Evaporator Case: Service and Repair

COOLING UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system.
3. Remove the under cover, glove compartment, and glove compartment cover.
4. Remove the stay.
5. Remove the passenger-side air bag module.

CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

6. Remove in the order as indicated below. Do not allow compressor oil to spill. Immediately plug all open fittings to keep moisture and dirt out of the system.




1. Cooler pipe No.4
2. Cooler pipe No.3
3. Power MOS FET connector
4. Evaporator temperature sensor connector
5. Cooling unit


7. Install in the reverse order of removal.
8. Perform refrigerant system performance test.

Cooling Unit Installation Note

1. When installing a new cooling unit (evaporator), add ATMOS GU10 compressor oil into the refrigeration cycle.

Supplemental amount (approximate quantity) 50 ml {50 cc, 1.7 fl.oz}

COOLING UNIT DISASSEMBLY/ASSEMBLY

CAUTION: If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.

1. Disassemble in the order as indicated below.




1. Air filter (without polyurethane)
2. Air filter (with polyurethane)
3. Power MOS FET
4. Cooler case (top)
5. Cooler case (bottom)
6. Sensor clamp
7. Evaporator temperature sensor
8. Evaporator
9. Expansion valve

2. Assemble in the reverse order of disassembly.

Expansion Valve Assembly Note

1. Replace the O-rings at the expansion valve joints.
2. Apply compressor oil to the O-rings and connect the joints.
3. Tighten the joint to the specified torque using two open-end wrenches.




4. Assemble the heat-sensing tube as shown in the figure.




5. Verify that the capillary tube is not in the shaded zone.

Evaporator Temperature Sensor Assembly Note




1. Assemble the evaporator temperature sensor as shown in the figure.