Before You Begin:
* Safety First: Wear safety glasses and gloves. Refrigerant is harmful if inhaled or comes into contact with skin. Have the system professionally evacuated and recharged – DO NOT attempt this yourself unless you have proper certification and equipment.
* Gather Tools and Materials: You'll need various tools, including screwdrivers (Phillips and flathead), sockets, wrenches, pliers, a shop rag, a vacuum pump (for the AC system), refrigerant, and possibly a special AC service manifold gauge set. Also, acquire a new evaporator core specifically for your 1997 Chevy Tahoe. You'll likely need a repair manual for your specific model.
* Disconnect the Battery: This is crucial to prevent electrical shorts.
General Steps (This is a simplified version and might not cover every detail):
1. Drain the Cooling System: This is essential to prevent coolant from spilling during the process.
2. Access the Evaporator Core: This usually involves removing the dashboard or significant portions of it. This is the most labor-intensive part of the job. You'll likely need to remove the glove box, various trim pieces, and possibly parts of the dashboard itself. Your repair manual is absolutely critical here.
3. Disconnect the AC Components: Carefully disconnect the AC hoses, electrical connectors, and any other components connected to the evaporator core. Remember where everything goes! Take pictures or make detailed notes.
4. Remove the Evaporator Core: Once access is gained, carefully remove the evaporator core. This might involve removing mounting brackets or other components. Be gentle to avoid damaging surrounding parts.
5. Install the New Evaporator Core: Carefully install the new evaporator core, ensuring it's properly seated and all connections are secure.
6. Reconnect the AC Components: Reconnect all the AC hoses, electrical connectors, and other components, referencing your notes or pictures.
7. Reassemble the Dashboard: Carefully reinstall all the removed dashboard parts, trim pieces, and the glove box.
8. Refill and Test the System: This is critical and should be done by a professional. A technician will evacuate the system, check for leaks, and recharge it with the correct amount of refrigerant. Driving the vehicle and testing the AC system thoroughly is necessary.
Important Considerations:
* Complexity: Replacing an evaporator core is a very involved job, often requiring specialized tools and knowledge of automotive AC systems.
* Professional Help: If you're not comfortable with automotive repair, it's strongly recommended to take your Tahoe to a qualified mechanic specializing in AC repair. The cost of a professional repair is likely less than the potential cost of damaging other components during a DIY attempt.
* Repair Manual: A repair manual specific to your 1997 Chevy Tahoe is indispensable. It will provide detailed instructions, diagrams, and torque specifications.
This information is for general guidance only. Always refer to your vehicle's repair manual for precise instructions and safety precautions. Attempting this repair without the proper knowledge and tools can lead to significant damage and expense. A professional mechanic is the safest and often most cost-effective route for this type of repair.
