Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Evaporator Core

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REMOVAL & INSTALLATION



See Figures 1 and 2

R-12 refrigerant is a chlorofluorocarbon which, when released into the atmosphere, can contribute to the depletion of the ozone layer in the upper atmosphere. Ozone filters out harmful radiation from the sun. An approved R-12 recovery/recycling station that meets SAE standards should be used when discharging the system. Follow the operating instructions provided with the equipment exactly to properly discharge the system.

  1. Discharge the refrigerant system, as described in General Information & Maintenance of this repair guide.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On the 626 and MX-6, remove the under cover and glove box at this time.
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  7. Disconnect and plug the evaporator suction and discharge lines from their respective fittings. Plug the fittings immediately to prevent the entry of dirt and moisture into the system.
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  9. On the 929, remove the grommets from the expansion valve. On the 323 and 626, remove the grommets from the suction and discharge lines. On the 323, remove the glove box at this time.
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Click image to see an enlarged view

Fig. Fig. 1: Remove the glove box to access the evaporator housing



Click image to see an enlarged view

Fig. Fig. 2: The core is located inside an evaporator housing (on the left in this photo), and the blower unit is on the right

  1. Remove the drain hose from the cooling unit (evaporator housing). Remove the lower duct.
  2.  
  3. On the 929, remove the instrument lower panel and glove box. Remove the blower duct.
  4.  
  5. Remove the sealing plates from both sides of the evaporator housing.
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  7. Detach the electrical and vacuum connections from the evaporator housing. On the 323, remove the air duct bands.
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  9. Unfasten the retaining bolts or nuts and remove the evaporator housing assembly from the vehicle.
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  11. Separate the evaporator housing and remove the evaporator core. Remove the thermostat and the expansion valve.
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  13. Inspect the fins of the evaporator for blockage. Remove any blockage with compressed air. Check the suction and discharge fitting connections for cracks. Replace the core if cracks are evident.
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WARNING
Never clean the evaporator core with water!

To assemble:
  1. Connect the expansion valve to the evaporator inlet fitting. Before threading the 929's fitting, make sure that the O-ring is positioned properly on the pipe union fitting. On the 929, torque the fitting to 23-30 inch lbs. (2.6-3.4 Nm). On the 323, 626 and MX-6, torque the fitting to 22-25 ft. lbs. (30-34 Nm).
  2.  
  3. Connect the discharge fitting to the expansion valve, if so equipped. Torque the fitting to 9-10 ft. lbs. (12-14 Nm). On the 323, install the packing to seal the heat sensitive tube of the expansion valve.
  4.  
  5. Assemble the upper and lower case halves and install the thermoswitch. Install the thermoswitch sensing bulb's six core fins away from the opposite expansion valve and insert it 1-1 1 / 2 in. (25-38mm).
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  7. Fasten the case halves with the retaining clips.
  8.  

To install:
  1. Installation of the cooling unit is essentially the reverse of the removal procedure with the following exceptions:
    1. Adjust the position of the cooling unit so that its connections are aligned with those on the heater and blower units.
    2.  
    3. On the 323, torque the discharge tube fitting to 9-10 ft. lbs. (12-14 Nm) and the suction tube fitting to 22-25 ft. lbs. (30-34 Nm). On the 626, MX-6 and 929, torque both tube fittings to 11-18 ft. lbs. (15-24 Nm).
    4.  
    5. If the evaporator core was replaced, add approximately 50cc of new compressor oil to the compressor.
    6.  
    7. Evacuate, charge and leak test the system as described in General Information & Maintenance . Check the system for proper operation.
    8.  

  2.  

 
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