Getting Ready to Crack Evaporator Case - Advice Needed
 

Hi all,

Well, as you might have read, my "new" '85 Targa has a bad A/C evaporator motor. Reading through the various posts, it doesn't seem to be that bad of a job replacing it. I inspected the job this morning, and am giving myself a few days to accomplish the task, going at it "part time" of course.

I have a few questions before I commence, so I can cut down on my errors. Hopefully, those that have been through this before can provide me some guidance/shortcuts.

1. I can't tell from the diagrams how the bolts that connect the brackets to the case engage the nut. Before I remove these bolts, is the nut secured in the case, or is it loose on the other side? I don't want to pull a bolt only to hear the nut fall under the evaporator.

2. Are the spring clips the only thing holding the case itself together? There are three bolts in the top of the case, two holding one end of the brackets that secure the assembly, and one in a very precarious spot behind the blower "hump," tucked neatly in a little crevice. Do these bolts have to be removed to split the case?

Thanks, and any other advice that will make this job easier would be most appreciated!!!!!!!!!!!!!!!!!!!!

I have my entire evaporator out of the car right now and I can take some pictures to show how it goes together. The spring clips slide on from one side. the other side has a lip that prevents the spring clip from being pushed off. DON'T try to pop the clips off you will break the plastic case. Slide them back off the way they were pushed on. Several of the bolts hold the fan to the top of the plastic case and I believe the nuts are wedged into the plastic case on the underside. I would remove all of the clips and try to lift the case top up. you will also have to pull out the temp switch sense wire. it is pushed into the case and makes contact with the evaporator fins. They seal the hole where the sense wire goes in with duct seal. Several years ago I went into the evaporator to repair the fan (noisy bearings). You don't have to disconnect any of the freon lines unless you want to replace the evaporator.

I think it's the Griffiths web site that gives useful hints on how to break open the box...and simple alternatives on how to reseal it...using sheet metal screws or nylon ties as I recall...since the push -tab style speed nuts will be a bear to reinstall because of space limitations...
---Wil Ferch

As everyone has said, careful with the spring clips. They are very strong, and care is needed to avoid breaking the case ears themselves.

On the front RHS of the evap case you will see the temperature capilliary, which needs to be removed CAREFULLY. It is an very thin-walled Al tube, which will break if you bend it too far or if you bend it then try to straighten out the bend. Just be gentle it will come out fine.

The fan assembly is captive in the top of the case - no need to touch the screws before you lift the top off. As an alternative to working on the motor, a new replacement is around $70. Pelican has them, and so does Vertex [in FL].

Griffiths sells a kit to allow you to make it possible to access the evaporator box without removing it from the car. The kit includes very detailed instructions, and also new seals to ensure that that box seals properly. The instructions alone were worth the expense. If you're going to do the job, I'd suggest buying the kit.

Good luck.

Does the "kit" come with any tools?

Hey Mike,
If you feel inclined to take a few pictures along the way of your repair, it would probably help a few of us that have the same problem.
BTW- the car looks great!!
Nice find.:)

OK.......I have a crappy digital camera, but I'll take some pictures nonetheless.

I've got three of the four clips off, and I can see why it would be a nightmare getting them back on. After taking three of them off, I could design a tool that would make this a walk in the park! The clips have holes in the top and bottom lip, so all you need is a tool that would go into these holes to spread the clip. I'm sure they make one, but I'm also sure it's not designed to work at these funky angles. You'd need one that could be positioned 360 degrees in all planes.

Well, I'm taking a breather, as the last clip (the one on the back of the case) is proving to be quite difficult. I retrieved the three I removed. I looped a small wire in the upper hole before pushing them off, so they wouldn't fall under the evaporator. I also sprayed some 303 Protectant on them to help them slide off.

For those of you who did the R&R in 2 hours, my hats off to you.

Sounds like progress Michael. At least today is alot cooler than the last two weeks here in Florida.
Thanks in advance for the pictures.

Can't Get Back Clip!
 

I'm having a devil of a time getting the last clip, which is on the back of the evaporator box. The bracket that mounts the evaporator to the "fire" wall is in the way, but I'm afraid to remove it because I'm uncertain about the nut on the other end of the bolt that holds the bracket to the box.

Does anyone know for sure how/if that nut is secured? I'm afraid if I pull the bolt, the nut and washer will fall under the evaporator coil. It doesn't feel like the nut is secure, but I can't tell for certain. Grrrrrr................

Anyone taken the bolts out?

I have an evaporator assembly with good fan and motor. It is for sale if anyone needs one.

Pic Attached:

http://forums.pelicanparts.com/uploa...assembly s.jpg