Evaporator Core: Service and Repair

Data:
Version
- Copper pipes and aluminum ribs
Face area/depth
- 8.3 dm2/80 mm, 5 rows
Refrigerating capacity
- 6.9 KW (6000 (kcal/h))

Note: If contamination is found in the expansion valve, then the receiver dehydrator and the expansion valve are to be replaced. When the evaporator is replaced, inject 40 cm3 new compressor oil.

Removal:
1. Remove evaporator housing. Service and Repair
2. Remove heat exchanger.
3. Remove electronic switching unit.

4. Unscrew expansion valve (35) from evaporator and close line connections with plugs.

5. Unscrew screws (67) on housing for main air flap.

6. Remove clamps (refer to arrow) on main flap housing

and lift off housing for main flap.

7. Disconnect bowden wires (48 and 56) for footwell and defroster nozzle flaps. Remove clamps (57 and 58).

8. Remove clamps (refer to arrow) on evaporator housing

as well as on heater box and remove housing cover.

9. Pull vacuum lines (refer to arrows)

from switch-over valve (14).

10. Unscrew fastening screw (68).

11. Lift off clamp (94) from Bowden wire for not heatable fresh air at the right by means of a screw driver,

and pull out bearing shaft (95).

12. Remove clamps (70) on side member at the right and lift off side member (71).

13. Lift clamp (94) from bowden wire for not heatable fresh air at the left by means of a screwdriver

and pull-out bearing shaft (95).

14. Unscrew fastening screw (87).

15. Remove clamps (70) on side member at the left and lift off side member (72).

16. Lift heater box top (75) from evaporator box bottom.

17. Pull temperature sensor (15) out of evaporator

or capillary of ETR-switch (15) out of guide tube and remove evaporator from evaporator housing-lower half.

Installation:

Attention! The air conditioner cabinet should be well sealed along horizontal separating joint. Particularly important ranges are behind expansion valve and temperature or blower control.

18. Clean evaporator housing, paying attention to perfect passage of condensation drain connection. Remove any foam inserts in condensate drain hoses (arrow) 1st version.

19. Install new evaporator (80) free of damage into evaporator housing (81).

20. Carefully insert temperature sensor (15) in-between evaporator plates and make sure that sensor is correctly seated and has good contact or slip capillary of ETR switch up to red mark into guide tube. If required, rebend plates for temperature sensor accordingly.

21. Place heater box top (75) on evaporator housing bottom.

22. Mount side member (72) left with clamps (70) and screw (87).

23. Mount side member (71) right with clamps (70) and screw (68).

24. Slip bearing shaft (95) at left and right into heater box and check operation of flaps for not heatable fresh air. Then mount fastening clamp (94) for bowden wire left and right