Evaporator Core: Service and Repair

EVAPORATOR UNIT ON-VEHICLE INSPECTION
1. Check quantity of refrigerant gas during refrigeration cycle.
2. Install manifold gauge set.
3. Run the engine at 2,000 rpm at least 5 minutes.
4. Read the manifold gauge and check the gas leakage from the evaporator by using gas leak detector.
1) If the expansion valve is clogged low pressure, reading will drop to 0 kg/cm2, otherwise it is okay.
2) If the expansion valve is clogged or gas leak from the evaporator, then repair or replace as necessary.

REMOVAL AND INSTALLATION

NOTE:
Plug all of the open fittings immediately after removal in order to keep moisture out of the air conditioning system.

1. Disconnect battery negative terminal.






2. Discharge refrigerant from the air conditioning system.
3. Disconnect fittings connected to the evaporator unit from the engine compartment.






4. Remove the main crash pad assembly.






5. Remove the glove box support bracket.






6. Disconnect the thermostatic switch connector.






7. Remove the evaporator upper and lower mounting bolts.






8. Remove the evaporator unit.

EVAPORATOR UNIT
9. Installation is the reverse order of removal.

NOTE:
1. While installing each of removed fitting, replace 0-ring (if exists) and apply specified lubricant.
2. Be careful not to bend or twist refrigerant lines in order to install them easily.
3. After installation, evacuate, charge and teat the air conditioning system.