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amr75wcr
10-04-12, 11:14 PM
One of the techs at work has invested in a flash endoscope for looking inside engines so we had a look inside the ac box today and now i really understand why cabin filters have been added to late model vehicles. Well after 238000k on the Pajero this is what we have found.

Aussie_Dan
11-04-12, 09:01 AM
Oh dear, you've got some mud happening in there Wayne!
Any idea if you can relatively easily get into the evaporator to give it a cleanout from up above the passengers footwell perhaps?
Dan.

psproule
11-04-12, 05:23 PM
It's Alive! Yuck.

amr75wcr
11-04-12, 06:56 PM
Oh dear, you've got some mud happening in there Wayne!
Any idea if you can relatively easily get into the evaporator to give it a cleanout from up above the passengers footwell perhaps?
Dan.

Not sure at this stage, I did sent the prob down to view the top of the evaporator and it is no where as bad, according to the MM parts fiche the fan section will detach from the main heater box. Weather the are able to be spilt with the dash in is the unknown factor at this stage.
Wayne

amr75wcr
11-04-12, 06:57 PM
It's Alive! Yuck.

I guess it's a combination of the dust poring in the rear vents and no cabin filter, after all the Ac lives in recirc.
Wayne

amr75wcr
14-04-12, 09:10 PM
Ok so today it was dismantle the Pajero dash to try and clean the air con evaporator. Well i have to say hats of to the guys at MM total job took about 2 hours as the air box unit is in three seperate parts and can be split with the dash in.
Firstly remove the top glove box, its not that difficult so i didn't take pics, one the top glove box is out the center piece of the air box needs to be removed. http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05145.jpg
this piece is the bit that allows access to evaporator. Don't forget to unplug the wiring connector on the resistor.
under the main glove box the plastic trim needs to be removed
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05140.jpg
threaded clip at the back and two plastic phillips type screw heads under the glove box trim.
This clip is in a bastard of a spot to get
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05141.jpg
Once the top dash i removed and the lower trim there is two bolt and one clip in the back of the air duct between the fan and evaporator housing.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05142.jpg
remove these whilst you a crawling around on the ground.
Next step is to release the lower glove box so it will allow better access just push either side of the glove box to allow the stops to clear the dash.

Once the lower dash is out of the way the is a large metal bracket held in by a 10mm bolt remove it.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05139.jpg
Once this is out of the way there is a 10 and 8 mm bolts that need to be removed as well as a phillips screw holding the bracket on top of the air chanel, it holds the feron tubing in place at the tx valve there is only the one screw on it.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05138.jpg
After these 4 bolts and one screw have been removed the center air duct will slide straight down it may need a little jiggling to clear the dash and the floor carpet, i needed to pull back on the bottom of the dash panel where the center console joins to clear the metal framework on the inside of the dash.
This is the piece you are trying to remove.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05135-1.jpg

After it is out this was the state of the evaporator.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05132.jpg
Then came the question how to clean the bloody thing, i grabber the garden hose moved the car to a slight angle so the drain hole was downhill, grabbed a towel and wrapped it around the hose fittings. i put the adjustable nozzle on the flat spray pattern and held it inside the evaperator box and began to spary in small burts.

I put the hose in here.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05128.jpg
I think half of WA and QLD flowed freely from the drain hole, after a few minutes of flushing and the water was running clear this was the result.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05134.jpg
Job done refitting is a matter of holding your tongue right as well to get the duct back in but all in all not that bad.
After refitting it i tested the air con again and now the air hammers out the vents on high speed which was a far cry from last week.
So if you air seems a bit ordinary before rushing of to the auto electricans to have a regas my suggestion would be check the evaporator for clogging.
Next mission fix the rear air vent dusting problem.
Wayne

brianwanless
15-04-12, 07:23 PM
Well done Wayne. Great post, the photos make it very clear. It will make a huge difference to the airflow. Sometimes the worst looking jobs turn out to be fairly simple, if you take it stage by stage and put all the screws, bolts and bits you remove in separate containers. I find that helps a lot when trying to put it all back together. Good job. Brian.

