Evaporator Core: Service and Repair

Fig. 5 Front blower motor & evaporator assembly. R & V Series:

C, K, R & V SERIES

FRONT UNIT

1. Disconnect battery ground cable, then discharge system refrigerant.
2. Remove stud nuts projecting through dash panel from selector duct.
3. Remove evaporator case cover by removing dash and case cover retaining screws, Fig. 5.
4. Disconnect inlet and outlet lines at evaporator core. Plug all open connections.
5. Remove expansion tube, refer to ``Expansion Tube, Replace.''
6. Remove evaporator core.
7. Reverse procedure to install. When installing new evaporator units, add 3 fluid ounces of fresh refrigerant oil to new unit prior to installation. Use new O-rings coated with clean refrigerant oil at connections.

OVERHEAD SYSTEM

1. Disconnect battery ground cable, then discharge system refrigerant.

Fig. 6 Rear duct assembly. R & V Series with overhead system:

2. Remove rear duct drain tube, duct to header bracket and roof panel screws, then rear duct assembly, Fig. 6.

Fig. 7 Rear blower motor & evaporator assembly. R & V Series with overhead system:

3. Disconnect blower harness lead and ground wire, Fig. 7.
4. Disconnect refrigerant lines at evaporator/blower assembly. Plug all open connections.
5. While supporting unit, remove blower/evaporator assembly support screws at roof rail. Place unit upside down on bench, then remove upper to lower case retaining screws. Remove lower case half.
6. Remove upper case to support screws and case from evaporator core.
7. Remove inlet and outlet lines at expansion valve. Plug all open connections.
8. Remove expansion valve capillary bulb from outlet line, then the valve.
9. Remove plastic screen retaining pins at core and screen.
10. Reverse procedure to install, using new O-rings coated with clean refrigerant at connections. When installing a new evaporator core, add 3 fluid ounces of fresh refrigerant oil to unit prior to installation.