Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Evaporator Core/Cooling Unit

Print

REMOVAL & INSTALLATION



1983-90 Pulsar

See Figures 1, 2, 3 and 4



Click image to see an enlarged view

Fig. Fig. 1: Using 2 wrenches to remove or install A/C fittings



Click image to see an enlarged view

Fig. Fig. 2: Always plug A/C lines after disconnecting to prevent moisture from entering the system



Click image to see an enlarged view

Fig. Fig. 3: Removing the cooling unit-1983-90 Pulsar, Sentra similar



Click image to see an enlarged view

Fig. Fig. 4: If there is not enough clearance, cut out the section of instrument panel between the 2 lines using a hacksaw-all models

  1. Disconnect the battery ground cable.
  2.  
  3. Discharge the air conditioning system, refer to Routine Maintenance for more details.
  4.  
  5. Remove the glove compartment door, box and trim panel. Refer to Body & Trim for instrument panel procedures.
  6.  
  7. Disconnect all electrical connectors from the cooling unit. Disconnect the air conditioning pipes from the evaporator housing using a backup wrench.
  8.  

For vehicles with factory installed air conditioning, it may be necessary to cut and discard the instrument panel support. Before cutting, cover the blower motor vent holes with tape. After cutting, brush the shavings away from the area around the blower motor and remove the tape. This procedure may not be necessary on 1987-92 vehicles. Check the clearance before cutting the instrument panel support.

  1. Remove cooling unit fixing bolts.
  2.  
  3. Remove cooling unit from vehicle.
  4.  

To install:
  1. Install the cooling unit and mounting bolts in the vehicle.
  2.  
  3. Connect all electrical connectors to the cooling unit.
  4.  
  5. Connect battery cable and charge the air conditioning system.
  6.  
  7. Check system for proper operation.
  8.  

1982-86 Sentra
  1. Discharge the refrigerant from the system as described in General Information & Maintenance . Disconnect the battery ground cable.
  2.  
  3. Using a backup wrench, disconnect the refrigerant lines running to the evaporator on the engine compartment side of the firewall. Immediately tape or cap the openings. Remove the piping grommet and cover.
  4.  
  5. Remove the lower instrument panel cover from the passenger's side of the dash panel. Remove the glove box.
  6.  
  7. Cover the blower motor vent holes with tape. Then, cut out the section of the lower instrument panel brace between two bolt holes that will block removal of the blower and evaporator.
  8.  
  9. Clean all shavings away from the blower motor. Remove the blower motor. Remove the tape covering the blower motor cooling holes. Disconnect the electrical connector at the thermostat.
  10.  
  11. Unbolt the evaporator case from the firewall and remove it.
  12.  
  13. Cut the seals where the upper and lower halves of the case fit together, using a knife. Then, remove the clips fastening the case halves together and separate the case halves. Remove the evaporator coil.
  14.  

To install:
  1. Install the evaporator back into the case and assemble it in reverse of disassembly. Use a sealer at the joints formed by cutting the seal earlier.
  2.  
  3. Begin installing the unit by guiding the tubes through the firewall. Then, situate it against the firewall with the bolt holes in the brackets and firewall lined up. Install and tighten the mounting bolts.
  4.  
  5. Connect the electrical connectors at the thermostat.
  6.  
  7. Install the blower motor.
  8.  
  9. Install a replacement plate for the dash panel.
  10.  
  11. Install the glove box and lower instrument panel pad. Remove the tape or plugs, coat the sealing surfaces of the flare fittings with clean refrigerant oil and tighten both, using a backup wrench.
  12.  
  13. Have the refrigerant system evacuated with a vacuum pump. Reconnect the battery. Have the system charged, or charge it with refrigerant yourself as described in General Information & Maintenance . Check the system for proper operation and for leaks.
  14.  

1987-94 Sentra
  1. Discharge the refrigerant from the system as described in General Information & Maintenance . Disconnect the battery ground cable.
  2.  
  3. Using a backup wrench, disconnect the refrigerant lines running to the evaporator on the engine compartment side of the firewall. Immediately tape or cap the openings. Remove the piping grommet and cover.
  4.  
  5. Remove the lower instrument panel cover from the passenger's side of the dash panel. Remove the glove box.
  6.  
  7. Cut out the section of the lower instrument panel brace located between the two marks in the illustration that will block removal of the evaporator.
  8.  

This procedure may not have to be performed on the 1991-92 Sentra. Check the clearance between the instrument panel brace and evaporator housing before cutting.

  1. Disconnect the electrical connector at the thermostat.
  2.  
  3. Unbolt the evaporator case from the firewall and remove it.
  4.  
  5. Cut the seals where the upper and lower halves of the case fit together, using a knife. Then, remove the clips fastening the case halves together and separate the case halves.
  6.  
  7. Remove the evaporator coil.
  8.  

To install:
  1. Install the evaporator back into the case and assemble it in reverse of disassembly. Use a sealer at the joints formed by cutting the seal earlier.
  2.  
  3. Begin installing the unit by guiding the tubes through the firewall. Then, situate it against the firewall with the bolt holes in the brackets and firewall lined up. Install and tighten the mounting bolts.
  4.  
  5. Connect the electrical connectors for the thermostat.
  6.  
  7. If the instrument panel brace was cut, mend or replace the brace as required.
  8.  
  9. Install the glove box and lower instrument panel pad. Remove the tape or plugs, install new O-rings, coat the sealing surfaces of the flare fittings with clean refrigerant oil and tighten both, using a backup wrench.
  10.  
  11. Have the refrigerant system evacuated with a vacuum pump. Reconnect the battery. Have the system charged, or charge it with refrigerant yourself as described in General Information & Maintenance . Check the system for proper operation and for leaks.
  12.  

1995-96 Sentra
  1. Be sure the ignition switch is in the OFF position. Disconnect the negative battery cable, then disconnect the positive battery cable. Wait 10 minutes before continuing with this procedure so that the SRS (air bag system) will have sufficient time to discharge.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly discharge the air conditioning system as outlined in General Information & Maintenance .
  6.  
  7. Remove the steering wheel.
  8.  
  9. Remove the complete instrument panel assembly as outlined in General Information & Maintenance 0.
  10.  
  11. Disconnect and plug the A/C refrigerant lines from the evaporator core/cooling unit and disconnect the heater unit hoses.
  12.  
  13. Remove the mounting fasteners that mount the heating and cooling unit assembly to the interior side of the firewall.
  14.  
  15. Separate the cooling unit from the heating unit and remove from vehicle.
  16.  
  17. Remove the evaporator core from the cooling unit assembly.
  18.  

To install:
  1. Install the evaporator core into the cooling unit assembly.
  2.  
  3. Place the heater unit and cooling unit into proper position in the vehicle against the interior side of the firewall. Install and tighten the heater and cooling unit mounting fasteners.
  4.  
  5. Install the entire instrument panel assembly.
  6.  
  7. Reconnect the A/C refrigerant lines. Be sure to install new O-rings and coat the sealing surfaces of the refrigerant lines with clean, fresh refrigerant oil. Tighten the refrigerant lines using a backup wrench.
  8.  
  9. Reconnect the heater hoses to the heater/cooling unit assembly.
  10.  
  11. Install the steering wheel.
  12.  
  13. Reconnect the positive battery cable, then reconnect the negative battery cable.
  14.  
  15. Refill the cooling system.
  16.  
  17. Evacuate, charge and leak test the A/C system as outlined in General Information & Maintenance and check the system for proper operation.
  18.  

 
label.common.footer.alt.autozoneLogo