Evaporator Core: Service and Repair

Evaporator

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Drain refrigerant from the A/C system. Refrigerant, Draining

Remove:
- the heat exchanger. Service and Repair
- the steering shaft. Service and Repair
- the brake pedal. Pedal Box, Brake




Lift up both air conditioning (A/C) pipes from their mountings below the right-hand spring strut turret.
Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.
Pull the pipes away from the evaporator connection.

Removal

Removing the evaporator
The evaporator has pipes that are integrated in the factory. These pipes must be cut in order to remove the unit. The evaporator in the service kit has separate pipes, however.





Remove:
- the 2 screws and remove the right-hand half of the lead-in. See the illustration
- the section that holds the heat exchanger and evaporator pipes apart.




Cut off the evaporator pipes.
Pull and press out the pipes through the seal. See the illustration.




Remove the 3 screws. Remove the cover.
Pull out the evaporator. Pull alternately at the top and bottom edges. It may be hard to remove.

Note! Note how the seal is located on the evaporator.

Installation

Note! For tightening torques, see Specifications. [1][2]Body and Frame

Installing the evaporator
Install a new seal, using the removed evaporator as a template.




Install the evaporator far enough that the cover can be installed (approximately 3-4 mm inside the opening).
Position the front edge of the cover between the evaporator and the heater unit.
Tighten the 3 screws.
Install the loose pipe section between the evaporator and the connection in the engine compartment. Start by inserting it through the lead-in seal. Then connect the block mounting to the evaporator using 2 M5 screws. Tighten. See: Tightening torque [1][2]Body and Frame.





Note! Pull the insulation for the pipes as far in towards the evaporator as possible before installing the spacer and the right-hand half of the lead-in.

Install:
- the spacer that holds the heat exchanger and evaporator pipes apart
- the right-hand half of the lead-in using the 2 screws.

Installing components

Install:
- the M8 screw securing the air conditioning (A/C) pipes in the engine compartment. See: Tightening torque [1][2]Body and Frame
- the heat exchanger. Service and Repair
- the brake pedal. Pedal Box, Brake
- the steering shaft. Service and Repair


Finishing

Checking the function and leak tracing
Vacuum pump the air conditioning (A/C) system. Vacuum Pumping.
Fill the air conditioning (A/C) system with refrigerant. Refrigerant, Filling
Leak trace the air conditioning (A/C) system.
- Leak detection, tracer agent Leak Detection, Tracer Agent
- Leak tracing, electronic leak tracer Leak Tracing, Electronic Leak Tracer