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. Disconnect the evaporator hoses from the compressor and the receiver drier. Use a second wrench to support the hose adaptors.

Mounting Screws:

5. Working underneath the dash unit remove the two screws securing the blower closing panel. Slide the panel out of the two lower retaining clips.
6. Remove the Nyloc nut and washer from the evaporator case mounting bracket.

Mounting Nuts:

7. Remove the two Nyloc nuts securing both center dash panel and evaporator case mounting bracket.

Mounting Scews:

8. Remove the six screws securing the lower edge of the louvre panel to the evaporator case.

CAUTION: Care must be taken when removing dash components. They can easily be scratched or damaged by incorrect leverage and excessive force.

9. Pry out, using equal leverage top and bottom, the mirror control switch. Disconnect the two multiplugs.
10. Repeat instruction 9 for removal of the clock. Disconnect electrical leads and the bulb holder.
11. Pry out along the lower edge the four air vents.
12. Remove the nine screws securing the evaporator housing and louvre panel to the dash ton.
13. Withdraw panel clear of the dash top.
14. Carefully withdraw the refrigerant hoses and evaporator condensation drain tubes through the bulkhead.
15. Remove the air hose from the end of the evaporator case upper.
16. Disconnect electric wiring to the blower motor and electronic thermostat at the multiplugs.
17. Remove the evaporator case assembly from the vehicle and place on a surface that will not scratch the casing.

REFIT
1. Place the evaporator assembly on the floor of the vehicle and reconnect two wiring connectors.
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. Fit the evaporator assembly to its location and reconnect the air hose at the end of the evaporator casing. Ensure the center dash panel is eased over the evaporator case mounting bracket on the shared mounting point.

Louvre Panel:

4. Feed the electrical connections to the clock and mirror control switch through their apertures in the louvre panel (38). Refit the louvre panel.
5. Reconnect electrics (39) to the clock and mirror control switch and fit them to louvre panel.
6. Fit the air vents (40).

Evaporator Case Mounting:

7. Secure, using three new Nyloc nuts and plain washers, the evaporator case mounting brackets.
8. Ensure condensation tubes are free from kinks and able to drain off water. Fit the blower closing panel.
9. Connect the two refrigerant hoses to the compressor and receiver drier. Tighten.
10. Evacuate the system.
11. Charge the complete system.
12. Perform a leak test on any accessible disturbed joints.
13. Perform a functional check.
14. Check compressor oil level.
15. Disconnect the gauge set.