2025-01-23

Evaporator (1st Generation) (Remove and Replace)

Correction code 18201012

  • 2025-01-21: Added Note on separately adding correction code 18200102 and condensed procedure.
  • 2023-04-06: Updated to latest validation.
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Note
This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate activity to the Service Visit.

Removal

  1. Move the LH and RH front seat backward.
  2. Recover the refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  3. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  4. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  5. Remove the bolts (x2) that attach the front HVAC filter housing, and then remove the HVAC filter housing.
  6. Fully lower and extend the steering column.
  7. Disconnect 12V power. See Disconnect 12V Power.
  8. Remove the center console. See Center Console Assembly (Remove and Replace).
  9. Remove the LH middle A-pillar trim.
  10. Remove the screw that attaches the lower instrument panel trim.
  11. Remove the LH lower A-pillar trim.
  12. Remove the RH instrument panel side cover.
  13. Remove the RH middle A-pillar trim.
  14. Release the clips (x13) that attach the RH instrument panel lower assembly, and then remove the assembly from the vehicle.
  15. Remove the glove box. See Glove Box (Remove and Replace).
  16. Remove RH footwell cover. See Assembly - Cover - Footwell - Passenger's (Remove and Replace).
  17. Remove the RH lower A-pillar trim.
  18. Remove the LH and RH shock tower covers.
  19. Remove the fuse box cover.
  20. Remove and discard the nyloc nut that attaches the 12V supply cable to DCDC.
  21. Release the clips (x3) that attach the 12V battery supply cable to the fuse box and strut tower cross beam.
  22. Disconnect the pyrotechnic fuse connector.
  23. Remove the bolts that attach the fuse box to the body.
  24. Release the fuse box from the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the fuse box to the RH side to release the tabs, and then lift up the fuse box.
  25. Disconnect the remaining connectors from the bottom of the fuse box.
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    Note
    Depress locking tabs on sides of flip type connector and flip lever on connector to reseal
  26. Remove the clip that attaches the harness to the LH shock tower brace.
  27. Remove the bolt that attaches the wiper motor to the LH shock brace.
  28. Remove the bolts (x2) that attach the LH air suspension reservoir bracket to the LH shock brace.
  29. Remove the A/C line bracket bolt on the RH shock brace.
  30. Remove the bolts (x2) that attach the air reservoir bracket to the RH shock brace.
  31. Remove the bolts (x3) that attach the LH shock tower brace.
  32. Remove the bolts that attach the RH shock tower brace.
  33. Remove the bolts (x3) that attach the wiper motor, and then disconnect the connector.
  34. Remove the screws (x2) that attach the air suspension reservoir to the bracket.
  35. Set the air suspension reservoir aside for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the suspension reservoir below the A/C line.
  36. Remove the IP top pad assembly. See Assembly - Top Pad - Instrument Panel (Remove and Install).
  37. Remove the defrost mesh grille assembly. See Assembly - Mesh Grille - Defrost (Remove and Replace).
  38. Remove the RH IP finisher. See Assembly - Finisher - Instrument Panel - RH (Remove and Replace).
  39. Remove the screws (x2) that attach the LH inner IP finisher with vent to the IP carrier, and then remove it from the IP carrier (3x clips) .
  40. Remove the LH IP finisher. See Assembly - Finisher - Instrument Panel - LH (Remove and Replace).
  41. Remove the steering column. See Steering Column (Remove and Replace).
  42. Remove the instrument cluster. See Instrument Cluster (Remove and Replace).
  43. Remove the MCU. See Media Control Unit (Remove and Install).
  44. Remove the IP carrier. See IP Carrier (Remove and Replace).
  45. Remove the cross car beam. See Cross Car Beam (Remove and Replace).
  46. Remove the bolts (x2) that attach the TXV to the evaporator, and then disconnect the A/C tubes and TXV from the HVAC unit.
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    Note
    Discard the O-rings.
  47. Disconnect the remaining electrical connectors (x3) and harness clips (x3) from the HVAC assembly.
  48. Remove the bolts (x2) that attach the HVAC assembly to the cowl .
  49. Remove the nuts (x5) that attach the HVAC assembly to the bulkhead.
  50. Release the HVAC drain hose from the nipple on the HVAC assembly while removing the HVAC assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug pipe connections to prevent ingress of moisture or dirt. Put suitable absorbent material around the affected area to absorb any spilled fluid.
  51. Remove the foam spacer from the HVAC pipe inlet area.
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    Note
    The foam spacer can be reused, if not damaged.
  52. Remove the screws (x9) that attach the lower evaporator cover.
  53. Remove the screw (x6) that attach the upper evaporator cover.
  54. Remove the screws (x2) that attach the evaporator inlet pipe to the HVAC case.
  55. Remove the evaporator from the HVAC case.
  56. With the evaporator on the bench, remove the screws (x3) that attach the plastic mounting bracket.

