A/C Evaporator Core Replacement

1.	Recover the refrigerant with a recovery/recycling/charging station.

2.

Cut the joint caps (A) and thoroughly clean around the joints of dirt and debris by pressurized air or detergent. Remove the stops (B), then disconnect the receiver line (C) and the suction line (D). Clean inside wall of the joints of dirt and debris using a refrigerant oil (KEIHIN SP-10) applied swab. Do not use compressed air or detergent after disconnecting the joints. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

3.	Remove the blower unit.

4.	Remove the self-tapping screws and the pipe cover (A), then remove the bolts, the inlet and outlet pipes (B), and the expansion valve (C).

5.	Disconnect the connector (A) from the evaporator temperature sensor, then remove the connector clip (B). Remove the self-tapping screws and the duct (C).

6.	Pull out the evaporator core (A) with the plate (B).

7.

Install the core in the reverse order of removal, and note these items. If you're installing a new evaporator core, add refrigerant oil (KEIHIN SP-10). Make sure the plate is installed on the evaporator in the correct direction. Make sure the inside wall of the joints are clean and free from dirt and debris. 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 right 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. Replace the joint caps and the stops with new ones at joints. After installing the stops, insert the receiver line and the suction line slowly in to the joints until they lock. Securely install the joint caps and they will not come off. Charge the system.