[c900]

For my 1990 9000 carlsson, The Ac evap has been out of the car for 7 yrs and it's time to sort that out and get the climate stuff functioning. I've got a new aftermarket (OEM new unobtainable) correct part number AC evap unit and I'm having trouble getting the two parts of the plastic housing to fit together properly on the end where the pipes come up through the lid.

I've double-checked and the evap unit is slotted into place correctly. Sadly my flickr acct got deleted (NFI why) so I can't link up any pics but the only possibility I can come up with is that the piping matrix at the fitting end is a bit different in how all the tubes are joined and may be pressing on the top bit of the housing when it's pushed down.

I'll be a bit more 'pushy' and see if it will go, but I'm mindful that the OEM original one (very dead) had the pipework done somewhat differently.

The Evap unit is Saab 96 24 925. There's one currently on Ebay that looks identical to the new oldstock aftermarket one I'm fitting up now:

Saab 9000 1986 1987 1988 1989 1990 1991 NEW AC Evaporator Core EV 5909ATC | eBay

Find many great new & used options and get the best deals for Saab 9000 1986 1987 1988 1989 1990 1991 NEW AC Evaporator Core EV 5909ATC at the best online prices at eBay! Free shipping for many products!

www.ebay.com

I've found that I need to actually modify (slightly) the opening in the top cover of the evap housing and bend slightly the 'flange' on the end of the evap unit that fits into the slots in the housing. Simple job with some pliers (for the metal flange) and files (for the plastic of the top cover) and all is going together well.

 

[c900]

Woo hoo pics are back. https://flic.kr/p/2on1Ny6
https://flic.kr/p/2on4msK
I'm working on the external bits now - inserting the defrost thermo-contact (don't have a new one of those) etc. Mostly new oldstock bits overall.

 

[c900]

Defrost thermocontact and sensor probe re-fitted.

https://flic.kr/p/2oneqTQ
Had to take out the rubber grommet to see where to place the sensor probe.

 

[Ryengoth]

Did your evap retaining plate come off in one piece? I have some evap box repair and evap coil testing vids on my channel.

 

[c900]

I didn't have anything come apart unexpectedly. I'm not sure what you mean by 'retaining plate'.

one question - the thermo-coil for the TX valve. Is that supposed to be clipped to the pipe of the evap core or does it sit freely in the air path coming from the blower fan? It's the one thing I don't remember since taking the evap assy out of the car about 7 yrs ago and pulling it all apart.

https://flic.kr/p/2oo2EeJ

 

[Ryengoth]

That looks like a Sanden setup. I don't know I have the all-in-one evap valve for the Seiko Seiki 134a conversion.

 

[Ryengoth]

Typically HVAC systems that use an external capillary bulb (or capillary coil) for control need the bulb to be tight against the top side of the line that goes from the evaporator coil to the compressor (on the low side) (large line). In this case I would just secure it as tight as possible and as close to the coil as you can on that line. I would use metal zip ties or crimp rings like you use on fuel lines. Just be careful not to squish the coil at all. Plastic zip ties will eventually crack and your TXV will start misbehaving.