector or soap solution
• Verify no coolant leaks at heater hose connections
• Test all dashboard functions including gauges, lights, HVAC controls, and airbag warning light operation
• Verify proper blower motor operation at all speeds
• Test temperature blend door operation from full cold to full hot
• Check AC system pressures with manifold gauges: typical 25-35 PSI low side, 150-250 PSI high side at idle with 80°F ambient

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