ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Evaporator Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Air conditioning evaporator assembly-1994 Amigo and Pick-up shown



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Fig. Fig. 2: Evaporator assembly exploded view-1994 Amigo and Pick-up shown



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Fig. Fig. 3: Evaporator assembly exploded view-1986 Pick-up shown

The refrigerant must be recovered by a licensed repair shop. Please refer to General Information & Maintenance of this manual before discharging/recovering the A/C system or disconnecting air conditioning lines.

The following procedure may need to be altered, depending on the vehicle and interior options. You may find it necessary to remove additional components to make air conditioning service easier. Center consoles, seats, glove box, storage areas and floor gear shift levers are all components that may or may not interfere with extracting the evaporator assembly from under the dash.

  1. Recover the refrigerant at a licensed air conditioning service shop as outlined in General Information & Maintenance .
  2.  
  3. Disconnect the negative (-) battery cable.
  4.  
  5. Disconnect and plug the inlet and outlet pipe from the evaporator.
  6.  


CAUTION
Some 1994 and later models were equipped with passenger side air bags. If equipped with air bags, the SRS/air bag system must be disabled before the working under the dash. Failure to disable the air bag system may result in unnecessary system repairs and possible personal injury. Do not damage, cut, or attempt to alter the yellow SRS wiring harness.

  1. Remove the glove box and disconnect the thermoswitch wire.
  2.  


WARNING
When refrigerant lines are disconnected you must IMMEDIATELY cap all openings to prevent the entry of moisture in the system resulting in contamination and corrosion of internal components. ALSO, minimize the amount of time that the system remains discharged by planning the job well before hand. No matter how well you cap the lines, some moisture is bound to enter and damage the system over time if it remains in a discharged state.

  1. Disconnect the defroster hose and remove the evaporator housing retaining nuts and bolts. Remove the evaporator assembly, being careful not to damage the seals.
  2.  
  3. Remove the housing retaining clips and split the housing in two. Be careful not to damage the seals.
  4.  
  5. Using a backup and flare nut wrench, remove the expansion valve.
  6.  
  7. Remove the evaporator from the case, being careful not to damage the seals.
  8.  

To install:
  1. Install the evaporator core into the case, making sure all seals are in place and good condition.
  2.  
  3. Using a backup and flare nut wrench, install the expansion valve.
  4.  
  5. Install the housing halves and retaining clips. Be careful not to damage the seals.
  6.  
  7. Install the evaporator housing and connect the defroster hose. Be careful not to damage the seals.
  8.  
  9. Install the glove box and connect the thermoswitch wire.
  10.  
  11. Connect the inlet and outlet pipe to the evaporator.
  12.  
  13. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance . If installing a new core follow Evaporator Core procedures and add approximately 1.7 ounces of refrigerant oil.
  14.  

After you have made repairs you should take the vehicle to a licensed air conditioning technician to have the system tested for leaks then recharged. Newer air conditioning systems equipped with R134a refrigerant are NOT compatible with R-12 refrigerant.

  1. Connect the negative (-) battery cable and check operation.
  2.  

 
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