Removal & Installation
Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain cooling system. Remove glove box. Disconnect electrical connectors, if necessary. Remove floor air distribution duct.
On diesel models, remove Powertrain Control Module (PCM) and mounting tray. On all models, remove trim panels. Remove blower motor cover. Remove blower motor-to-case screws, and remove blower motor. Loosen steering column bolts from instrument panel. Remove carrier and body bracket bolts supporting instrument panel (located on firewall and at each end of instrument panel). Tilt back or remove instrument panel as necessary.
Remove coolant recovery tank. Remove heater hoses at heater core. Disconnect inlet and outlet lines at evaporator core, and cap openings. Remove accumulator. Remove A/C-heater assembly-to-firewall screws and bolts. Remove A/C-heater assembly from vehicle.
Remove heater core cover from A/C-heater assembly. Remove heater core and seal from A/C-heater assembly. Remove air distribution lower case. Remove evaporator core from A/C-heater assembly. See Fig. 3.
To install, reverse removal procedure. Add 3 ounces of clean refrigerant oil to evaporator. Lubricate NEW "O" rings with clean refrigerant oil prior to installation. Fill cooling system, and check for leaks. Evacuate, charge, and leak test system.