Evaporator Core: Service and Repair

Evaporator Core Replacement

1. Recover the refrigerant with a recovery/recycling/charging station A/C Refrigerant Recovery.

2. Remove the bolt (A).






3. Remove the nut, then disconnect the A/C lines (A), and remove the O-rings (B) from the evaporator core.






4. Remove the stud bolt (A).





5. Remove the blower unit Blower Unit Removal/Installation.

6. Disconnect the connectors (A) from the evaporator temperature sensor and the power transistor, then remove the connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seal (D).






7. Carefully pull out the evaporator core (A) without bending the lines, then remove the plate (B).






8. Remove the clip (A) and the evaporator temperature sensor (B).

NOTE: The evaporator temperature sensor is installed in the fin at the 7th fin from the left side by the factory preset.






9. When the evaporator temperature sensor is reinstalled, set the evaporator temperature sensor in the eight fin from the left side (one fin over from the previous position).





10. Install the core in the reverse order of removal and note these items:

- If you're installing a new evaporator core, add the appropriate amount of refrigerant oil (SP-10) Service and Repair.
- Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage.
- Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption.
- Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
- Make sure that there is no air leakage.
- Charge the system A/C System Charging.