Aussie_Dan
15-04-12, 08:45 PM
Top job Wayne, thanks for being the guinea pig and showing us all how it is done!
Cheers, Dan.

amr75wcr
15-04-12, 08:57 PM
Top job Wayne, thanks for being the guinea pig and showing us all how it is done!
Cheers, Dan.

No probs, at least I can confirm that it has not been to no advantage. The air conditioning has a very noticeable improvement.
Wayne

AJC
15-04-12, 09:04 PM
No probs, at least I can confirm that it has not been to no advantage. The air conditioning has a very noticeable improvement.
Wayne

Thanks Wayne...i think! There goes another Sunday!

Al

green monster
17-04-12, 08:12 PM
cheers Wayne,, im convinced mine will be in a similar state,, will get right on it
thanks mate.

Huck
17-04-12, 09:34 PM
Well done buddy, just exactly what i think has happened, Last 18 months has been 2 big central Aus trips in convoy, I get a muddy smell when i whack the air on if it has not been used for a couple of days. So this is very much on the to do list now. (with every thing else)
Great post and so informative.
I love this forum :)

Dude
19-04-12, 06:47 PM
Hi am75wcr,

Does it look possible to remove the evap coil from where you were at without removing the dashboard?

Mine has a leak.

dude.

amr75wcr
19-04-12, 07:01 PM
Hi am75wcr,

Does it look possible to remove the evap coil from where you were at without removing the dashboard?

Mine has a leak.

dude.

To be honest I didn't really have that close a look, I just had a closer look at my photos and I think the whole air box would need to come out. As to the ability to get the air box out without taking out the dash I really don't know but it think it would be dash out.
And no I am not going to be the pioneer on that.

Just checked the workshop manual DASH OUT

Wayne

Dude
19-04-12, 08:22 PM
:curse5[1]:

colcam
06-01-13, 01:01 PM
Just done the cabin filter mod by Wayne:
http://www2.pajeroclub.com.au/forum/showthread.php?t=23100
Very straight forward thanks mate.

Bought the filter from him at A Cullen & Sons:
http://www2.pajeroclub.com.au/forum/showthread.php?t=27930
Great price and even better service - you can't go wrong.

Then cleaned out the evaporator detailed in this post. The evaporator wasn't as bad as in Waynes pics but the amount of leaves and dirt and crap that was clogging the drain hole was certainly the cause of the wet smelly carpet because the water couldn't get away.

I had to put a hose up the drain pipe were it comes out next to the gearbox to try and clear it out. I couldn't believe the amount of debris that kept coming out. I alternated from hosing the evaporator then back up the drain pipe a few times before it started running clear. I had someone in the cab telling me when to stop squirting so I didn't fill up the box too much. She also had a hook to snag some of the larger bits that wouldn't fit down the drain.

Fingers crossed there'll be no more smelly carpet or iceing up.
This problem has been annoying the crap out of me for a few years now and as usual the local MM dealer was useless .

One thing I did find when I removed the centre air duct, was the resister that screws in under it (in your first pic) is rusted.
What does it do and does rust = stuffed?


Cheers

Cameron

steveandviv
06-01-13, 03:22 PM
Yea, me too. Busy weekend. To hot though at the moment.

pauld
07-01-13, 05:45 PM
I believe your resistor block is for the different fan speeds, it's in the duct to keep it cool. Should be right until the fan stops working (if it ever does).

colcam
07-01-13, 07:02 PM
Thanks Paul

amr75wcr
07-01-13, 11:09 PM
I believe your resistor block is for the different fan speeds, it's in the duct to keep it cool. Should be right until the fan stops working (if it ever does).

Yes the resistor is in the duct for cooling and it will eventually fail, first indication will be the loss of a single fan speed, from memory about $60-70 from mm
Wayne

marcthelegend
08-01-13, 09:02 AM
Wonder if anyone could help, I did the cleaning steps described but somehow during all that managaed to block the drain plug? Anyway it filled up the condenser which eventually trailed back into the fan blades on corners and drenched the carpet, once I finally unblocked it I was showered with all sorts of things collected in there.

