Acura Coupes and Sedans 1986-1993 Repair Guide

Evaporator & Expansion Valve

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REMOVAL & INSTALLATION



1986-89 Integra

See Figures 1, 2 and 3



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Fig. Fig. 1: Location of the control units to be removed before removing the evaporator-1986-89 Integra



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Fig. Fig. 2: Mounting bolt locations of the blower-1986-89 Integra



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Fig. Fig. 3: Exploded view of the evaporation assembly-1986-89 Integra

  1. Disconnect the negative battery cable.
  2.  
  3. Have the refrigerant recovered from the A/C system.
  4.  
  5. Disconnect the receiver and suction lines from the evaporator. Be sure to cap the open fittings immediately to keep dirt and moisture out of the system.
  6.  
  7. Remove the glove box screws and glove box. Remove the glove box frame screws and frame.
  8.  
  9. Remove the headlight control retractor unit with bracket.
  10.  
  11. Remove the console box as follows:
    1. If equipped with a manual transmission, remove the shifter lever knob.
    2.  
    3. Lift up the parking brake lever. Remove the center cap and lid.
    4.  
    5. Remove the console attaching screws and lift the console up off the floor boards.
    6.  

  12.  
  13. Remove the bolts, screws and console box bracket.
  14.  
  15. Unbolt the lower dashboard bracket from the support bracket and insert a suitable tool to retain a clearance of 12-15mm, to ease in the blower removal.
  16.  
  17. Loosen the sealing band. Remove the lower bolt and loosen the upper bolt for the blower motor.
  18.  
  19. Slide the blower motor to the right as far as possible. Disconnect the drain hose from the lower evaporator housing.
  20.  
  21. Remove the evaporator housing retaining bolts and remove the evaporator case from underneath the dashboard.
  22.  
  23. Disconnect the thermostat wire and pull the wire out of the clamp at the top of the evaporator case.
  24.  
  25. Pull the evaporator sensor out from the evaporator fins. Remove the tapping screws and clips from the housing.
  26.  
  27. Carefully separate the housing and remove the evaporator covers.
  28.  
  29. Remove the evaporator from the case and remove the expansion valve if necessary.
  30.  

To install:
  1. Install the expansion valve capillary tube against the suction line and wrap it with tape. Reassemble the upper and lower housings with clips, making sure there are no gaps between them. Reinstall the thermostat sensor in its original position. Be sure to apply sealant to the grommets and make sure there is no air leakage after the installation is complete.
  2.  
  3. Install the evaporator and connect the drain hose. Move the blower back into position and install the bolts.
  4.  
  5. Install the sealing band and the brackets. Install the console box, the retractor control unit and the heater relay.
  6.  
  7. Install the glove box frame and the glove box. Connect the refrigerant lines and have the system recharged. Connect the negative battery terminal.
  8.  

1990-93 Integra

See Figures 4 and 5



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Fig. Fig. 4: Mounting the evaporator assembly-1990-93 Integra



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Fig. Fig. 5: Exploded view of the evaporation assembly-1990-93 Integra

  1. Disconnect the negative battery cable.
  2.  
  3. Have the refrigerant recovered from the A/C system.
  4.  
  5. Disconnect the receiver and suction lines from the evaporator. Be sure to cap the open fittings immediately to keep dirt and moisture out of the system.
  6.  
  7. Remove the right and left lower dashboard covers, the glove compartment and front console. Remove the right knee bolster.
  8.  
  9. Remove the bands around the evaporator and disconnect the thermostat. Pull the wiring out of the clamps.
  10.  
  11. Remove the nuts and bolt holding the evaporator. Lower the evaporator and remove the thermostat. Pull the thermostat sensor from the fins.
  12.  
  13. Remove the screw and clips and separate the housings. Pull off the covers to expose the evaporator core and expansion valve.
  14.  

