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

Evaporator Core

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Carefully cut the case parting face with a knife



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Fig. Fig. 2: Lift the upper case carefully off of the evaporator core



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Fig. Fig. 3: Gently remove the evaporator core



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Fig. Fig. 4: The thermosensor must be correctly positioned for proper cooling

  1. Remove the evaporator assembly from under the dash panel. Follow all Air Conditioning precautions.
  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. Remove the electronic thermostat retaining clip, grommet and sensor from the assembly.
  2.  
  3. Remove the clips and attaching screws.
  4.  
  5. To remove the lower case, slit the case parting face with knife, since the lining is separated when removing the evaporator.
  6.  
  7. Remove the cover and then remove the core.
  8.  
  9. Tear off the insulation from around the expansion valve.
  10.  
  11. Remove the expansion valve. Use a backup wrench to prevent the valve tubing from twisting.
  12.  

To install:
  1. Install the evaporator core into the case, make certain insulation is in good condition and use new seals.
  2.  
  3. Make certain to position the themosensor close to the center of the core.
  4.  
  5. Coat all threads and O-rings with refrigerant oil. Add approximately 1.5 ounces of refrigerant oil if this is a new evaporator.
  6.  
  7. Using a backup and flare nut wrench, install the expansion valve.
  8.  
  9. Install the housing halves and retaining clips. Be careful not to damage the seals.
  10.  
  11. Install the evaporator assembly.
  12.  
  13. Connect the inlet and outlet pipe to the evaporator.
  14.  
  15. Evacuate, leak test and charge the air conditioning system as outlined in General Information & Maintenance .
  16.  

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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