Evaporator Core: Service and Repair

Evaporator, Replacing

Removal

Evaporator

Remove the dashboard.

The climate control unit.

Remove:







- the inner and outer seals for the pipe lead-ins.

Remove:







- the retaining clip and pipe from the heat exchanger.

Remove:







- the sensor.

Remove:







- the 4 screws for the air cleaner (ACL) and cover.

Remove:







- the 3 screws for the central electrical unit.

Fold out the central electrical unit. Remove the seal

Remove:







- the blower fan motor cover, (1 screw)
- the blower fan motor (4 screws).

Remove:







- the screw for the bracket for the recirculation motor.

Loosen:
- the catches for the divisions of the upper and lower sections using a screwdriver and pipe wrench as illustrated. Start at one end.







- Lift off the lower section
- Lift out the evaporator.

Remove:







- the expansion valve, (2 screws)
- the expansion valve block
- the seal.

Installation

Evaporator

Install:

- NOTE: Use new O-rings lubricated with compressor oil.

- O rings on the evaporator pipe
- the expansion valve.
- Position the evaporator in the upper fan housing
- Check that the seal sits in the correct groove at the expansion valve
- Install the lower fan housing. Press so that the mounting lugs are in line with the upper half
- Ensure that the mounting lugs line up
- Check that the seal sits in the correct groove at the expansion valve
- Press the upper fan housing into the lower
- Check that the upper fan housing is secured to the lower
- Install new retaining clips around the fan housing to ensure a good seal.

Install:
- the central electrical unit seal
- the central electrical unit. Screw it into place
- the air cleaner (ACL) and cover
- new inner and outer seals for the pipe lead-ins around the heat exchanger-refrigerant pipes.

Install:
- the climate control unit.
- the dashboard in the car.