Evaporator Core: Service and Repair

Data
Version Pipes and ribs made of aluminum
Face area/depth 6.0 sq. dm/96 mm


NOTE: If the evaporator is renewed. the receiver dehydrator and expansion valve must also be renewed (83-540 and 552). When renewing the evaporator. pour 40 cc fresh compressor oil into the evaporator.


Removing
1 Drain air conditioning system.
2 Remove cover on air inlet Procedures







3 Release bulkhead (48) by unscrewing the screws (arrows) on the left and right sides of the bulkhead. Then pull bulkhead forwards up to the engine.







4 Remove expansion valve (35) Service and Repair







5 Remove blower motor (M2) Service and Repair







6 Unscrew screws (arrows) and lift out lower section of housing (67).







7 Pull temperature sensor (B10/6) out of guide tube.
8 Unclip clamps (arrows) at left and right sides of frame (69) and remove frame.







9 Lift evaporator (80) with pan (6) and condensate water drain hoses (4 and 4a) out of evaporator housing.


Installing







10 Clean inside of pan (6) and check that the condensate water drain hoses (4 and 4a) are completely clear of blockage.
11 Insert evaporator (80) into pan (6).







12 Insert evaporator with pan into evaporator housing. Then mount rubber grommets (arrows) of condensate water drain hoses (4 and 4a).







13 Flange frame (69) to evaporator housing and clip in place with clamps (arrows).
14 Insert temperature sensor (B10/6) as far as possible into guide tube.







15 Fit lower section of housing (67) with screws (arrows).
16 Install blower motor Service and Repair







17 Remove closing cap (80a) of new evaporator from evaporator pipes by unscrewing both screws (arrows).
18 Install expansion valve Service and Repair
19 Renew receiver dehydrator Service and Repair







20 Fit bulkhead (48) and fasten with screws (arrows).
21 Install cover on air inlet Procedures
22 Evacuate air conditioning system and refill; check function and check for leaks Testing and Inspection