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leaking rear evaporator

cheddar85 on Tue August 25, 2009 11:26 PM User is offline

Year: 1997
Make: plymouth
Model: grand voyager
Engine Size: 3.3
Refrigerant Type: r134a
Country of Origin: United States

I've had a leak on this car for a little while now and I finally got around to finding it, of course it's the rear evaporator! I need help to figure out how to remove it, mainly how and where to disconnect the lines. I've already got the box mostly torn apart, I just don't want to accidentally break something trying to get it out. Thanks for the help!

robs on Wed August 26, 2009 3:07 PM User is offlineView users profile

Remove right rear quarter trim panel and pillar trim, discharge a/c system and remove the following in this order:
distribution duct
rear A/C unit
blower motor scroll
evaporator cover
remove nut securing refrigerant block to expansion valve
remove evaporator and expansion valve from unit
discard "O" rings between refrigerant block and expansion valve
plug all openings in A/C system
cover refrigerant block sealing surface
remove Torx head screws and remove expansion valve.
To install, reverse removal procedure. Install new "O" rings between refrigerant block and expansion valve. Tighten Torx head screws to 70-125 INCH lbs. (8-14 N.m). Add same amount of oil drained from evaporator back into evaporator.

Edited: Wed August 26, 2009 at 4:33 PM by robs

HVargas on Wed August 26, 2009 4:00 PM User is offlineView users profile

Great post Rob. Be sure that you have recycled all of the refrigerant out of the system before you open it and be sure to pull a vacuum for at least 30 minutes after replacing the evaporator. If it appears you have lost oil out of the leaking spot I would recommend adding a couple ounces of oil to it as well. Then recharge with 48oz of R134a. I would recommend a professional do this if you do not have the proper equipment. Cans are ok, but kind of hard to tell if you have gotten it all out and if it even had a full amount in the can to start with. Good luck to you!


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cheddar85 on Thu August 27, 2009 11:20 AM User is offline

Alright thanks guys! I'm going out of town for a few days so I'll tear into it when I get back. I have all the equipment to do it myself, except to recover the refrigerant of course. I'll let everyone know how it works when it's finished.

newton5 on Fri August 28, 2009 1:50 AM User is offlineView users profile

Umm, guys...??? Just a heads up.
There is a big problem with corrosion between the rear evaporator connection block and the expansion valve block on "later" Chrysler minivans. The o-ring grooves corrode and leak. It's back in the RR wheel well below the floor, so it catches lots of road gook from the RR wheel.
Replacing the evaporator itself may be a temp fix or no fix at all depending on which side of the connection the corrosion is on. I think 1997 was the first applicable "later" year. I've seen this happen in Chrysler minivans as new as '06 here in salty Ohio.
The Chrysler Dealer has a "revised" evaporator and expansion block assembly that is supposed to correct this issue. I've done a few of these and can't see a physical difference in the new and old parts?
I've seen my share of leaky Mopar minivan front evaps, but very few rears that actually leaked in the core itself.

Edited: Fri August 28, 2009 at 2:16 AM by newton5

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