Evaporator Core: Service and Repair
Remove1. Disconnect battery negative lead.
2. Recovery refrigerant from air conditioning system. Refer to "Refrigerant Recovery, Recycling, Recharging". Service and Repair
3. Remove fascia duct bezel. Service and Repair
4. Remove 3 nuts securing evaporator casing to mounting bracket.
5. Disconnect drain tube from drain pipe on LH side of casing.
6. Position 2 heater hoses to side of air intake tube.
WARNING: Wear eye and hand protection when disconnecting components containing refrigerant.
7. Using a backing spanner, loosen union nut from evaporator return pipe and disconnect. Discard 'O' ring.
8. Using a backing spanner, loosen union nut from evaporator feed pipe and disconnect. Discard 'O' ring.
CAUTION: Plug the connections.
9. Ease 2 evaporator studs from their rubber bushes, release grommet from bulkhead, withdraw pipes from aperture and position evaporator unit on floor.
10. Remove screw securing harness 'P' clip to rear of casing.
11. Disconnect Lucar (B wire) from motor.
12. Disconnect Lucars (G, U, and R wires) from resistor unit.
13. Remove screw securing mounting bracket flange to casing.
14. Remove screws securing each end of blower flanges to upper casing.
15. Remove 6 screws securing upper to lower casing.
16. Remove tape sealing air duct inside casing.
17. Release tape sealing pipes to casing.
18. Cut through sealant along casing joint and gaskets.
19. Ease upper from lower casing and remove upper casing.
20. Lift evaporator unit from lower casing. Do not carry out further dismantling if component is removed for access only.
21. Using a backing spanner, loosen union nut from pipe and remove high pressure pipe. Discard 'O' ring.
22. Loosen clip and withdraw capillary tube coil from low pressure pipe and withdraw coil from pipe.
23. Loosen capillary tube union nut and disconnect from low pressure pipe.Discard 'O' ring.
24. Using a backing spanner, loosen union nut and remove expansion valve from pipe. Discard 'O' ring.
Refit
25. Lubricate NEW 'O' rings with refrigerant oil and fit to pipe ends.
26. Fit expansion valve to pipe, DO NOT tighten union nut.
27. Connect capillary tube and tighten union nut.
28. Position capillary tube coil on low pressure pipe and secure with clip.
29. Wrap capillary coil and union with prestite tape.
30. Connect high pressure pipe to expansion valve, carefully align with low pressure pipe and tighten union nut.
31. Tighten expansion valve union nut.
32. Position evaporator unit in lower casing, align bracket and engage blower flange screws, DO NOT tighten.
33. Position upper casing, engage lower casing flange and secure with screws. Ensure mounting bracket screw engages evaporator bracket.
34. Tighten blower flange screws.
35. Apply Silicone sealant to casing joint and insulating tape to seal pipes to casing.
36. Apply sealing tape around air duct joint.
37. Position evaporator unit in footwell.
38. Connect multiplugs to compressor relays and secure harness 'P' clip.
39. Connect Lucars (G, U, and R) to resistor unit and (B) to motor.
40. Lift evaporator, insert pipes into aperture and engage mounting studs.
41. Connect drain tube to pipe.
42. Fit grommet into aperture.
43. Lubricate NEW 'O' rings with refrigerant oil and fit to
44. Carry out a functional check. joints.
45. Using a backing spanner, engage high pressure pipe and tighten union nut.
46. Using a backing spanner, engage low pressure pipe and tighten union nut.
47. Fit nuts and secure evaporator casing to mounting bracket.
48. Fit fascia duct bezel.
49. Evacuate and recharge air conditioning system.
50. Reconnect battery negative lead.
51. Perform leak test on disturbed joints
52. Carry out system test. Refer to: Testing and Inspection.