I noticed shortly after this happened that I can turn the fan to 1, 2 and 3 but when I hit 4 I get an immediate 'electrical burn' smell followed shortly by the 30amp fuse blowing? I have a new fan on order from the US ($90 from there, at least $250 from here, only difference is the connector) which should arrive late this week, early next.

Would the resistor pack be able to cause this issue as well?

Cheers

Marc

amr75wcr
08-01-13, 11:07 AM
Possibily it may have shorted the resistor, just one question how did you get water all the way back to the fan, did you remove the center section of the air box between the fan and evaporator?
Wayne

MickG
08-01-13, 01:26 PM
I'd have to recheck my schematic, but i seem to recall that the highest fan speed (4) by passes the resistor block. So I'd be looking for a short in that section of wiring, and not the res block.
Did u happen to check that the fan worked when removed from the car, by connecting directly to a spare battery? This would replicate 4th speed operation.

marcthelegend
09-01-13, 10:16 AM
Possibily it may have shorted the resistor, just one question how did you get water all the way back to the fan, did you remove the center section of the air box between the fan and evaporator?
Wayne

I followed all the steps listed above (took everything apart etc.) and in doing so, the dirt must have clogged the drain plug, anyway I noticed the condensation had formed a puddle roughly 100k's from a nearest town so had to push on, only when I arrived at the remote camping spot could I unblock it (had a 500ml of water by that point!) and I suppose by that time, it destroyed something.

Following this the fan began to make demonic screaching noises when operated at any speed.

Hoping it would not be the resistor pack!

Cheers

Marc

Aussie_Dan
29-01-14, 11:05 AM
Well I finally got around to it today. Took just over 1.5 hours after following Wayne's advice above.
My aircon stunk of dirt and dust every time you hit the aircon button. There were a couple of small leaves and bits of other crap trapped under the evaporator but mine was nowhere near as dirty as Wayne's. Not even in the same league!
I made up a wand with a 90 degree micro spray nozzle and a isolation tap out of irrigation bits and pieces that I had laying around. After a couple of passes with the wand I noticed that the evaporator box was filling up as the drain was blocking. My Paj has the mod with the extended drain pipe. I reached down behind the engine to the firewall and took the extended pipe off and jammed a large cable tie up the hole to unblock it.
After a few more sprays and a bit more work with the cable tie to keep unblocking the drain, I was happy with the end result. The first pass of water came out absolutely filthy and by the end it was coming out clean.
I put the extended drain hose back on and put everything back together under the dash.
Very happy with the result, no more dust / dirt smells from the aircon!
Cheers, Dan.

Picko
07-05-14, 10:04 AM
Thanks Wayne for the very usefull info, I think i had 1/2 of western queensland lodged in the evaporator. One trick i found before hosing it out was the vacum it 1st. I did this by duct taping 1/2 meter or so garden hose to the end of the vaccum cleaner hose, helped a lot. cheers. cabin filter will be fitted on the weekend

muppo
05-08-14, 04:12 PM
Just done the clean today it was all done including the cabin filter mod in 2hrs. I also removed the whole fan unit and cleaned it out. Simply remove two retaining screws for wiring loom and three fan assembly screws and the whole thing comes out , makes it soo much easier to clean the whole ducting out too.

Great forum, lots of great tips, keep it up everyone.

dou_nut
30-10-14, 03:23 PM
Hello..
Guys newbie...here...
I just want to ask someone who knows or done...this,,,
I have NM 2002 pajero...AUto...V6 with LPG ,,,Dual fuel...

It had pretty weak air condition...so I took it to mechanic to refill and check where is the leak is....
Mechanic couldn't find the leak...so he just refilled it....
Now I have cool air...front of the car (driver side and passenger side)...
If we turn the air con for the rear ....we are getting cool or warm air to front and bit cool air to rear...so we are not getting good air condition at all when we turn the rear section...

