Evaporator Case: Service and Repair

NOTE: The following procedure was compiled from field experience.

Removal
1. Evacuate a/c system. SEE Heating and Air Conditioning. Procedures
2. Drain approx. 2 liters of radiator coolant.
3. Remove both front seats.
4. Remove push-button control unit.
5. Remove center console.
6. Remove instrument panel.

Heater Hose Connections To Heater Core:

7. Disconnect heater hoses.

Rear Compartment Air Ducts, Right:

8. Remove air ducts for rear compartment heater.

Air Duct On Transmission Tunnel:

9. Remove air ducts on transmission tunnel.

Pre-resistor Plug On Heater Box:

10. Pull off plug (b) and open cable bands on heater box. Loosen all electrical connections on heater box. Remove electrical plugs from evaporator temperature regulator (ETR).

Switchover Valves ACC:

11. Remove 6-point vacuum distributor and electric plugs from switchover valves.

Heater Box Housing Support:

12. Remove support on transmission tunnel.

Expansion Valve With Cover Removed:

13. Remove lines (15 and 16) from expansion valve. Then close with plugs.

Condensation Tube Connection On Evaporator Housing:

14. Remove condensate drain hose (22) from evaporator housing.

Air Jet, Blower Cage, Fresh/Recirculate Air Flap Vacuum Element:

15. Remove hoses from air jet.

Evaporator Housing Mounting Brackets:

16. Remove nut (1) and angular fastening bracket (a).

Righthand Angular Holding Bracket Heater Box, Integrated A/C & ACC Housing:

17. Remove nut on righthand upper angular holding bracket.

Lefthand Angular Holding Bracket Heater Box, A/C And ACC Integrated Housing:

18. Remove nut on lefthand upper angular holding bracket.
19. Remove evaporator housing with heater box while holding heater pipes up so no coolant will leak out.
20. Remove vacuum hoses from main air flap vacuum element and fresh/recirculating air flap vacuum element.

Evaporator To Heater Housing Brackets And Clips:

21. Remove evaporator housing from heater box by removing nuts (2) and clamps (b).


Installation
1. Connect evaporator housing to heater box and mount expansion valve.
2. Plug vacuum lines to main air flap vacuum element and fresh/recirculating air flap vacuum element.
3. Mount evaporator housing with heater box to front wall while guiding heater tubes through grommets in front wall.
4. Secure evaporator housing at top to front wall.
5. Install lower angular holding bracket.

Condensation Drain Tube (34):

6. Mount condensate drain hoses (22 and 34).
7. Install support at transmission tunnel.
8. Connect lines (15 and 16) to expansion valve. Check 0-ring and threads and coat with cold-flowing oil.
9. Install electric lines and connect plugs.
10. Install air ducts for rear compartment heater.
11. Connect heater hoses and add coolant.
12. Install instrument panel and center console.
13. Install push-button control unit.
14. Install driver's seats.
15. Evacuate a/c system, and refill. SEE Heating and Air Conditioning. Procedures
16. Check functions of ACC. SEE Testing and Inspection. Testing and Inspection