92evaporator 1.jpg3024x4032 2.3 MB

I have been trying to find where my leak is in the AC system of my '92 convertible. After carefully examining every connection today, this is what I found. I hope you can see the crack in the fitting of the evaporator where the muffler connects. Any ideas how to get around this. I am trying to source a used evaporator without too much luck.
And before I hear that I don’t need AC because it is a convertible and I have gotten away without it for the last 18 years, I was planning to take the wife to Virginia in late June in this car. If you have ever been stuck on I-95 around Washington DC you would understand.

 

I'm from DC, you're gonna need AC.

pan back a bit, I can't tell where the crack is. It looks like youre near the condenser, but is that the firewall I'm looking at?

 

Least you didnt do it to yourself. There was so much insulative schmoo on the end of my evap that I couldn't see it was hex shaped, which is clear in your pic.

Tried to pull the old line off and twist the end of the evap straight off. Lotta work for cold air.

 

Yes, that is the firewall.

 

I had to scrape off a bunch of he schmoo to get at the expansion valve so I could remove it. I guess it is supposed to be there.

 

US Part Number: 80631
Canada Part Number: N/A










Permatex® Thread Sealant with PTFE



Category: Thread Sealants
Economical general-purpose fitting sealant. Outperforms tapes and pipe dopes. Seals and resists pressure in air, oil, diesel fuel and hydraulic systems. Remains pliable at higher and lower temperatures. Temperature range -65°F to 300°F (-54°C to 149°C); resists common shop fluids.

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Automobile

Suggested Applications: Air conditioning fittings, temperature sending fittings, and hydraulic fittings

 

I'm afraid the only option is a replacement evaporator. That's a dash out job to do, but it actually isn't that bad if you don't have airbags - do you? Even if you do, it's simple to make the tool to disarm the drivers side and remove.

Depending on your VIN, the evaporator is the same as a Series III sedan.

 

Is the crack in the evaporator or in the expansion valve? Both are available, but as Jagboi said, the evaporator is a dash out job to get to the A/C and heater unit, remove it and replace the evaporator. If you have to do this, you will need a friend to get the unit out, it is heavy.
Best to remove the seats, then the console, radio, remove/disconnect any switches, instrument binnacle, steering wheel, then the glove box interior, then the actual dash comes out reasonably easily. All takes time, take loads of photos of loom positions etc etc. One of the side benefits is that you can clean up all the earths and power distribution points etc etc.

 

I am going to try a product called La-co Heat-seal stik. Apparently, it is used in the AC field for filling cracks by heating up the area to 350 degrees and then applying the epoxy. If it works, I should get at least a temporary solution.
I am still having trouble finding a replacement evaporator. I have been told that SC parts has them made for them. I am still waiting for a reply from them to confirm that.

 

Jaguar Partno_AEU1191*_AIRCON EVAPORATOR XJ6 XJ12 XJS_David Manners Group with Alts

 

That was a good find, a crack there could have gone unnoticed for a long time.

 

It still looks to me from the photo that the crack is in the valve though, not the pipe coming though the bulkhead.

 

Unfortunately it is in the pipe coming through the bulkhead. The expansion valve has been removed in this picture. It attaches to the pipe that can be seen behind this fitting with the green o'ring still attached.

 

Well I performed the repair using the Laco heat seal stick. It looked like it had filled the crack so after smoothing out the repair area, I assembled the muffler and used some teflon sealant as an insurance trying to make sure it sealed. I pulled a vacuum for about an hour. After 4 hours the vacuum has dropped a little. Not like before but I am not encouraged. I just placed the order for a new evaporator. At least winter hasn't finished yet in Vermont.

 

carefully braze on the inside would be my suggestion. I have removed a matrix unit from an XJS....not fun.

 

I had purchased a new aluminum compressor and new filter/drier before finding the cracked fitting. I decided to go ahead and install them since I had them. After that I pulled a vacuum for about an hour and it only dropped partway down after 12 hours. I pulled another vacuum for 2 hours and checked after another 12 hours and the vacuum did not change. I checked it again this morning and the vacuum has maintained. Success! Now I hopee it works properly once charged.