Toyota Cressida and Van 1983-1990

Evaporator Core

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CAUTION
Please refer to before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

REMOVAL & INSTALLATION



The following procedures are for factory installed air conditioned vehicles, as opposed to dealer or aftermarket installed air conditioning systems.

Cressida


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Fig. Fig. 1 Exploded view of the disassembled cooling unit; the evaporator is located in the center-1983-88 Cressida



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Fig. Fig. 2 The evaporator is located in the center of the cooling unit-1989-90 Cressida

  1. Disconnect the negative battery cable. Discharge the refrigerant system.
  2.  
  3. Disconnect the suction flexible hose from the cooling unit outlet fitting.
  4.  
  5. Disconnect the liquid line from the cooling unit inlet fitting. Cap the open fittings immediately to keep the moisture out of the system.
  6.  
  7. Remove the grommets from the inlet and outlet fittings.
  8.  
  9. Remove the glove box with the under cover. Unplug all necessary connectors, such as the pressure switch connector and the A/C harness.
  10.  
  11. Remove the cooling unit attaching nuts and bolts. Remove the cooling unit from the vehicle.
  12.  
  13. Place the cooling unit on a suitable work bench and unscrew the thermistor, if so equipped.
  14.  
  15. Using suitable tools, remove the lower cooling unit case clamps and retaining screws.
  16.  
  17. Unplug the connectors and wire harness. Remove the upper cooling unit case retainer screws and clips. Remove the upper case from the evaporator.
  18.  
  19. Remove the heat insulator and the clamp from the outlet tube. Disconnect the liquid line from the inlet fitting of the expansion valve.
  20.  
  21. Disconnect the expansion valve from the inlet fitting of the evaporator. Remove the pressure switch (if so equipped) if required and remove the evaporator from the cooling unit.
  22.  

Before installing the evaporator, check the evaporator fins for blockage. If the fins are clogged, clean them with compressed air. Never use water to clean the evaporator. Check the fittings for cracks and or scratches and repair as necessary.

To install:

  1. Connect the expansion valve to the inlet fitting of the evaporator and tighten to 17 ft. lbs. Be sure that the O-ring is positioned on the tube fitting.
  2.  
  3. Connect the liquid line tube to the inlet fitting on the expansion valve. Tighten the nut to 10 ft. lbs.
  4.  
  5. Install the pressure switch, if removed. Tighten to 10 ft. lbs. Install the clamp and heat insulator to the outlet tube.
  6.  
  7. Install the upper and lower cases on the evaporator. Install the thermistor.
  8.  
  9. Install the A/C wiring harness to the cooling unit and all other necessary components.
  10.  
  11. Install the cooling unit assembly and its retaining nuts and bolts. Be careful not to pinch the wiring harness while installing the cooling unit.
  12.  
  13. Install the glove box and the grommets on the inlet and outlet fittings.
  14.  
  15. Connect the liquid line to the cooling unit inlet fittings and tighten to 10 ft. lbs.
  16.  
  17. If the evaporator was replaced, add 1.4-1.7 oz. of compressor oil to the compressor. Connect the negative battery cable.
  18.  
  19. Evacuate the A/C system. Have an authorized service station recharge the system, operate it and check for leaks.
  20.  

Van
FRONT COOLING UNIT


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Fig. Fig. 3 Exploded view of the front cooling unit-Van



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Fig. Fig. 4 Disconnect the suction and liquid lines from the front cooling unit-Van



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Fig. Fig. 5 Unfasten the cooling unit nuts and bolts, then remove the unit from the vehicle-Van

  1. Disconnect the negative battery cable. Discharge the refrigerant system.
  2.  
  3. Disconnect the suction flexible hose from the cooling unit outlet fitting.
  4.  
  5. Disconnect the liquid line from the cooling unit inlet fitting. Cap the open fittings immediately to keep the moisture out of the system.
  6.  
  7. Remove the grommets from the inlet and outlet fittings.
  8.  
  9. Remove the glove box with the under cover. Unplug all necessary connectors, such as the pressure switch connector and the A/C harness.
  10.  
  11. Remove the cooling unit attaching nuts and bolts. Remove the cooling unit from the vehicle.
  12.  
  13. Place the cooling unit on a suitable work bench and disassemble it as follows:
  14.  
    1. Unplug the connectors at the cooling unit case.
    2.  
    3. Remove the amplifier.
    4.  
    5. Remove the wire harness.
    6.  
    7. Remove the 7 case retaining clips.
    8.  
    9. Remove the case retaining screws.
    10.  
    11. Remove the upper case unit.
    12.  
    13. Remove the thermistor along with the thermistor holder.
    14.  
    15. Remove the lower case unit.
    16.  
    17. Disconnect the liquid tube from the inlet fitting of the expansion valve.
    18.  
    19. Remove the packing and the heat sensing tube from the suction tube of the evaporator.
    20.  
    21. Remove the expansion valve.
    22.  


