RHD

Evaporator
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

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.

All vehicles
1 Make the SRS system safe.
For additional information, refer to Standard Workshop Practices Standard Workshop Practices
2 Recover the A/C refrigerant.
For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair
3 Remove the steering column.
For additional information, refer to Steering Column Service and Repair




4 Remove the driver lower air bag module support bracket.

Vehicles with manual transmission
5 Remove the clutch pedal assembly.
For additional information, refer to Clutch Pedal - RHD

Vehicles with automatic transmission
6 Remove the secondary bulkhead center panel.
For additional information, refer to Secondary Bulkhead Center Panel - 2.2L Diesel

All vehicles
7 Remove the accelerator pedal assembly.
For additional information, refer to Accelerator Pedal Service and Repair

Vehicles with manual transmission








8 Remove the brake pedal assembly.

Vehicles with automatic transmission








9 Remove the brake pedal assembly.

All vehicles





10 Remove the RH floor console extension.





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

11 Disconnect the A/C pipes from the TXV.









12 Disconnect the blower motor electrical connector.




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





13 Carefully ease apart and break the plastic pipe covers.





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

15 Remove the remainder of the plastic
pipe covers.





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





17 Remove the evaporator pipes.









18 Remove the evaporator core.

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

Installation
All vehicles




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




3 Cut a slot in each side of the service door to accommodate the heater core and evaporator core housing.




Install the service door.
Secure the 4 clips.
Install the 4 screws.




4 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.
5 Remove the TXV assembly from the service replacement evaporator pipes.
6 Guide the service replacement evaporator pipes through the bulkhead so that approximately 20mm is visible in the engine compartment.
7 Install the TXV captive clamping plate.





NOTE:
Install new O-ring seals.
8 Install the service replacement evaporator pipes to the evaporator.
Torque to: 5 Nm
9 Connect the blower motor electrical connector.

NOTE:
Install new O-ring seals.

10 Install the TXV assembly.
Torque to: 4 Nm

NOTE:
Install new O-ring seals.

11 Connect the A/C pipes to the TXV and tighten the M6 nut.
Torque to: 9 Nm

12 Install the RH floor console extension.

13 Install the brake pedal assembly.
Torque to: 25 Nm

14 Install the brake pedal clevis pin.

15 Connect the stoplamp switch and speed control deactivator switch electrical connectors.

16 Secure the wiring harness to the brake pedal bracket.

17 Install the accelerator pedal assembly.
For additional information, refer to Accelerator Pedal Service and Repair

Vehicles with automatic transmission

18 Install the secondary bulkhead center panel.
For additional information, refer to Secondary Bulkhead Center Panel - 2.2L Diesel

Vehicles with manual transmission

19 Install the clutch pedal assembly.
For additional information, refer to Clutch Pedal - RHD

All vehicles

20 Install the driver lower air bag module support bracket.
Torque to: 7 Nm

21 Install the steering column.
For additional information, refer to Steering Column Service and Repair

22 Recharge the A/C system.
For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Service and Repair

23 Connect the battery ground cable.
For additional information, refer to Specifications Vehicle Jump Starting