Evaporator Core: Service and Repair

Evaporator

NOTE: The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Important information

NOTE: This method only applies to left-hand drive vehicles (LHD).

Drain refrigerant from the A/C system.

Draining coolant and removing the cover





Remove the expansion tank cap.

Raise the vehicle.
Remove the shield under the vehicle. It is secured with 7 clips. See the illustration.

Install a hose on the nipple at the radiator.
Feed the hose down to a container.
Open the nipple. Drain off the engine coolant.

Disconnect the quick-release connectors for the cooler hoses at the cowl panel in the engine compartment.

Removing components





Remove:
- the center console.
- the multimedia module (MMM) (if applicable).
- the glove compartment.
- the central electrical unit from its bracket.
- the 2 nuts for the central electrical unit bracket (see the illustration). Disconnect the cable harness from the bracket
- the heat exchanger. Vehicles with split pipes see:: Heat exchanger and vehicles with complete pipes see: Heat exchanger.





Lift up both air conditioning (A/C) pipes from their mountings below the right-hand spring strut turret.

Remove the 1 screw securing the air conditioning (A/C) pipes to the evaporator. See the illustration.

Pull the pipes off from the evaporator connection.

Removal

Removing the evaporator

The evaporator has pipes that are integrated in the factory. These pipes must be cut in order to remove the unit. The evaporator in the service kit has separate pipes, however.





Remove:
- the 2 screws and remove the right-hand half of the lead-in. See the illustration
- the section that holds the heat exchanger and evaporator pipes apart.





Cut off the evaporator pipes.
Pull and press out the pipes through the seal. See the illustration.





Remove the 3 screws. Remove the cover.
Pull out the evaporator. Pull alternately at the top and bottom edges. It may be hard to remove.

NOTE: Note how the seal is located on the evaporator.

Installation

NOTE: For tightening torques, see: Tightening torque. Mechanical Specifications

Installing the evaporator

Install a new seal, using the removed evaporator as a template.





Install the evaporator far enough that the cover can be installed (approximately 3-4 mm inside the opening).

Position the front edge of the cover between the evaporator and the heater unit.
Tighten the 3 screws.

Install the loose pipe section between the evaporator and the connection in the engine compartment. Start by inserting it through the lead-in seal. Then connect the block mounting to the evaporator using 2 M5 screws. Tighten. See: Summary of tightening torques for specific components.

NOTE: Pull the insulation for the pipes as far in towards the evaporator as possible before installing the spacer and the right-hand half of the lead-in.





Install:
- the spacer that holds the heat exchanger and evaporator pipes apart
- the right-hand half of the lead-in using the 2 screws.

Installing components

Install:
- the M8 screw securing the air conditioning (A/C) pipes in the engine compartment. See: Summary of tightening torques for specific components
- the heat exchanger. Vehicles with split pipes see:: Heat exchanger and vehicles with complete pipes see: Heat exchanger.
- the central electrical unit bracket using the 2 nuts. Install the cable harness
- the central electrical unit on the bracket.
- the center console.

Finishing

Checking the function and leak tracing

Tighten the drain nipple on the radiator.
Fill with coolant and warm up the engine until the thermostat opens. Top up if necessary.

Check that the pipe coupling does not leak.

Vacuum pump the air conditioning (A/C) system. See: Vacuum pumping. Fill the air conditioning (A/C) system with refrigerant. See: Refrigerant, filling. Leak trace the air conditioning (A/C) system. See: Leak detection, tracer agent or: Leak tracing, electronic leak detector.

Install:





- the glove compartment.
- the multimedia module (MMM) (if applicable).
- the shield under the vehicle using the 7 clips.