Evaporator Core: Service and Repair

Removal and Installation

- Disconnect the battery earth lead.
- Remove the console assembly.
- Remove the fascia board.
- Drain the engine coolant into a suitable container.
- Depressurize the air conditioning system.
- Remove the expansion valve.
- Remove the air conditioning unit assembly.
- Remove the heater pipe guide plate securing screws and remove the guide plate.
- Remove the screws securing evaporator sensor and withdraw the sensor from evaporator.
- Remove the screws securing the solenoid mounting plate and displace mounting plates from unit.
- Remove harness to casing earth bolt and displace the harness.
- Cut and remove harness to casing securing ratchet straps and displace the harness from casing.
- Displace vacuum hose from casing.
- Displace and remove casing securing clips.
- Split casing and remove evaporator from unit.
- Remove expansion valve guide plate securing screws and remove plate.
- Displace and remove plate from evaporator.

- Fitting the new evaporator is the reversal of the removal procedure.
- Refill the engine cooling system with coolant.
- Recharge the air conditioning system.