Evaporator Core

DESCRIPTION The A/C evaporator (1) and its insulator (2) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator is positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heater core and heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. The A/C evaporator tubes (3) are connected and sealed to the A/C expansion valve by use of rubber O-rings (4) and a tapping block (5). The A/C evaporator can only be serviced by removing and disassembling the HVAC housing.

OPERATION Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C expansion valve is removed from the A/C evaporator. The A/C evaporator cannot be repaired and must be replaced if leaking or damaged.

NOTE: LHD model shown in illustration. RHD model similar.

The A/C evaporator (1) and its insulator (2) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator is positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heater core and heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator.

The A/C evaporator tubes (3) are connected and sealed to the A/C expansion valve by use of rubber O-rings (4) and a tapping block (5).

The A/C evaporator can only be serviced by removing and disassembling the HVAC housing.

Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C expansion valve is removed from the A/C evaporator.

The A/C evaporator cannot be repaired and must be replaced if leaking or damaged.

NOTE: LHD model shown in illustration. RHD model similar.

1. Remove the HVAC housing assembly and place it on a workbench. See REMOVAL. 2. Disassemble the HVAC housing. See DISASSEMBLY.

NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3).

NOTE: If the rubber seal around the evaporator tubes and tapping block is deformed or damaged, the seal must be replaced.

4. If required, remove the rubber seal (4) from around the evaporator tubes and tapping block (5).

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. See STANDARD PROCEDURE. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the REFRIGERANT OIL CAPACITIES chart to determine how much oil should be added to the refrigerant system. See STANDARD PROCEDURE.

NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

NOTE: LHD model shown in illustration. RHD model similar.

NOTE: Make sure the rubber seal for the evaporator tubes and tapping block is properly positioned in the HVAC housing opening.

1. If removed, install the rubber seal (4) over the evaporator tubes and tapping block (5).

NOTE: Make sure that the foam insulator around the A/C evaporator is properly positioned within the HVAC housing.

2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 3. Assemble the HVAC housing. See ASSEMBLY. 4. Install the HVAC housing assembly. See INSTALLATION. 5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the REFRIGERANT OIL CAPACITIES chart to determine how much oil should be added to the refrigerant system. See STANDARD PROCEDURE. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

LINE-A/C DISCHARGE

NOTE: LHD model shown in illustration. RHD model similar.

The A/C evaporator (1) and its insulator (2) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator is positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heater core and heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator.

The A/C evaporator tubes (3) are connected and sealed to the A/C expansion valve by use of rubber O-rings (4) and a tapping block (5).

The A/C evaporator can only be serviced by removing and disassembling the HVAC housing.

Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C expansion valve is removed from the A/C evaporator.

The A/C evaporator cannot be repaired and must be replaced if leaking or damaged.

NOTE: LHD model shown in illustration. RHD model similar.

1. Remove the HVAC housing assembly and place it on a workbench. See REMOVAL. 2. Disassemble the HVAC housing. See DISASSEMBLY.

NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3).

NOTE: If the rubber seal around the evaporator tubes and tapping block is deformed or damaged, the seal must be replaced.

4. If required, remove the rubber seal (4) from around the evaporator tubes and tapping block (5).

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. See STANDARD PROCEDURE. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the REFRIGERANT OIL CAPACITIES chart to determine how much oil should be added to the refrigerant system. See STANDARD PROCEDURE.

NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

NOTE: LHD model shown in illustration. RHD model similar.

NOTE: Make sure the rubber seal for the evaporator tubes and tapping block is properly positioned in the HVAC housing opening.

1. If removed, install the rubber seal (4) over the evaporator tubes and tapping block (5).

NOTE: Make sure that the foam insulator around the A/C evaporator is properly positioned within the HVAC housing.

2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 3. Assemble the HVAC housing. See ASSEMBLY. 4. Install the HVAC housing assembly. See INSTALLATION. 5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the REFRIGERANT OIL CAPACITIES chart to determine how much oil should be added to the refrigerant system. See STANDARD PROCEDURE. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

LINE-A/C DISCHARGE