REMOVAL & INSTALLATION
See Figure 1
- Using an approved refrigerant recovery/recycling station which meets SAE standards, discharge the system at the service access port on the underside of the combination valve. See Routine Maintenance of this repair guide.
- Remove the instrument panel and lay it on the front seat.
- Drain the cooling system and disconnect the heater hoses at the core tubes.
- Disconnect the refrigerant lines at the combination valve. Use a back-up wrench on the suction throttling valve manifold. Cap all openings immediately!
- Disconnect the wiring at the blower resistor. Remove the screw attaching the air inlet duct and blower housing assembly support brace to the cowl top panel.
- Disconnect the black vacuum supply hose at the check valve, in the engine compartment.
- Also in the engine compartment, remove the 2 nuts retaining the evaporator case to the firewall.
- In the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel.
- Remove the nut retaining the left end of the evaporator case to the firewall and the nut retaining the bracket below the evaporator case, to the dash panel.
- Carefully pull the case away from the firewall and remove the case from the car.
- Remove the air inlet duct and blower housing assembly from the case.
- Remove the screws and snap-clips securing the halves of the case and separate the case halves.
- Lift out the evaporator core, seal and combination valve from the lower case half.
Assembly and installation is the reverse of removal and disassembly. Be sure to keep in mind the following points:
- Always use new O-rings coated with clean refrigerant oil.
- Be sure that the restrictor is installed in the evaporator inlet line.
- Make sure that the core seal fits over the case lower half edge.
- Make sure that the temperature blend door and heat/defrost door are properly positioned.
- Always use new sealer between the case halves.
- Make sure that the drain hose is not kinked.
- When everything is back together, turn on the blower and check for air leaks around the case.
- Evacuate, charge and leak test the system, as described in Routine Maintenance . Be sure to observe all safety precautions.
The use of an approved R-12 recovery/recycling machine that meets SAE standards is required. Follow the operating instructions provided with the equipment exactly to properly charge the system.