What can we do about it? Anything I can have a look or do before taking it to mechanic?

dou_nut
30-10-14, 03:36 PM
Ok so today it was dismantle the Pajero dash to try and clean the air con evaporator. Well i have to say hats of to the guys at MM total job took about 2 hours as the air box unit is in three seperate parts and can be split with the dash in.
Firstly remove the top glove box, its not that difficult so i didn't take pics, one the top glove box is out the center piece of the air box needs to be removed. http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05145.jpg
this piece is the bit that allows access to evaporator. Don't forget to unplug the wiring connector on the resistor.
under the main glove box the plastic trim needs to be removed
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05140.jpg
threaded clip at the back and two plastic phillips type screw heads under the glove box trim.
This clip is in a bastard of a spot to get
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05141.jpg
Once the top dash i removed and the lower trim there is two bolt and one clip in the back of the air duct between the fan and evaporator housing.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05142.jpg
remove these whilst you a crawling around on the ground.
Next step is to release the lower glove box so it will allow better access just push either side of the glove box to allow the stops to clear the dash.

Once the lower dash is out of the way the is a large metal bracket held in by a 10mm bolt remove it.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05139.jpg
Once this is out of the way there is a 10 and 8 mm bolts that need to be removed as well as a phillips screw holding the bracket on top of the air chanel, it holds the feron tubing in place at the tx valve there is only the one screw on it.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05138.jpg
After these 4 bolts and one screw have been removed the center air duct will slide straight down it may need a little jiggling to clear the dash and the floor carpet, i needed to pull back on the bottom of the dash panel where the center console joins to clear the metal framework on the inside of the dash.
This is the piece you are trying to remove.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05135-1.jpg

After it is out this was the state of the evaporator.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05132.jpg
Then came the question how to clean the bloody thing, i grabber the garden hose moved the car to a slight angle so the drain hole was downhill, grabbed a towel and wrapped it around the hose fittings. i put the adjustable nozzle on the flat spray pattern and held it inside the evaperator box and began to spary in small burts.

I put the hose in here.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05128.jpg
I think half of WA and QLD flowed freely from the drain hole, after a few minutes of flushing and the water was running clear this was the result.
http://i934.photobucket.com/albums/ad186/amr75wcr/DSC05134.jpg
Job done refitting is a matter of holding your tongue right as well to get the duct back in but all in all not that bad.
After refitting it i tested the air con again and now the air hammers out the vents on high speed which was a far cry from last week.
So if you air seems a bit ordinary before rushing of to the auto electricans to have a regas my suggestion would be check the evaporator for clogging.
Next mission fix the rear air vent dusting problem.
Wayne

Do you have to pull out all the dash? or just glowbox?
I have NM pajero...and air con is not so cold...just front section...
Rear section's air is not cold enough....thinking about cleaning...as you did...

Mnemonic
01-03-15, 04:16 PM
I did mine today and and was no trouble when i followed this guide.
My paj is a 2004 diesel auto pov pack, so im always looking for ways to mod, improve and maintain the old girl.
After cleaning the condenser out I gotta say the air con is just bloody freezing!
Love it!

Thanks so much for going to the trouble :beer[1]:

Bru9
11-03-15, 06:53 PM
I'm confused by grabbed a towel and wrapped it around the hose fittings. i put the adjustable nozzle on the flat spray pattern and held it inside the evaperator box and began to spary in small burts.

Does the removed part to be cleaned, have delicate parts inside that water can't touch?

TheTaipan
11-03-15, 08:03 PM
I'm confused by

Does the removed part to be cleaned, have delicate parts inside that water can't touch?


The delicate parts are in the compressor but mate don't get water or moisture in the evaporator or any part of the system. The hoses you have have discontented need to be sealed off so no moisture can enter. The ends of the evaporator also need to be sealed of when spraying water around.

Water/moisture is bad for any refrigeration system.

