Evaporator Core: Service and Repair

Evaporator Core Replacement

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

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






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






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

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






6. Remove the self-tapping screw (A), push the upper cover (B) toward the front of the vehicle, then remove the upper cover.






7. Remove the bolts and the expansion valve (A) and the inlet/outlet lines from the evaporator core assembly without bending the lines.






8. Carefully pull out the evaporator core assembly (A), then remove the plate (B).






9. Pull out the evaporator temperature sensor (A) from the evaporator core.






10. Install the evaporator temperature sensor in the evaporator core, and note these items:

- When the evaporator temperature sensor (A) is installed into the new evaporator core, set the sensor into the factory-preset position (B, C).
- When the evaporator temperature sensor is reinstalled into the original evaporator core, set the sensor into the new position (D, E) because the fin may be deforming by the previous installation.

Installing into the factory-preset position





Installing into the new position





11. Install the core in the reverse order of removal and note these items:

- If you're installing a new evaporator core, add refrigerant oil (SP-10) Service and Repair.
- 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.