SMU - Revised Evaporator Core Replacement Procedure

This bulletin is being issued to revise the Evaporator Core Replacement procedure in the Heating, Ventilation and Air Conditioning sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Removal Procedure

1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement.
2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
3. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.



4. Disconnect the electrical connectors.
5. Remove the compressor hose assembly from the accumulator. Refer to Compressor/Condenser Hose Replacement - Auxiliary.
6. Remove the bypass valve bracket from the outer case.
7. Remove the evaporator tube from the accumulator.
8. Remove the relay bracket.
9. Remove the evaporator tube from the evaporator. Refer to the appropriate procedure:

•	Evaporator Tube Replacement

•	Evaporator Tube Replacement - Auxiliary Front




10. Remove the screws from the outer evaporator case.
11. Remove the outer case from the module.
12. Remove the screws in order to split the evaporator module in half.
13. Remove the inner case from the module.
14. Remove the evaporator core.

Installation Procedure

1. Install the evaporator core.

Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the inner case to the evaporator module.

Tighten
Tighten the screws to the evaporator case to 6 N·m (53 lb in).

3. Install the outer case to the evaporator module.

Tighten
Tighten the screws to the evaporator case to 6 N·m (53 lb in).

4. Install the evaporator tube to the evaporator.

•	Evaporator Tube Replacement

•	Evaporator Tube Replacement - Auxiliary Front

5. Install the bypass valve bracket to the outer case.
6. Install the evaporator to the accumulator.
7. Install the compressor hose assembly to the accumulator. Refer to Compressor/Condenser Hose Replacement - Auxiliary.
8. Install the relay bracket.
9. Connect the electrical connectors.
10. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
11. Refill the engine coolant. Refer to Draining and Filling Cooling System.
12. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging.
13. Install the air cleaner. Refer to Air Cleaner Assembly Replacement.