on the passenger side ITS bolted 2 the firewall - behind the dash board.
The evaporator is enclosed in the vehicle air box which is part of the HVAC system. The HVAC system must be removed from the car to access the evaporator. This is a seriously difficult job for the novice and requires almost the complete removal of the dashboard and console plus disconnection of lines on the engine side of the firewall. The GM Service manual does not go into full detail regarding removal of the HVAC unit so you should find someone who can assist.
CAUTION: Some models are equipped with anti-theft-radio make sure you have the activation code before disconnecting battery * Have the AC system discharged * Disconnect negative battery cable * Working from the engine compartment side of the firewall,disconnect the air conditioning lines from the evaporator inlet and outlet pipes. * Inside the car,remove the dash * Remove the glove box supportbracket * Disconnect the thermostatic switch electrical connector and then diconnect the vacuum line between the door and the heater unit * Remove the upper and lower evaporator case mounting bolts * Remove the evaporator unit from the car * Remove the sponge pad which insulates the evaporator inlet and outlet pipes * Cut the foam that lines the opening on both sides of the evaporator case.Unclip the upper and lower evaporator cases and then separate the upper case from the lower case * Detach the thermostatic switch from the evaporator case and detach the thermistor mounting clip from the evaporator unit,and then remove the thermostatic switch and the thermistor as a single assembly * Remove the evaporator unit from the lower case and then remove the expansion valve assemby from the evaporator
From under the hood, recover the refrigerant and disconnect battery, remove the drier, two ac line connections to evaporator core, two heater hoses from heater core, vacuum line that goes to firewall and evaporator case nuts at firewall. From the inside of the car, remove center console, center the steering wheel, lock steering and remove steering column assembly. Remove pillar trim, kick panels, defrost trim, remove bolts along the top and sides of dash, disconnect any vacuum lines that go from the ac controls to the evaporator case, unplug any electrical connectors that prevent the right side of the dash from being swung over to allow access of the evaporator case. Use a tie down strap to secure the dash out of the way if needed while accessing the evaporator case. There is a picture of a Mustang with the dash removed at DenLorsTools.com in the Tech Artice How To section. Remove the evaporator case from the vehicle and replace the evaporator, put two ounces of refigerant oil directly into the replacement evaporator. Reverse removal procedures, evacuate and recharge system.
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