Bru9
12-03-15, 06:04 PM
The delicate parts are in the compressor but mate don't get water or moisture in the evaporator or any part of the system. The hoses you have have discontented need to be sealed off so no moisture can enter. The ends of the evaporator also need to be sealed of when spraying water around.

Water/moisture is bad for any refrigeration system.

It seems a bit like cleaning the grill on a radiator? Just plug up the hose openings.

blues
13-11-15, 08:51 AM
Thanks mate for a great writeup. I have a 2005 NM GLX with pissweak cabin air on max fan, so I will have a go at this soon.

chrisfarru
10-01-16, 01:23 PM
Thanks for the DIY

Pretty easy to get to once you watch your pics. Mine wasn't that filthy was full of leaves and other crap. Over the NY we've done heaps of 4WD tracks on very dusty roads. I could see the dust build up inside the vents, and could taste the dust inside the cabin. So evaporator is nice and clean now and a cabin filter installed. Happy days breathing clean air

Rich0
03-04-17, 08:11 AM
Great write up, thanks. Did mine on the weekend. Not as bad as that but still some gunk in it so cleaning it was worthwhile.

Also added the cabin filter mod (link in this thread above). Why I hadn't done that already is beyond me. So easy!

I used my on board air compressor and gun tool to give the condenser a blast. Problem was though, I have it on a pressure switch so when I gave it the initial blast it flattened some of the condenser blades. Followed that with a few squirts of the garden hose on spray and it cleaned up nicely.

My drain plug was blocked too but again, a quick blast with the air compressor dislodged all the silt and the water flowed out freely.

Job done. No more leaky foot well, no more internal dust plume on fan setting 4 and breathing cold clean air!


Sent from my SM-G930F using Tapatalk

Mitty
05-04-18, 08:11 AM
So Ghendo was kind enough to send me a copy of this thread with the photos. Happy to pass on the favour if anyone needs it

Has anyone tried cleaning the evaporator via the filter slot? Could I just snake a hose down there and give it a blast or do I risk doing some damage?

I'm just going off the photos so not sure exactly what else is in there

stanmiko
13-04-18, 09:16 PM
So Ghendo was kind enough to send me a copy of this thread with the photos. Happy to pass on the favour if anyone needs it

Has anyone tried cleaning the evaporator via the filter slot? Could I just snake a hose down there and give it a blast or do I risk doing some damage?

I'm just going off the photos so not sure exactly what else is in there

If you could send me a copy with the pics in place that would be fantastic.
I've done the cabin filter mod, but would love to clean the rest out and keep it clean now.
Cheers

GHendo
14-04-18, 09:01 AM
If you could send me a copy with the pics in place that would be fantastic.
I've done the cabin filter mod, but would love to clean the rest out and keep it clean now.
CheersHi mate

Welcome to the forum.

So that we can send you a copy of the instructions, you’ll need to send Mitty (or myself) a PM (Private Message) which includes your email address – that way we can email you back the PDF file as an attachment.

Cheers

Geoff

Skexis
02-03-19, 11:21 AM
Bit of a thread necro but any chance of reposting the pics that have disappeared?

Edit: also am I right in thinking a 2003 NP is not fitted with a cabin air filter?

GHendo
03-03-19, 06:50 AM
Hi mate

You would be right in thinking a 2003 NP is not fitted with a cabin air filter.

If you PM me your email address I’ll send you a PDF I have of the threat you want which includes the pictures – I filed it away on my computer before the pics disappeared.

Cheers

Geoff

ItsAllNew
29-03-19, 12:47 AM
Hi mate

Welcome to the forum.

So that we can send you a copy of the instructions, you’ll need to send Mitty (or myself) a PM (Private Message) which includes your email address – that way we can email you back the PDF file as an attachment.

Cheers

GeoffHi. Could I also get a copy of the condenser cleaning instructions and pictures.

Appears.that some of the original thread pictures are missing.. and may help our up coming journey conditions to have this working well..

Got myself the filter to fit with modern.. and have compressor for clean. Any other tips?



Cheers, Heath

Sent from my SM-G930F using Tapatalk