Evaporator Core: Service and Repair

Evaporator

REMOVAL

1. Disconnect the ground cable from battery.
2. Using the refrigerant recovery system, discharge refrigerant.
3. Remove the intake boot.

CAUTION: Move aside the intake boot to perform the operation without disconnecting the PCV hose.

4. Remove the expansion valve - cooling.
1. Remove the bolt, and detach the hose - pressure suction and the pipe - evaporator cooling.






2. Remove the bolt, and remove the expansion valve - cooling.

PREPARATION TOOL:
Hexagon wrench: 4 mm (0.16 in)







5. Remove the glove box.
6. Remove the engine control module (ECM).
1. Release the lock and remove the relay holder.
2. Remove the harness clip, and disconnect the connector.






3. Remove the nuts (a).
4. Loosen the nut (b), and remove the engine control module (ECM).






7. Remove the blower motor unit assembly.
1. Release the claws, and then remove the grille assembly - ventilation RH.
2. Disconnect the blower motor relay and each connector.






3. Remove the bolts and nuts to remove blower motor unit assembly.

NOTE: Remove the RH upper nut from the mounting portion of the grille assembly - ventilation RH.






8. Remove the evaporator assembly - cooling.
1. Disconnect the connector and lock of the thermostat - cooling.
2. Remove the screws and detach the cover.






3. Remove the cover - heater unit.
a. Disconnect the connector for the power transistor or resistor.
b. Remove the screws and clips to remove the cover - heater unit.






4. Remove the bolt, and detach the pipe - evaporator core.


PREPARATION TOOL:
Hexagon wrench: 4 mm (0.16 in)






5. Pull out the evaporator assembly - cooling from the case - heater unit.






6. Remove the thermostat - cooling from the evaporator assembly - cooling.







INSTALLATION

CAUTION:
- If the evaporator assembly - cooling has been replaced, add an appropriate amount of compressor oil to the evaporator assembly - cooling.
- When the evaporator assembly - cooling has been replaced, replace the packing of the expansion valve - cooling with a new one, and then apply compressor oil.
- Make sure that the water seal packing on the cover attachment area is securely attached.
- Replace the O-rings with new parts, and then apply compressor oil.
- After installing the grille assembly - ventilation RH, check that the air vent grille of the grille assembly - ventilation RH is inserted correctly into the air vent duct.

1. Install the thermostat - cooling to the specified position.
2. Install each part in the reverse order of removal.


Blower motor unit:
Tightening torque:
T: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
Engine control module (ECM):
Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

3. Charge refrigerant.