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Evaporator (front) removal 1. Remove the hvac housing from the vehicle. See hvac housing (front) . Remove the heater hoses from the heater core. 2. Remove and discard the foam seal from the hvac housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. Remove the expansion valve from the evaporator inlet and outlet tube fittings. See expansion valve . 3. Disconnect the hvac wire harness connector for the blower motor from the motor connector receptacle on the bottom of the outboard end of the evaporator housing. Disengage the hvac wire harness from the routing clips molded into the outside of the hvac housing components. 4. Remove the 3 screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. See fig. 41 . 5. Pull the top of the distribution housing away from the evaporator housing far enough to disengage the 2 hook formations on the bottom of the distribution housing from the 2 receptacles on the evaporator housing. See fig. 42 . 6. Remove the 2 screws that secure the upper intake air housing to the lower intake air housing. Remove the 3 screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening. 7. Remove the upper intake air housing from the top of the evaporator housing to expose the recirculation air door and the blower wheel housing. See fig. 43 . Remove the 2 screws that secure the upper half of the recirculation air door to the lower half of the door. 8. Remove the upper half of the recirculation air door from the lower half of the door. See fig. 44 . Remove the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half. 9. Carefully separate and remove the upper half of the evaporator housing from the lower half. Be certain not to lose the rubber grommet for the hvac wire harness evaporator temperature sensor take out. This grommet is located on the inboard side of the flange around the expansion valve/evaporator tube opening on the dash panel side of the unit where it is captured in notched area between the upper and lower housing halves. See fig. 45 . 10. Carefully lift the evaporator and its foam wrap out of the lower half of the evaporator housing as a unit. Be certain not to lose the clam shell type rubber seal that is fitted to the evaporator inlet and outlet tubes where they exit he evaporator housing.

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damper with low pressure service valve* in refrigerant hose from expansion valve to compressor. Only use kent moore acr 4 or equivalent 2 – refrigerant hose* from expansion valve to compressor with damper 3 – refrigerant pipe* from receiver dryer to expansion valve 4 – high pressure service valve* manual a/c system components in engine compartment, servicing only use kent moore acr 4 or equivalent 5 – a/c pressure switch f129 or high pressure sensor g65 switch/sensor can be removed without discharging refrigerant system. Tightening torque 8 nm (71 in. Lb) always replace o-ring. F129 electrical checking f129 functional checks g65 checking f129 and g65 can also be checked using vas 5051/5052 in mode “guided fault finding” . G65 is monitored by obd of ecm. Function: f129 switches coolant fan v7 to the next higher speed when pressure increases in refrigerant circuit. F129 switches off a/c clutch whenever excessive refrigerant system pressure is present (e.G.: insufficient air flow over condensor or if system is overcharged). F129 switches off a/c clutch whenever insufficient refrigerant system pressure is present (e.G.: refrigerant has leaked out). G65 supplies refrigerant system pressure signal to coolant fan control module j293 and engine control module. 6 – expansion valve* removing and installing 7 – dust and pollen filter with activated charcoal filter removing and installing 8 – ambient temperature switch f38 switches off a/c clutch n25 at low outside temperatures.