Installation

  1. Install the screws (x2) that attach the evaporator mounting bracket to the new evaporator (torque 2 Nm).
  2. Install the evaporator into the HVAC case.
  3. Install the screws (x6) that attach the upper evaporator cover to the HVAC case (torque 2 Nm).
  4. Install the screws (x9) that attach the lower evaporator cover to the HVAC case (torque 2 Nm).
  5. Install the screws (x2) that attach the HVAC evaporator inlet pipes to the HVAC case (torque 2 Nm),
  6. Install the foam seal onto the HVAC case.
    Informational PurposesAn informational icon, calling your attention
    Note
    Reuse the original foam seal if it is not damaged.
  7. Position the HVAC assembly back into the vehicle for installation./
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    Note
    Move all loose harness connections out of the way to prevent damage while re-installing the HVAC assembly in the vehicle.
  8. Route the PTC heater to the HVAC assembly for installation and slide it into the HVAC assembly.
  9. Install the screws (x3) that attach the PTC heater to the HVAC assembly (torque 1 Nm).
  10. Position the HVAC assembly cross brace for installation to the HVAC assembly.
  11. Install the screws (x2) that attach the HVAC assembly cross brace to the HVAC assembly (torque 1 Nm).
  12. Position the HVAC assembly RH lower air duct for installation.
  13. Install the screws (x2) that attach the RH lower air duct to the HVAC assembly (torque 1 Nm).
  14. Connect the sensor connector for the RH lower air duct on the HVAC assembly.
  15. Move the HVAC assembly into position for installation and connect the drain hose.
  16. Install the nuts (x5) and bolts (x2) that attach the HVAC assembly to the body (torque 6 Nm).
  17. Connect HVAC blower assembly and RKE connectors, and attach the harness edge clips (x2).
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    Note
    2x connectors, 2x edge clips
  18. Connect thermal controller connectors (x4) and install the edge clip.
  19. Install the bolts (x2) that attach the A/C Lines with TXV to the evaporator at the bulkhead (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings prior to installation and lubricate them with ND-11 oil.
  20. Perform a system vacuum test, and then recharge the refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  21. Put the air suspension reservoir into position.
  22. Loosely install the screws (x2) that attach the air suspension reservoir brackets.
  23. Torque the air suspension reservoir brackets to 2.5 Nm.
  24. Install the bolts that attach the LH shock tower brace and torque the bolts as illustrated.
    Figure 1. Torque 2x bolts at 20 Nm
    Figure 2. Torque 1x bolt at 30 Nm
  25. Install the RH shock tower brace and torque the bolts as illustrated.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 20 Nm, 1x bolt, 13mm, 20 Nm
    Figure 3. Torque 2x bolts at 20 Nm
    Figure 4. Torque 1x bolt at 20 Nm
  26. Install the air suspension reservoir bracket mounting bolts (x2) to the RH shock brace (torque 6 Nm).
  27. Install the bolt that attaches the A/C line bracket bolt to the RH shock brace (torque 6 Nm).
  28. Install the bolt that attaches the wiper motor to LH shock brace (torque 6 Nm).
  29. Install the bolts (x2) that attach the air suspension reservoir bracket to the LH shock brace (torque 6 Nm).
  30. Install the wire harness fir tree clip to LH shock brace.
  31. Position the fuse box into the vehicle and reconnect the harness connectors (x3)
  32. Slide the fuse box onto the body to attach the tabs (x2) into the crossbar.
  33. Install the bolts that attach the fuse box to the body (torque 6 Nm).
  34. Reconnect the pyrotechnic fuse connector.
  35. Attach the clips (x3) that hold the 12V battery supply cable to the fuse box and strut tower beam.
  36. Install a new nyloc nut that attaches the 12V supply cable to DCDC (torque 12 Nm).
  37. Install the fuse box cover.
