This procedure covers removal and replacement of the AC evaporator core, which requires complete dashboard removal and AC system discharge/recharge.

Warnings

Tools required

Parts

• AC evaporator core × 1 — 88501-06150 or equivalent
• Evaporator expansion valve × 1 — 88719-06010 or equivalent
• AC line O-rings × 6 — Use OEM specification
• PAG oil (ND-11) × 1 — 00289-1AC11
• R-134a refrigerant × 1 — Use OEM specification
• Evaporator thermistor/sensor × 1 — Reuse if not damaged
• Dashboard fastener clips × 10 — Assorted replacement clips

Fluids

• PAG oil (ND-11) — 0.25 qt

Preparation

1. Ensure vehicle is on level ground with parking brake applied
2. Disconnect negative battery terminal and wait minimum 90 seconds for airbag system discharge
3. Recover AC refrigerant using certified recovery machine and document amount recovered
4. Remove both front seats by unbolting seat track bolts for better access
5. Remove all personal items from vehicle and protect interior surfaces with fender covers
6. Take detailed photos of dashboard connector locations and routing before disassembly
7. Prepare labeled bags or organizer for fasteners from each major component

Procedure

1. 1

   Remove lower dashboard panels and steering components
   Remove lower dashboard trim panels on both driver and passenger sides. Remove steering column lower cover and upper cover. Loosen steering column mounting bolts (do not remove completely). Lower steering column to access upper dashboard fasteners. Disconnect all electrical connectors from steering column switches.
2. 2

   Disconnect instrument cluster and center console
   Remove instrument cluster bezel and disconnect cluster electrical connectors. Remove center console trim panels and shifter surround. Disconnect climate control panel and audio system connectors. Remove center console mounting bolts and remove console completely.
3. 3

   Remove glove box and passenger airbag
   Remove glove box by pressing in side stoppers and lowering completely. Disconnect glove box light if equipped. Remove passenger airbag mounting bolts (typically 4 bolts). Carefully pull airbag out and disconnect yellow airbag connector. Store airbag face-up in safe location away from work area.
   ⚠️Handle airbag carefully and always place face-up. Never point airbag at yourself or others.
4. 4

   Disconnect main dashboard wiring and fasteners
   Locate and disconnect all remaining dashboard wiring harnesses including: BCM connectors, HVAC connectors, instrument panel harness connectors, antenna lead, and any other connectors. Remove dashboard mounting bolts (typically 6-8 bolts along top edge and sides). Remove A-pillar trim panels on both sides to access side dashboard bolts.
5. 5

   Remove complete dashboard assembly
   With assistant support, carefully pull dashboard rearward while checking for any remaining connected wires or fasteners. Lift dashboard up and out through passenger door opening. Place dashboard on padded surface to prevent damage. Mark and photograph any remaining connections before fully separating.
   ⚠Dashboard is heavy and awkward. Use two people minimum to prevent damage and injury.
6. 6

   Disconnect AC lines at firewall
   From engine bay, disconnect AC refrigerant lines at firewall connections to evaporator. Immediately cap all open AC fittings with proper plugs or plastic caps to prevent moisture entry. Remove insulation and sound deadening around evaporator case access area inside cabin.
   ⚠Cap all AC line openings within 5 minutes to prevent moisture contamination of system.
7. 7

   Remove evaporator case covers
   Remove blower motor assembly if needed for access. Remove evaporator case cover screws and carefully separate case halves. The evaporator case is typically held by multiple screws around perimeter. Note position of any drainage tubes or grommets for reassembly.
   Torque spec

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

   Remove expansion valve and extract evaporator
   Disconnect evaporator thermistor/temperature sensor connector. Remove expansion valve mounting bolts and carefully extract expansion valve from evaporator. Note orientation and position. Carefully slide evaporator core out of case, noting direction and any spacers or insulators. Inspect case for debris, leaves, or moisture damage.
   Torque spec

