Evaporator Core: Service and Repair

Sedan/Hatchback:

REMOVAL OF COOLING UNIT
1. Disconnect the negative cable from the battery.
2. Recover the refrigerant from the system.
3. Disconnect the suction tube from the cooling unit outlet fitting.
4. Disconnect the liquid tube from the cooling unit inlet fitting.

NOTE: Cap the open fittings immediately to keep moisture out of the system.

5. Remove grommets from inlet and outlet fittings.
6. Remove glove box.
7. Disconnect electrical connectors.
8. Remove three screws and three nuts.
9. Remove cooling unit.

DISASSEMBLY OF COOLING UNIT
1. Disconnect connectors from amplifier and thermistor.
2. Remove wire harness.
3. Remove amplifier.
4. Remove three clips.
5. Remove three screws.
6. Remove upper unit case.
7. Remove thermistor with thermistor holder.
8. Remove lower unit case.

REMOVAL OF EXPANSION VALVE
1. Disconnect the liquid tube from the inlet fitting of the expansion valve.
2. Remove the packing and heat sensing tube from the suction tube of the evaporator.
3. Remove expansion valve.

INSPECTION OF EVAPORATOR
1. Check the evaporator fins for blockage.If the fins are clogged, clean them with compressed air.

CAUTION: Never use water to clean the evaporator.

2. Check fittings for cracks or scratches.

ASSEMBLY OF COOLING UNIT
1. Connect the expansion valve to the inlet fitting of the evaporator. Torque the nut.

Torque: 22Nm (16 ft-lb)

NOTE: Be sure that the 0-rings are positioned on the tube fitting.

2. Install the holder to the suction tube with heat sensitizing tube.
3. Connect the liquid tube to the inlet fitting of the expansion valve. Torque the nut.

Torque: 13 Nm (10 ft-lb)

4. Install lower unit case to the evaporator.
5. Install thermistor to the evaporator.
6. Install upper unit case.
7. Install three screws.
8. Install three clips
9. Install amplifier.
10. Install wire harness.
11. Connect connectors to amplifier and thermistor.

INSTALLATION OF COOLING UNIT
1. Install the cooling unit with three screws and three nuts.
2. Connect connectors.
3. Install glove box.
4. Install grommets on inlet and outlet fittings.
5. Connect liquid tube to cooling unit inlet fittings.Torque the nut.

Torque: 13 Nm (10 ft-lb)

6. Connect suction tube to cooling unit outlet fitting. Torque the nut.

Torque: 32 Nm (24 ft-lb)

7. If evaporator was replaced, add compressor oil to the compressor.

Add: 40-50 cc (1.4-1.7 fl.oz.)

8. Connect the negative cable to the battery.
9. Evacuate the air conditioning system.
10. Charge air conditioning system with refrigerant and check for leaks.

Specified amount: 600-750 g (1.3-1.7 lb)