To install:
  1. Install the expansion valve capillary tube against the suction line and wrap it with tape. Reassemble the upper and lower housings with the screw and clips, making sure there are no gaps between them. Reinstall the thermostat sensor in its original position. Be sure to apply sealant to the grommets and make sure there is no air leakage after the installation is complete.
  2.  
  3. Install new O-rings at all connections and install the evaporator and bands.
  4.  
  5. Install the knee bolster, console, glove box and dash covers.
  6.  
  7. Connect the refrigerant lines and have the system recharged. Connect the negative battery terminal.
  8.  

1986-90 Legend

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Have the refrigerant recovered from the A/C system.
  4.  
  5. Disconnect the receiver and suction lines from the evaporator. Be sure to cap the open fittings immediately to keep dirt and moisture out of the system.
  6.  
  7. Remove the glove box lower cover and glove box. Remove the glove box frame and side duct.
  8.  
  9. Disconnect the wire connector from the evaporator sensor connector and the thermostat switch connector.
  10.  
  11. Remove the screws and retaining bolts attaching the evaporator assembly to the body of the vehicle. Remove the evaporator assembly case from the upper floor boards of the vehicle.
  12.  
  13. Pull the evaporator sensor out from the evaporator fins. Remove the screws and clips from the housing.
  14.  
  15. Carefully separate the housing and remove the evaporator covers.
  16.  
  17. Remove the evaporator from the case and remove the expansion valve.
  18.  

To install:
  1. Install the expansion valve capillary tube against the suction line and wrap it with tape. Reassemble the upper and lower housings with clips, making sure there are no gaps between them. Reinstall the evaporator sensor in its original position. Be sure to apply sealant to the grommets and make sure there is no air leakage after the installation is complete.
  2.  
  3. Install the evaporator and connect the thermostat. Install the glove box frame, duct, glove box and cover.
  4.  
  5. Connect the refrigerant lines and have the system recharged. Connect the negative battery terminal.
  6.  



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Fig. Fig. 6: Exploded view of the evaporation assembly-1986-90 Legend

1991-93 Legend

The evaporator is removed in the same manner and procedure as the heater core. Refer to the heater core removal procedure in this Section. Remember to replace the O-rings on all connections during assembly.

Vigor

See Figure 7

Refer to the Heater Core removal and installation procedure in this Section for additional art, if required.

  1. Remove the dashboard. Drain the coolant from the system and recover the refrigerant from the air conditioning system.
  2.  
  3. Disconnect the heater hoses from the heater at the firewall. Catch the coolant that will run out.
  4.  
  5. Remove the bolts holding the air conditioner lines to the evaporator at the firewall. Remove the mounting nuts at the firewall.
  6.  
  7. Remove the duct and connector from the assembly. Remove the mounting nuts and the heater/evaporator assembly.
  8.  
  9. Remove the duct, pipe covers and pipe clamp. Remove the blower motor relay.
  10.  
  11. Remove the clips and the screws to separate the housing covers. Remove the evaporator from the case and remove the expansion valve.
  12.  

To install:
  1. Install the expansion valve capillary tube against the suction line and wrap it with tape. Reassemble the upper and lower housings with clips, making sure there are no gaps between them. Reinstall the evaporator sensor in its original position. Be sure to apply sealant to the grommets and make sure there is no air leakage after the installation is complete.
  2.  
  3. Install the heater fan relay. Install the pipe covers, pipe clamp and the air duct.
  4.  
  5. Use sealant at the air conditioning grommets and install the heater/evaporator assembly. Torque the mounting bolts to 7 ft. lbs. (10 Nm).
  6.  



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Fig. Fig. 7: Exploded view of the evaporation assembly-Vigor

  1. Install the firewall located mounting nut and torque to 16 ft. lbs. (22 Nm).
  2.  
  3. Install the air conditioner lines and torque the mounting nut to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the heater hoses and control valve. Install the dashboard. Fill and bleed the cooling system. Recharge the air conditioning system.
  6.  

 
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