Evaporator Core: Service and Repair

A/C Evaporator Core Replacement

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

2. Remove the bolt from the A/C line clamp (A).

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






4. Remove the bolt, then disconnect the A/C line (A) from the evaporator core and remove the O-rings (B).






5. Disconnect the connectors (A) from the evaporator temperature sensor and the blower resistor, then remove the connector clip (B). Remove the self-tapping screws, the expansion valve cover (C), and the seals (D).






6. Remove the bolts (A), the O-rings (B), and the inlet and outlet lines (C) from the evaporator core (D). Be careful not to bend the lines.






7. Carefully pull out the evaporator core (A).






8. Remove the clip (A) and the evaporator temperature sensor (B).
NOTE: At the factory, the evaporator temperature sensor is installed at the 6th row of fins from the side opposite of the expansion valve.






9. Reinstall the evaporator temperature sensor. If the evaporator is new, install the sensor on the 6th row of fins, counting from the side opposite the expansion valve. If you are reinstalling the old evaporator, install the sensor on the 7th row of fins.

10. Install the evaporator core in the reverse order of removal, and note these items:
- If you're installing a new evaporator core, add refrigerant oil (SP-10). A/C Refrigerant Oil Replacement (With A/C)

- 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 (With A/C)