Evaporator Core: Service and Repair

Evaporator - LHD

Removal

NOTE: The removal of this component involves cutting an aperture in the evaporator housing wall and cutting through the high and low pressure A/C lines. A service repair kit is supplied to cover this procedure.

1. Disconnect the battery ground cable.
2. Recover the A/C refrigerant.
3. Remove the plenum chamber panel.
4. If installed, remove the anti-theft alarm horn with integral battery.





CAUTION: Make sure that all openings are sealed. Use new blanking caps.

5. Disconnect the A/C pipes from the TXV.









7. Remove the RH floor console extension.





8. Remove the glove compartment.





















14. Remove the CJB bracket.





15. Remove the 3 spring clips.
Release the 4 plastic clips.





16. Remove the lower cover.
Position the upper cover aside for access.





17. Cut the A/C pipes at the marked position.









19. Guide the cut evaporator pipes through the bulkhead so that approximately 20 mm is visible in the engine compartment.





20. Remove the evaporator pipes.













23. Remove the evaporator core.





24. Remove any debris from the heater core and evaporator core housing.

Installation
1. Apply the foam strips from the service kit to the evaporator core.





2. Install the evaporator core.
3. Install the service door.
Secure the 4 clips.
Install the 4 screws.





4. Install the pollen filter cover.
5. Apply the asphalt tape from the service kit to the service replacement evaporator pipes.





CAUTION: Make sure that all openings are sealed. Use new blanking caps.

6. Remove the TXV assembly from the service replacement evaporator pipes.
7. Guide the service replacement evaporator pipes through the bulkhead so that approximately 20 mm is visible in the engine compartment.
8. Install the TXV captive clamping plate.

NOTE: Install new O-ring seals.

9. Install the service replacement evaporator pipes to the evaporator.

Torque: 5 Nm





10. Install the CJB bracket.

Torque: 10 Nm

11. Secure the wiring harnesses to the CJB bracket.
12. Install the CJB.
13. Connect the 5 electrical connectors to the CJB and secure the front carpet.
14. Install the CJB lower access cover.
15. Install the passenger side footwell duct.
16. Install the glove compartment.
17. Install the RH floor console extension.

NOTE: Install new O-ring seals.

18. Install the TXV assembly.

Torque: 4 Nm

NOTE: Install new O-ring seals.

19. Connect the A/C pipes to the TXV and tighten the M6 nut.

Torque: 9 Nm

20. Install the anti-theft alarm horn with integral battery.
21. Install the plenum chamber panel.
22. Recharge the A/C system.
23. Connect the battery ground cable.