Before You Begin:
* Consult a repair manual: A Haynes or Chilton manual specific to your 1996 Chevy truck is crucial. It will provide detailed instructions, diagrams, torque specifications, and other critical information.
* Gather tools: You'll need a variety of tools including sockets, wrenches, screwdrivers, pliers, a refrigerant recovery system (mandatory to protect the environment), a vacuum pump, a manifold gauge set, possibly a special evaporator core removal tool, and possibly a sealant for the connections.
* Disconnect the battery: This is essential for safety.
* Protect yourself: Wear safety glasses, gloves, and appropriate clothing.
* Prepare the area: Work in a clean, well-ventilated area.
General Steps (Highly Simplified and May Vary):
1. Recover refrigerant: Use a refrigerant recovery system to safely remove the refrigerant from the A/C system. This is absolutely critical. Releasing refrigerant into the atmosphere is illegal and harmful to the environment.
2. Access the evaporator core: This usually involves removing a significant portion of the dashboard. This is often the most time-consuming and challenging part of the job. You may need to disconnect various components like the heater core, blower motor, and other parts of the HVAC system. Your repair manual will be your guide here.
3. Disconnect the evaporator core: Disconnect the refrigerant lines carefully. Note their positions for reassembly. You may need to use special tools to disconnect the lines and prevent damage.
4. Remove the evaporator core: This often involves removing mounting brackets and carefully maneuvering the core out of its housing. Again, your repair manual will be crucial.
5. Install the new evaporator core: Carefully install the new evaporator core, ensuring it's properly seated and secured.
6. Reconnect the refrigerant lines: Reconnect all the refrigerant lines, paying close attention to their correct orientation. Use new O-rings where necessary.
7. Reassemble the dashboard and HVAC components: Carefully reassemble the dashboard and all other components you removed, following the reverse order of disassembly.
8. Evacuate and recharge the system: Use a vacuum pump to evacuate the system, removing any air and moisture. Then, charge the system with the correct amount of refrigerant using a manifold gauge set. Consult your repair manual for the correct amount and type of refrigerant.
Important Considerations:
* Complexity: This is a complex repair. The amount of disassembly required can vary significantly depending on your truck's model and trim level.
* Potential for Damage: There's a high risk of damaging other components during disassembly and reassembly.
* Safety: Improper handling of refrigerant can be dangerous and illegal.
Strongly Recommended: If you lack significant automotive repair experience, take your truck to a qualified mechanic. The cost of a professional repair will likely be less than the cost of the parts and your time, especially if you damage something in the process. The risk of improperly recharging the system and damaging the compressor is substantial.
