Evaporator Core: Service and Repair

EVAPORATOR-A/C

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only model similar.

REMOVAL

NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service of the A/C evaporator.




1. Remove the HVAC housing assembly and place it on a workbench .
2. Remove the air distribution housing (2) from the HVAC housing (1).
3. Remove the air inlet housing (3) from the HVAC housing.

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.




4. Remove the foam seal (1) from the flange (2) located on the upper half of the HVAC housing (4).
5. Remove the two screws (3) that secure the flange to the HVAC housing and remove the flange.

NOTE: If the foam insulator for the A/C evaporator or its tubes is deformed or damaged, it must be replaced.

6. Carefully lift the A/C evaporator and tubes (7) out of the lower half of the HVAC housing (6).

INSTALLATION

NOTE:
- If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system.
- If the foam insulator for the A/C evaporator or its tubes is deformed or damaged, it must be replaced.




1. Install the A/C evaporator and tubes (7) into the lower half of the HVAC housing (6). Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulators around the A/C evaporator and its tubes are properly installed.
2. Install the flange (2) to the upper half of the HVAC housing (4).
3. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.




4. Install the foam seal (1) onto the flange.
5. Install the air inlet housing (3) onto the HVAC housing (1).
6. Install the air distribution housing (2) onto the HVAC housing.
7. Install the HVAC housing assembly.