Evaporator Core: Service and Repair

Evaporator

Service Repair No - 82.25.20

Remove
1. Depressurise A/C system.







2. Remove bolt securing pipes to TXV valve.
3. Release both pipes from TXV valve.
4. Remove and discard 2 'O' rings from pipes.

CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.

5. Remove fascia.







6. Remove bolt from face level ducting and remove ducting.







7. Disconnect 3 multiplugs from A/C switches and heater harness.







8. Remove 2 nuts securing evaporator to body.
9. Release evaporator from drain hose and air intake, remove evaporator assembly.
10. Release harness from evaporator securing clips.







11. Remove 7 screws from evaporator casing and remove top half of casing.







12. Remove evaporator from casing.
13. Remove 2 Allen key bolts securing TXV valve, remove valve and discard 2 'O' rings.

Refit
1. Lubricate new 'O' rings with clean refrigerant oil and fit to evaporator pipes
2. Fit evaporator pipes to TXV valve and fit bracket, fit and tighten bolt to 10 Nm (7 lbf.ft).
3. Carefully fit evaporator to casing.
4. Fit top half of evaporator casing.
5. Fit 7 screws to casing.
6. Fit harness in securing clips.
7. Locate evaporator assembly to drain hose and air intake, position evaporator to body.
8. Fit and tighten nuts securing evaporator to body.
9. Connect multiplugs to heater harness and A/C switches.
10. Position face level vent ducting, fit and tighten bolt.
11. Fit fascia.
12. Clean evaporator pipes.
13. Lubricate new 'O' rings with refrigerant oil.
14. Fit 'O' rings to evaporator pipes.
15. Clean evaporator pipes.
16. Fit pipes to TXV valve and fit bracket, tighten bolt to 10 Nm (7 lbf.ft).
17. Charge A/C system.