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First as you can see, the dash has to be completely removed.~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Remove the instrument panel and lay it on the front seat.
Discharge refrigerant from A/C system.
Remove the high and low pressure hoses and cap the openings to prevent dirt and moisture from entering.
Disconnect the liquid line and accumulator/drier inlet tube from the evaporator core at the dash panel and cap the lines.
Remove suction accumulator/drier and bracket. If necessary, remove throttle cable bracket and position out of way.
Disconnect heater hoses from heater core. Plug hoses and cap heater core tubes to prevent coolant loss during removal of evaporator case.
Disconnect vacuum supply hose (black) from the inline vacuum check valve in the engine compartment.
Working under the hood, remove three nuts retaining the evaporator case to the dash panel.
In the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel.
Remove one nut retaining the bracket below the evaporator case to the dash panel.
Carefully pull the evaporator case away from the dash panel and remove assembly from vehicle.
Remove three screws and pull air inlet duct away from evaporator case.
With a small saw, cut the top of the evaporator case between the dotted lines and make sure all burrs are removed from cut edges.
Remove evaporator core from the case.
Hold the cover against the case firmly and drill five 11/16 in. (5mm) diameter holes for the retaining screws.
When working on a evaporator core, it is necessary to replace the suction/accumulator drier. Before replacing the evaporator core, it must be leak tested in the vehicle to verify that it is leaking.
Remove the evaporator housing. Refer to the procedure earlier in this section.
Separate the heater core from the A/C evaporator housing.
Remove the A/C recirculating air duct.
Remove the vacuum hose harness from its mounting points on the evaporator housing.
Remove the heater air damper door vacuum control motor.
Remove the heater blower motor resistor.
Remove the blower motor.
Remove the heater outlet floor duct.
Remove the A/C evaporator drain tube seal from the housing.
Attach the A/C evaporator drain tube seal to the core housing.
Install the heater outlet floor duct.
Install the blower motor and fan cage assembly.
Attach the heater blower motor resistor.
Install the heater air damper door vacuum control motor.
Place the vacuum hose harness, and attach to the mounting points on the evaporator housing.
Install the A/C recirculating air duct.
Install the heater core to the A/C evaporator housing.
Reinstall the evaporator housing assembly in the vehicle.
Evacuate, charge and leak test the system. See Routine Maintenance.
Check the operation of the system.