GM Astro/Safari 1985-1996 Repair Guide

Evaporator Core

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Two evaporator cores are used, one in the front (engine compartment) and one at the rear (overhead) door. The rear overhead air conditioning system works in conjunction with the front system.

REMOVAL & INSTALLATION



Before removing the evaporator core, the air conditioning system must be discharged. Refer to the air conditioning Discharging procedures in General Information & Maintenance and discharge the air conditioning system. The system should be discharged by a qualified technician with proper recovery equipment. It is illegal to discharge refrigerant into the atmosphere and you may need a permit to purchase new refrigerant. If you do not possess the proper equipment, training and permits to perform refrigerant recovery, allow a repair shop to do that step for you.

Front System

See Figure 1



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Fig. Fig. 1: Front evaporator case mounting

The front evaporator core is located in the engine compartment on the right side of the firewall inside the heater/evaporator/blower motor case.

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the radiator coolant collecting bottle and the windshield washer fluid bottle.
  4.  
  5. Disconnect any necessary electrical connectors.
  6.  
  7. Discharge the air conditioning system as outlined in General Information & Maintenance . Disconnect the air conditioning refrigerant lines from the evaporator.
  8.  
  9. Remove the relay bracket and move it aside.
  10.  
  11. Remove the evaporator/blower case nuts and the case, then separate the evaporator from the case.
  12.  

To install:
  1. Install the evaporator into the case and tighten the retainers.
  2.  
  3. Install the relay bracket.
  4.  
  5. Connect the air conditioning refrigerant lines to the evaporator.
  6.  
  7. Connect any necessary electrical connectors.
  8.  
  9. Install the radiator coolant collecting bottle and the windshield washer fluid bottle.
  10.  
  11. Connect the negative battery cable to the battery.
  12.  
  13. Evacuate and recharge the air conditioning system as outlined in General Information & Maintenance .
  14.  
  15. Start the engine, allow it establish normal operating temperatures and check the air conditioning cooling operation.
  16.  

Rear Overhead System

See Figure 1 in the Evaporator Blower Motor Section

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the rear evaporator/blower motor-to-vehicle cover.
  4.  
  5. Disconnect the electrical connectors from the rear blower motor and the resistor.
  6.  
  7. Discharge the air conditioning system as outlined in General Information & Maintenance . From under the left rear of the vehicle, remove the air conditioning line fitting-to-evaporator fitting nut.
  8.  
  9. Remove the evaporator/blower motor case-to-vehicle screws and the case from the vehicle.
  10.  
  11. Separate the air conditioning evaporator from the evaporator/blower motor case assembly.
  12.  
  13. Inspect the air conditioning line gaskets for damage and replace (if necessary).
  14.  

To install:
  1. Install the evaporator into the case. Install the case into the vehicle.
  2.  
  3. Torque the evaporator/blower motor case assembly-to-vehicle screws to 4 inch lbs. (0.5 Nm) and the air conditioning line fitting-to-evaporator fitting nut to 18 ft. lbs. (25 Nm).
  4.  
  5. Reconnect the electrical connectors.
  6.  
  7. Recharge the air conditioning system as outlined in General Information & Maintenance .
  8.  
  9. Start the engine, allow it establish normal operating temperatures and check the air conditioning cooling operation.
  10.  

 
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