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

   Prepare and install new evaporator
   Add specified amount of new PAG oil (typically 1-2 oz) to new evaporator core by pouring into inlet fitting. Slowly rotate evaporator to distribute oil. Install new O-rings on expansion valve (lubricate with PAG oil). Install evaporator into case with proper orientation matching original position. Ensure all insulators and foam seals are properly positioned.
   ℹ️Consult compressor oil capacity chart and add oil to evaporator to compensate for oil lost in old evaporator.
10. 10

    Install expansion valve and reconnect thermistor
    Install expansion valve with new lubricated O-rings onto evaporator core inlet. Torque expansion valve to specification. Reconnect evaporator thermistor/temperature sensor ensuring proper seating in evaporator fins. Route sensor wire through proper clip positions.
    Torque spec

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

    Reassemble evaporator case
    Clean evaporator case halves and inspect for cracks. Ensure drain tube is clear and properly positioned. Rejoin case halves carefully, ensuring all alignment tabs engage properly. Install evaporator case screws and torque to specification in cross pattern. Reinstall blower motor if removed.
    Torque spec

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

    Reconnect AC lines at firewall
    Install new O-rings on all AC line fittings, lubricating each with fresh PAG oil. Connect AC lines to evaporator fittings at firewall from engine bay side. Torque AC line fittings to specification. Ensure lines are properly routed without kinks or strain.
    ⚠Never reuse old O-rings. Always lubricate new O-rings with PAG oil before installation.
    Torque spec

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

    Reinstall dashboard assembly
    With assistant, carefully position dashboard assembly back into vehicle cabin. Route all wiring harnesses to proper locations using photos as reference. Install all dashboard mounting bolts and torque appropriately. Reconnect all electrical connectors in reverse order of removal including BCM, HVAC, instrument panel, and all switch connectors.
14. 14

    Reinstall passenger airbag and interior components
    Reconnect passenger airbag yellow connector and carefully position airbag into dashboard. Install airbag mounting bolts. Reinstall instrument cluster and reconnect. Reinstall glove box assembly. Reinstall center console and all trim panels. Reinstall steering column covers and reposition steering column to original position. Reinstall both front seats and torque seat bolts.
15. 15

    Evacuate and recharge AC system
    Reconnect negative battery terminal. Using AC service machine, pull vacuum on system for minimum 45 minutes to remove all moisture and air. System should hold vacuum without loss for 30 minutes (leak test). Recharge system with R-134a to specification (typically 18-22 oz, verify on underhood label). Add any additional PAG oil through service port if needed per machine recommendations.
    ⚠System must hold vacuum for 30 minutes minimum. Any vacuum loss indicates a leak that must be repaired before charging.

Reassembly

1. Verify all dashboard electrical connectors are fully seated and locked
2. Test all dashboard functions before final trim installation (lights, HVAC controls, audio, etc.)
3. Ensure airbag warning light extinguishes after battery reconnection (may require drive cycle)
4. Check that all dashboard panels and trim pieces fit flush without gaps or rattles
5. Verify drainage tube from evaporator case exits properly through firewall
6. Confirm steering column adjustments work properly and column is secure

Verification

• Start engine and verify AC compressor engages when AC is turned on
• Check for cold air from all dashboard vents within 2-3 minutes of operation
• Verify evaporator temperature sensor reading is accurate using scan tool (should show 35-45°F when system running)
• Inspect engine bay and cabin for any refrigerant leaks using leak detector or soap solution
• Confirm no unusual noises from dashboard or HVAC system during operation
• Test AUTO climate control mode if equipped to ensure proper system operation
• Verify center vent temperature reaches 40-45°F at idle with max AC
• Check that condensation drains properly from evaporator drain tube under vehicle
• Ensure no airbag warning lights are illuminated on dashboard
• Verify all dashboard functions work: gauges, switches, lights, radio, climate controls

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