  38. Connect the wiper motor connector, and then install the bolts (x3) that attach the wiper motor (torque 6 Nm).
  39. Install the cowl screen panel.
  40. Install the LH and RH shock tower covers.
  41. Install the nuts (x2) that attach the wiper arms (torque 31 Nm).
  42. Install the cross car beam. See Cross Car Beam (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Be cautious when installing the cross car beam, the brake switch is attached to the cross car beam and is susceptible to failure. Take care not to damage any surrounding components while placing the cross car beam into the vehicle.
  43. Connect headliner harness connectors (x3) at the LH A-pillar, and then attach the clip.
  44. Connect the cross car beam harness connectors at the LH lower A-pillar.
    Informational PurposesAn informational icon, calling your attention
    Note
    7x connectors: 2x coaxial brown and white at tuner, 2x coaxial blue, 1x coaxial purple, 2x connectors gray. Connectors at the tuner are routed through the amp and tuner bracket.
  45. Connect cross car beam harness to main harness connectors (x7) at the RH lower A-pillar.
  46. Install IP carrier into vehicle. See IP Carrier (Remove and Replace).
  47. Install the steering column. See Steering Column (Remove and Replace).
  48. Install the LH footwell cover. See Assembly - Cover - Footwell - Driver's (Remove and Replace).
  49. Install the steering column control module. See Module - Steering Column Control (Remove and Replace).
  50. Install the steering wheel. See Steering Wheel (Remove and Replace).
  51. Install the driver's airbag. See Air Bag - Driver's (Remove and Replace).
  52. Install the instrument cluster. See Instrument Cluster (Remove and Replace).
  53. Install the MCU. See Media Control Unit (Remove and Install).
  54. Install RH IP finisher assembly. See Assembly - Finisher - Instrument Panel - RH (Remove and Replace).
  55. Install LH inner IP finisher assembly. See Face Level Vent - Driver's - Inner (Remove and Replace).
  56. Install LH outer IP finisher. See Assembly - Finisher - Instrument Panel - LH (Remove and Replace).
  57. Install the screw (x4) that attach the IC bezel to the IP carrier (torque 2 Nm).
  58. Install the clips that attach the steering column gap hider to IC bezel.
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    Note
    Replace any damaged or missing clips prior to installation.
  59. Install LH lower dash trim. See Trim - Dash - Driver's Side - Lower (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2 Nm, 9x clips. Replace any damaged or missing clips prior to installation
  60. Install the defrost mesh grille assembly. See Assembly - Mesh Grille - Defrost (Remove and Replace).
  61. Install the IP top pad assembly. See Assembly - Top Pad - Instrument Panel (Remove and Install).
  62. Install the passenger airbag connectors.
  63. Install the bolts (x2) that attach the passenger airbag (torque 10 Nm)
  64. Install the center console. See Center Console Assembly (Remove and Replace).
  65. Install RH footwell cover. See Assembly - Cover - Footwell - Passenger's (Remove and Replace).
  66. Connect 12V power. See Disconnect 12V Power.
  67. Install the front HVAC filter housing.
  68. Install the bolts (x2) that attach the front HVAC filter housing (torque 1.5 Nm).
  69. Move LH front seat to original position
  70. Install the LH and RH A-pillar trim. See Trim - A-Pillar - LH (Remove and Install).
  71. Install the RH IP side cover.
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    Note
    3x clips, 1x connector.
  72. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  73. Install the underhood aprons.
  74. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
  75. Install LH IP side cover.
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    Note
    4x clips, 1x connector
  76. Exit Service Mode.
  77. Verify proper operation of the air conditioning.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure air conditioning blows cold.