For 1990-2009 cars

## Air Conditioning Evaporator Core Replacement RHD

### Removal Procedure

Caution: Refer to Safety Glasses Caution in the Preface section.

1. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
2. With the HVAC module assembly on a bench locate the thermal expansion (TX) valve retaining upper plastic cover (1).

Important: Unclip the TX valve retaining upper plastic cover (1) and remove by lifting upwards.

3. Remove the TX valve retaining upper plastic cover (1).
4. Remove the air inlet assembly to HVAC module assembly retaining screws (1).
5. Remove the air inlet assembly to HVAC module assembly retaining screws (1).

Important: Unclip the air inlet assembly (3) and carefully tilt downwards past the TX valve (2)

6. Remove the air inlet assembly (3) from the HVAC module assembly (1).

Important: Gently grasp the evaporator (1) pipes and slowly withdraw the evaporator from the HVAC module assembly (2).

7. Remove the evaporator (1) from the HVAC module assembly (2).
8. While the evaporator (1) is out of the HVAC module assembly (2), remove any contaminates from the housing such as hair, leaves or dust with a moist rag.

### Installation Procedure

Important: Install the evaporator core (1) by gently sliding into HVAC module assembly housing (2).

1. Install the evaporator core (1) to the HVAC module assembly housing (2).
2. Install the air inlet assembly (2) to the HVAC module assembly (1).

Notice: Refer to Fastener Notice in the Preface section.

3. Install the air inlet assembly to HVAC module assembly retaining screws (1).

Tighten
Tighten the screws to 1 N·m (8 lb in.)

4. Install the air inlet assembly to HVAC module assembly retaining screws (1).

Tighten
Tighten the screws to 1 N·m (8 lb in.)

Important: Make sure all the clips on the thermal expansion (TX) valve retaining upper plastic cover (1) are engaged to avoid an induced rattle condition.

5. Install the TX valve retaining upper plastic cover (1).
6. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement.