Disconnect the negative (-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
When the engine is cool, drain the engine coolant from the radiator. (Refer to EM group - "Coolant")
Remove the expansion valve (A) from the evaporator core.
Tightening torque :
7.8 ~ 11.8 N.m ( 0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 Ib-ft)
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
When installing, replace with a new O-ring (B).
Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
Remove the center console.
(Refer to BD group - "Center Console")
Remove the cowl top cover.
(Refer to BD group - "Cowl Top Cover")
Remove the steering handle and column.
(Refer to ST group - "Steering Column")
Loosen the cowl cross member mounting bolt (A).
Remove the left & right front filler trim and then disconnect the connector (A).
Disconnect the left & right multi box connectors (A).
Disconnect the passenger compartment junction box connectros (A).
Remove the floor console air duct (A).
Disconnect the air bag connectors (A).
Remove the heater & A/C control unit.
(Refer to the HA group - "Heater & A/C Control Unit")
Loosen the crash pad to the heater & blower unit mounting bolt (A).
Loosen the crash pad to the heater & blower unit mounting bolts (A).
Loosen the heater & blower unit mounting bolts (A).
Loosen the cowl cross member mounting bolts and then remove the crash pad and heater & blower unit assembly (A).
Disconnect the connectors and then remove the heater & blower unit (A) from the crash pad.
Separate the blower unit from the heater unit after loosening the screws.
Remove the heater core cover (A) after loosening the mounting screws.
Pull out the heater core (A) from heater unit.
Remove the heater unit lower case (A) after loosening the mount screws.
Pull out the evaporator core (A) from heater unit.
Installation is the reverse order of removal.
If you're installing a new evaporator, add refrigerant oil (PAG OIL).
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint, wash it off immediately
Apply sealant to the grommets.
Make sure that there is no air leakage.
Charge the system and test its performance.
Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
Refill the cooling system with engine coolant
