Evaporator Core: Service and Repair

A/C Evaporator Removal and Installation

Reference: Heater and Cooling Unit Components:Manual Type

CAUTION: Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers.

Removal
1. Disconnect negative (-) cable at battery.
2. Recover refrigerant from A/C system.

NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil.

3. Remove blower unit.




4. Disconnect suction pipe (1) and condenser outlet pipe (2) using special tools.

Special Tool
(A): 09991-15410 (For condenser outlet pipe)
(B): 09991-15420 (For suction pipe)

CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.

5. Fully remove packing from expansion valve.




6. Remove expansion valve pipe (1) from expansion valve (2).

CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.

7. Remove expansion valve (2) from evaporator.




8. Disconnect A/C evaporator inlet and outlet air temperature sensor couplers (1).
9. Remove A/C evaporator outlet air temperature sensor (2).
10. Remove air joint duct (3).
11. Pull out A/C evaporator from heater and cooling unit (4).

Installation
Reference: A/C Evaporator Inspection:Manual Type
Reference: A/C Evaporator Inlet and Outlet Air Temperature Sensors Inspection:Manual Type

Reverse removal procedure to install A/C evaporator noting the following instructions.
- Replenish specified amount of compressor oil to compressor suction side.
- Evacuate and charge refrigerant.
- Stick packing to expansion valve and expansion valve pipe after installation.
- Sufficiently apply compressor oil to fitting surface of O-ring and pipe.