Evaporator Case: Service and Repair

WARNING: Wear eye and hand protection when disconnecting components containing refrigerant. Plug all exposed connections immediately.

REMOVE
1. Open the hood and connect the gauge set.
2. Discharge the system.
3. Disconnect the battery negative lead.
4. Protect the eyes with safety goggles and wear gloves during instruction.
5. Disconnect the evaporator hoses from the compressor and the receiver drier. Use a second wrench to support the hose adaptors. Plug all the exposed connections immediately.

Mounting Screws:

6. Working inside the vehicle, withdraw the lower dash and remove the screws securing the lower edge of the center console.

Mounting Screws:

7. Remove the six screws securing the lower edge of the louvre panel to the console and evaporator case.
8. Remove the heater control panel and knobs from the center console.
9. Remove the center console.
10. Carefully pry out the four air vents.
11. Remove the screws securing the evaporator plenum and louvre panel to the dash top panel.

Evaporator Case Components:

12. Carefully withdraw the thermostat sensor from the fins of the evaporator, and pull the sensor pipe clear of the evaporator assembly.
13. Disconnect the electrical connectors at the rear of exterior driving mirror control switches and clock. and withdraw panel clear of the dash.

Mounting Screws:

14. Remove the screws securing the lower right mounting bracket.
15. Support the evaporator case and remove the two nuts securing the case and reinforcing strip to the upper mounting bracket.
16. Carefully withdraw the refrigerant hoses and evaporator condensate tubes through the bulkhead and remove the rear left hand air hose from the plenum.
17. Disconnect the wiring to mirror controls, blower motor and clock at the three wiring connectors.
18. Remove the evaporator and plenum assembly from the vehicle.

REFIT
1. Place the evaporator assembly on the floor of the vehicle and reconnect three wiring connectors disconnected at instruction 17.
2. Feed the hoses and evaporator condensate tubes through the bulkhead. Ensure that the openings and grommets are adequately sealed against ingress of dust and moisture.
3. Lift the unit into the mounting position and connect the rear left hand air hose. Fit the reinforcement strip and secure the casing to the upper bracket with two nuts.
4. Secure the lower right mounting bracket to the vehicle.
5. Position the left hand of the plenum so that the opening is centered over the fresh air outlet of the heater.
6. Carefully push the thermostat pipe into the evaporator fins.
7. Reconnect the wiring to the exterior mirror controls and clock, and refit the louvre panel. Secure the plenum casing and louvre panel to the dash top panel with the screws.
8. Refit the center console.
9. Refit the six screws securing the louvre panel to the center console and evaporator case.
10. Secure the lower edge of the console with four screws (two each side).
11. Refit the four air vents.
12. Connect the two refrigerant hoses to the compressor and receiver drier. Use refrigerant compressor oil on all mating surfaces to assist leakage prevention.
13. To compensate for oil loss, add 45 ml (1.5 fl oz) of the correct oil to the compressor.
14. Evacuate the system.
15. Charge the complete system.
16. Perform a leak test on any accessible disturbed joints.
17. Perform a functional check.
18. Disconnect the gauge set.