Evaporator Case: Service and Repair

Evaporator Case Assembly

Removal

NOTE: Evaporator case removal should only be required in unusual circumstances because all major components of the case assembly are serviceable without removing the case.

1. Disconnect the ground cable.

NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

2. Discharge the refrigerant system. Observe all safety precautions. Please refer to Heating and Air Conditioning/Srevice and Repair/
3. Disconnect the electrical hardshell connectors from the blower motor, the blower motor resistor and the pressure switch.
4. Disconnect the vacuum line from the check valve.
5. Disconnect the vacuum line from the vacuum source on the engine intake manifold; then, remove the line from the routing channel.
6. Disconnect the liquid line from the evaporator core inlet tube and cap the openings to prevent the entry of dirt and moisture.
7. Disconnect the suction line from the accumulator I drier with a Spring Lock Coupling Tool and cap the openings to prevent the entry of dirt and moisture.
8. Disconnect the heater hoses from the heater core tubes and plug the hoses with suitable 15.975mm (518 in.) plugs. Observe all safety precautions.
9. Remove the solenoid box cover, if so equipped, by removing the three bolts fastened through the fender liner. Remove the air cleaner and vacuum reservoir, if so equipped.
10. Remove three nuts from the engine compartment side of the evaporator assembly and one nut from the passenger compartment side of the assembly.
11. Remove the evaporator case assembly from the vehicle.

Installation










1. Before the evaporator case can be installed, it will be necessary to remove all insulation and install new. Apply RTV to any exposed staple holes. Three illustrations follow. The first shows the configuration of the insulators. The second shows how and where they are to be attached to the case. This second illustration also highlights the areas in which staples are not to be driven.

CAUTION: A misplaced staple could damage the evaporator core or leave a perforation in the case with a resulting air or water leak in the system.






2. Using 3/16-inch staples, staple the three foil covered insulators to the case. Approximately 45 staples are needed to adequately secure the insulation to the case.






3. The third illustration shows the fully insulated case installed in the vehicle.
4. Add 4 ounces of refrigerant oil to the accumulator. Install the accumulator in the mounting bracket and attach the bracket to the evaporator case flanges. Attach the bracket around the evaporator core inlet tube.






5. Install the wrap-around insulators on the accumulator; then install the two bundling straps to secure the insulators to the accumulator.
6. Position the evaporator case assembly over the mounting studs in the dash panel.
7. In sequence, install a retaining nut on the stud located near the upper middle portion of the case; then install a nut on the stud located near the upper inboard end of the case. Next, install a nut on each of the two lower studs