Evaporator Core: Service and Repair

Evaporator

Removal

Note: LHD model shown. RHD model similar.






1. Remove the HVAC housing assembly. HVAC Housing - Removal and Installation
2. Disassemble the HVAC housing as necessary to access the A/C evaporator (1). HVAC Housing
3. Carefully life the A/C evaporator and the foam seal (2) out of the lower half of the HVAC housing (3).
4. If required, remove the foam seal from the tapping block of the A/C evaporator. If the seal is deformed or damaged, it must be replaced.

Installation

Caution: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

Note: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system.

Note: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

Note: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

Note: LHD model show. RHD model similar.






1. If removed, install the foam seal (2) over the tapping block of the A/C evaporator (1). If the seal is deformed or damaged, it must be replaced.
2. Install the A/C evaporator into the lower half of the HVAC housing (3). Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and the the insulator around the A/C evaporator is properly installed.
3. Assemble the HVAC housing. HVAC Housing
4. Install the HVAC housing assembly. HVAC Housing - Removal and Installation
5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the rerfrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.