Before installing the evaporator, check the evaporator fins for blockage. If the fins are clogged, clean them with compressed air. Never use water to clean the evaporator. Check the fittings for cracks and or scratches and repair as necessary.

To install:

  1. Connect the expansion valve to the inlet fitting of the evaporator and tighten to 17 ft. lbs. Be sure that the O-ring is positioned on the tube fitting.
  2.  
  3. Install the holder to the suction tube with the heat sensitizing tube. Connect the liquid line tube to the inlet fitting on the expansion valve. Tighten the nut to 10 ft. lbs.
  4.  
  5. Reassemble the cooling unit assembly as follows:
  6.  
    1. Install the lower case unit.
    2.  
    3. Install the thermistor along with the thermistor holder.
    4.  
    5. Install the upper case unit.
    6.  
    7. Install the case retaining screws.
    8.  
    9. Install the 7 case retaining clips.
    10.  
    11. Install the wire harness.
    12.  
    13. Install the amplifier.
    14.  
    15. Attach the connectors at the cooling unit case.
    16.  

  7. Install the cooling unit assembly and its retaining nuts and bolts. Be careful not to pinch the wiring harness while installing the cooling unit. Attach all the necessary connectors.
  8.  
  9. Install the glove box along with the under cover. Install the grommets on the inlet and outlet fittings.
  10.  
  11. Connect the liquid line to the cooling unit inlet fittings and tighten to 10 ft. lbs. Connect the suction tube to the cooling unit outlet fitting, tighten to 24 ft. lbs.
  12.  
  13. If the evaporator was replaced, add 1.4-1.7 oz. of compressor oil to the compressor. Connect the negative battery cable.
  14.  
  15. Evacuate the A/C system. Have an authorized service station recharge the system, operate it and check for leaks.
  16.  

REAR COOLING UNIT


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Fig. Fig. 6 View of the rear cooling unit-Van



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Fig. Fig. 7 Remove the necessary components to gain access to the rear cooling unit-Van



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Fig. Fig. 8 Have a certified service station discharge, evacuate and recharge your A/C system



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Fig. Fig. 9 Unlike these fools, certified technicians are knowledgeable with refrigerant precautions

  1. Disconnect the negative battery cable. Discharge the refrigerant system.
  2.  
  3. Disconnect the suction flexible hose from the cooling unit outlet fitting.
  4.  
  5. Disconnect the liquid line from the cooling unit inlet fitting. Cap the open fittings immediately to keep the moisture out of the system.
  6.  
  7. Remove the grommets from the inlet and outlet fittings.
  8.  
  9. Remove the magnetic valve.
  10.  
  11. Remove the rear blower unit.
  12.  
  13. Disconnect the suction tube. Remove the 4 rear cooling unit retaining bolts and remove the rear cooling unit assembly.
  14.  
  15. Place the cooling unit on a suitable work bench and disassemble it as follows:
  16.  
    1. Unplug the connectors at the cooling unit case.
    2.  
    3. Disconnect the liquid tube from the inlet fitting of the expansion valve.
    4.  
    5. Remove the packing and the heat sensing tube from the suction tube of the evaporator.
    6.  
    7. Remove the expansion valve.
    8.  
    9. Remove the 5 case retaining clips.
    10.  
    11. Remove the case retaining screws.
    12.  
    13. Remove the upper case unit.
    14.  
    15. Remove the thermistor along with the thermistor holder.
    16.  
    17. Remove the lower case unit.
    18.  


Before installing the evaporator, check the evaporator fins for blockage. If the fins are clogged, clean them with compressed air. Never use water to clean the evaporator. Check the fittings for cracks and or scratches and repair as necessary.

To install:

  1. Connect the expansion valve to the inlet fitting of the evaporator and tighten to 17 ft. lbs. Be sure that the O-ring is positioned on the tube fitting.
  2.  
  3. Install the holder to the suction tube with the heat sensitizing tube. Connect the liquid line tube to the inlet fitting on the expansion valve. Tighten the nut to 10 ft. lbs.
  4.  
  5. Reassemble the cooling unit assembly as follows:
  6.  
    1. Install the lower case unit.
    2.  
    3. Install the thermistor along with the thermistor holder.
    4.  
    5. Install the upper case unit.
    6.  
    7. Install the case retaining screws.
    8.  
    9. Install the 5 case retaining clips.
    10.  

  7. Install the rear cooling unit into the vehicle and install the 4 retaining bolts.
  8.  
  9. Connect the suction tube to the rear cooling unit outlet fitting, tighten to 24 ft. lbs.
  10.  
  11. Install the rear blower unit.
  12.  
  13. Install the magnetic valve.
  14.  
  15. Connect the liquid tubes 10 ft. lbs.
  16.  
  17. If the evaporator was replaced, add 1.4-1.7 oz. of compressor oil to the compressor. Connect the negative battery cable.
  18.  
  19. Evacuate the A/C system. Have an authorized service station recharge the system, operate it and check for leaks.
  20.  

 
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