Evaporator Core: Service and Repair

Evaporator

To remove

IMPORTANT: If the pipes between the evaporator and the grommet in the bulkhead are jointless, they must be cut. Therefore, a new evaporator must then be fitted.

1. Drain the refrigerant from the A/C system.





2. Remove the glove box.
3. Cut the cable tie holding the wire harness to the service cover. Also cut the cable tie holding the cooler hose to the glove box.





4. Remove the service cover.
5. Remove the fresh-air filter and filter element.





6. Remove the ventilation fan.
7. Cut the A/C pipes to the evaporator with a sheet metal cutter or air-driven jigsaw.
The pipes are accessible from the engine compartment by the air recirculation flap.





8. Pull out the evaporator.
9. Detach the temperature sensor from the evaporator.
10. Remove the expansion valve.
11. Pull out the pipes from inside the cabin.
12. Vacuum pump the climate housing to remove any cuttings.

To fit





1. Make a hole for the temperature sensor in the center of the 5th cooling fin on the evaporator (from the passenger side). Use a tool with a rounded point, e.g. a cross-head screwdriver with diameter 4.5 mm.
Fit the temperature sensor in the evaporator.
2. Adjust the oil volume in the compressor, see Air Conditioning Compressor/Compressor Oil/Service and Repair.
3. Insert the plugged pipe set from inside the cabin.
4. Position the filter holder with the evaporator.
5. Push in the evaporator to the climate housing.
6. Remove the plugs from the A/C pipes and fit the expansion valve.
7. Position the PAD connection with the corresponding pipe set.





8 Locate the bolt in the PAD connection and tighten it from inside the engine compartment by the air recirculation flap

Tightening torque: 8 Nm (5.9 ft. lbs.)

9 Fit the ventilation fan.





10 Fit the fresh-air filter.
11 Fit the service cover.
12 Fasten the wiring harness and cooler hose with cable ties.





13 Replace the side trim on the center console.
Fit the glove box.
14 Vacuum pump the A/C system and fill with R134a refrigerant, see Refrigerant, A/C/Service and Repair.