2003 Aerio SX, awful smell, no cabin air filter?

[A7QOyKkoHict]

Recently bought a used 2003 Aerio with a moldy smell emanating from the air conditioner. I did some reading and everything points towards replacing the cabin air filter. I did some more reading and learned that 2003 Aerios don't have cabin air filters. Now what?

[fordem]

More often than not the problem is mildew in the evaporator housing.

Start by finding the evaporator housing drain and making sure it's not clogged, then get yourself a can of Lysol aerosol disenfectant, set the a/c to recirculate, locate the recirculate intake (usually behind the glove box) and with the blower on high, spray about half the can into the intake.

[A7QOyKkoHict]

Alright, the Lysol idea seem easy enough, definitely giving that a go. But, where is the evaporator housing? What does it do and what does it look like?

[fordem]

The evaporator housing houses the evaporator

OK - a quick A/C lesson - in an A/C system there are two heat exchangers, one inside the vehicle where the liquid refrigerant absorbs heat energy and evaporates becoming a gas, and a second outside the vehicle where the gaseous refrigerant releases the heat energy and condenses becoming a liquid. There is also a pump or compressor that keeps the refrigerant moving.

The inside heat exchanger is called the evaporator and is located behind the dash, usually on the passenger side, behind the glove box, the outside heat exchanger is called the condenser and is usually located infront of the radiator.

The evaporator is in a plastic enclosure which will have a drain at the bottom to allow any water that accumulates to drain, usually through a short piece of rubber tube out through the firewall - you're going to need to get under the car and look for a short piece of tube, maybe half an inch in diameter and no more than a few inches long, just sticking out of the floor/firewall on the passenger side - run a few inches of a straightened wire coat hanger through it to clear any blockage.

[A7QOyKkoHict]

Well, I went behind the glove box and I cant see anything that looks like I could spray lysol into. Any ideas?

I found the tube that drains the evaporator, sprayed some lysol into that, and watched it drain underneath the car, so no blockage there.

I sprayed a lot of lysol into the outside vents underneath the windshield wipers, hopefully that will kill something. But, since it's designed to rain into there, I imagine those vents are pretty well protected from the inside of the car.

Behind glove box: http://i.imgur.com/vuasO.jpg what is that thing?

Behind center console, I'm fairly certain the evaporator is the large white plastic box: http://i.imgur.com/YDWMl.jpg

Tube that drains from the evaporator to the outside: http://i.imgur.com/EcPwq.jpg

[fordem]

The white enclosure behind the glovebox most likely houses the blower fan at the bottom - see that rectangular section - full width, maybe 1" high? That looks like it could be your cabin filter, or the space where it fits, and above that maybe a door - do you have the intake set on recirculate?

[A7QOyKkoHict]

Interesting, thanks. I ordered a blower filter which I suppose I'll install in there later.

I switched the AC off recirculate to get some suction into the outside vents where I was spraying the lysol. It hasn't been long enough to get the car to stop smelling like lysol so I can't tell if this did it.

When I'm driving, I rarely use AC (I live in Los Angeles and never need it) but I still can smell whatever this is when I get into the car after the windows have been up for a while or when I turn on the AC with recirculation.

[fordem]

The reason I asked if it was on recirculate is that if it's not, the recirculate intake will be blocked or closed - switching between fresh & recirculate whilst watching the housing may reveal where the intake is as it opens & closes.

[A7QOyKkoHict]

Well, nothing about this is easy.

I looked around for the recirculating air intake for a while, found it, and can't get to it with a can of lysol. The intake is behind the blower and above where the filter would go. After completely removing the glove box I can barely get my hand around to touch the vent, let alone get back there with a can of disinfectant.

A few days ago I ordered a blower filter for this car, it's a "special order" and will take a while. When I get it, the plan is to cut away that slot above the blower, spray an assload of lysol into the slot while the AC is running, hope that kills whatever is stinking up my car, install the filter and be done with my investigation of the AC system.

I've also set off a can of "odor bomb" with the AC running and am hoping that will do something good.