This procedure covers replacement of the AC evaporator core, located inside the HVAC case behind the dashboard. Requires dashboard removal, refrigerant recovery, and system recharge.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — 88501-06250 or equivalent
• AC line O-ring kit × 1 — Use OEM specification
• Expansion valve × 1 — 88719-06060 (replace if corroded)
• Receiver/Drier × 1 — 88719-06100 (recommended with evaporator)
• PAG oil for R134a system × 1 — ND-11 or equivalent
• Evaporator case foam seals × 1 — Use OEM specification
• Dashboard fastener assortment × 1 — Retainer clips if broken

Fluids

• R134a refrigerant
• PAG oil ND-11

Preparation

1. Verify AC complaint (no cooling, musty smell, leaks) and confirm evaporator is root cause using leak detection or diagnosis
2. Park vehicle on level surface, set parking brake, and ensure engine is completely cool
3. Disconnect negative battery cable and wait minimum 90 seconds for airbag system discharge
4. Using certified AC recovery machine, recover all refrigerant from system and record amount removed
5. Remove cabin air filter from glove box area for access documentation
6. Protect seats and center console with blankets or seat covers
7. Label all electrical connectors with tape and marker during removal for reinstallation reference

Procedure

1. 1

   Remove steering wheel and column covers
   Remove lower dash panel below steering column. Disconnect SRS (airbag) connector behind steering wheel. Using T50 Torx socket, remove steering wheel bolt while holding wheel. Mark wheel position before removal. Remove upper and lower steering column covers (T20 Torx screws).
2. 2

   Remove instrument cluster and center stack
   Remove instrument cluster bezel using trim tools. Disconnect three electrical connectors behind cluster and remove cluster assembly. Remove center console trim panels starting from bottom and working up. Disconnect hazard switch, USB ports, and climate control connectors. Remove radio/infotainment head unit (four 10mm bolts).
3. 3

   Disconnect dashboard wiring and fasteners
   Working from both sides, disconnect all remaining electrical connectors along dashboard perimeter including: passenger airbag connector, glove box light, climate control sensors, and side defroster vent connectors. Remove dashboard mounting bolts: two at each A-pillar, two center upper bolts near windshield, two behind instrument cluster, and two at each side near kick panels (total approximately 10-12 bolts).
4. 4

   Remove dashboard assembly
   With all fasteners and connectors removed, carefully pull dashboard rearward and upward. Have assistant help support weight. Maneuver around steering column and lift out through passenger door opening. Dashboard weighs approximately 40-50 lbs. Set on protected surface.
5. 5

   Disconnect AC refrigerant lines at firewall
   From engine bay, locate AC liquid and suction lines at firewall near blower motor. Using 14mm flare nut wrench, carefully disconnect both lines from evaporator inlet/outlet tubes. Cap open lines immediately to prevent moisture and debris entry. Remove and discard old O-rings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
6. 6

   Remove blower motor assembly
   Inside cabin, disconnect blower motor electrical connector. Remove three mounting screws securing blower motor housing to HVAC case. Carefully withdraw blower motor assembly and set aside.
   Torque spec

   Blower Motor Screws7 Nm (5 lb-ft)
7. 7

   Separate HVAC case halves
   Remove all accessible screws and clips securing upper and lower HVAC case halves (approximately 8-12 fasteners around perimeter). Note positions of different length screws. Disconnect thermistor wire from evaporator if equipped. Carefully separate case halves, being mindful of remaining duct connections.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)

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

   Remove old evaporator core
   With case open, carefully lift out old evaporator core. Note orientation of inlet/outlet tube positions. Remove expansion valve from old evaporator using 12mm wrench. Inspect valve for debris or corrosion. Remove thermistor probe if attached to evaporator fins. Clean any debris or moisture from HVAC case interior.
   ⚠Old evaporator may contain residual oil and refrigerant. Have drain pan ready and dispose of properly.
   Torque spec

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

   Install new expansion valve and prepare evaporator
   Install new or cleaned expansion valve onto new evaporator core using new O-rings. Add 1-2 drops of PAG oil to O-rings before installation. Torque expansion valve to specification. Add 2 oz fresh PAG oil (ND-11) directly into evaporator inlet tube. Reinstall thermistor probe into evaporator fins at original location.
   ℹ️PAG oil amount compensates for oil lost with old evaporator. Verify total system oil capacity matches manufacturer specification.
   Torque spec

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

    Install evaporator into HVAC case
    Carefully position new evaporator core into lower HVAC case half, ensuring inlet/outlet tubes align with firewall openings. Verify foam seals are in place around evaporator perimeter to prevent air bypass. Check that drain tube passage is clear.
11. 11

    Reassemble HVAC case
    Align upper and lower HVAC case halves carefully. Install all case screws and clips in original positions, working around perimeter. Verify case seam is flush all around with no gaps. Reconnect thermistor wire connector.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Reinstall blower motor
    Position blower motor assembly back into HVAC case opening. Install three mounting screws and reconnect electrical connector. Verify impeller rotates freely without noise.
    Torque spec

    Blower Motor Screws7 Nm (5 lb-ft)
13. 13

    Reconnect AC lines at firewall
    Install new O-rings on both liquid and suction line fittings. Apply thin coat of PAG oil to O-rings. From engine bay, reconnect both AC lines to evaporator tubes at firewall using flare nut wrench. Torque to specification using crowfoot wrench adapter on torque wrench.
    ⚠Cross-threading AC fittings will cause leaks. Start threads by hand and verify smooth engagement before torquing.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
14. 14

    Reinstall dashboard assembly
    With assistant, carefully maneuver dashboard back into vehicle through passenger door. Guide around steering column and position onto mounting points. Install all dashboard mounting bolts finger-tight first, then torque center bolts followed by side bolts. Reconnect all electrical connectors using labels as reference.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Complete interior reassembly
    Reinstall radio/infotainment unit, instrument cluster, steering wheel (aligning marks made during removal), column covers, and all trim panels. Verify all clips engage properly. Reconnect negative battery cable.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify no tools or parts remain inside dashboard or HVAC case
3. Test all dashboard functions before AC recharge: lights, gauges, radio, climate controls, airbag light should illuminate then extinguish
4. Reinstall cabin air filter in correct orientation

Verification

• Connect AC service machine and perform vacuum test: pull vacuum to 29+ inHg for minimum 30 minutes. System should hold vacuum without decay (less than 1 inHg loss)
• If vacuum holds, recharge system with proper amount of R134a refrigerant (verify on underhood label, typically 17-19 oz for 2.5L Camry)
• Start engine and set AC to MAX/coldest setting with blower on high
• Verify compressor engages and both AC lines show appropriate temperatures (cold suction line, warm liquid line)
• Use infrared thermometer at center vents: should achieve 38-45°F with ambient temp 70-80°F
• Check for leaks at firewall connections using electronic leak detector or UV dye
• Verify no unusual odors from vents and condensate drains properly from evaporator drain tube
• Test all blower speeds and mode selections (defrost, floor, panel) for proper airflow
• Road test vehicle and verify cooling performance under load

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