Evaporator Case: Service and Repair

Evaporator Housing With Heating Box, Removal and Installation

Tightening Torques:
Suction hose to expansion valve
- 33 ± 4 Nm
Pressure hose to expansion valve
- 16 +2-1 Nm

Special Tools:
Open-box end wrench with 3/8" square insert
- 17mm 000 589 69 03 00
- 19mm 000 589 70 03 00
- 22mm 000 589 71 03 00
- 24mm 000 589 72 03 00

Note: Remove evaporator housing together with heater box.

Removal:
1. Discharge air conditioning system (recycling).
2. Drain coolant.
3. Slide back both front seats and cover.
4. Remove foot mats in footwell front left and right.
5. Remove instrument panel.
6. Remove center console.
7. Remove ABS control unit, if installed.






8. Loosen three hose straps on heat exchanger pipes (d, c) and pull off heater hoses.






9. Unscrew screws on air ducts (refer to arrow) at lift and right for rear passenger compartment heater and remove air ducts on transmission tunnel on driver's floor.






10. Pull 12-point plug from electronic switchgear for temperature control (9).






11. Pull 5- and 6- point plugs (refer to arrow)






from temperature dial (2, 3 and 13) as well as 2-point plug from temperature sensor, air volume and air distributing switch (4 and 24).






12. Pull vacuum lines from air volume switch (4).






13. Unscrew screws (37) from stiffening strut (38).






14. Loosen cable straps (refer to arrow) on blower housing.






15. Loosen cable straps (refer to arrow) for main cable harness on heater box.
16. Pull off air duct for fresh air nozzle left and right on heater box.






17. Pull 2-point plug from temperature sensors (6 and 7).






18. Unscrew screw (39) for electric lines on cable connector.






19. Separate electric plug connection (refer to arrow) on heater box and unclip coupling member from fastening holder (40).






20. Lift housing from expunsion valve (35).






21. Unscrew coolant line (66 and 67) from expansion valve (35) and close with plug. (Refer to section "Removal and installation of expansion valve").






22. Pull condensate drain hose (97) from lefthand and righthand connection of evaporator housing.






23. Pull off 2-point plug on switchover valve (14).






24. Unscrew screws (41) on lower holding angle bracket.






25. Unscrew nut (42) from angle bracket on blower housing.






26. Unscrew nut (43) on righthand upper angle bracket on front wall.






27. Unscrew screw (44) on lefthand upper angle bracket from heater box.
28. Pull evaporator housing with heater box to the rear, so that the heater pipes are disengaged from front wall.
29. Lift evaporator housing with heater box above front passenger footwell. Hold heater pipes vertical, so that no coolant will flow out.

Installation:
30. Mount evaporator housing with heater box from front passenger side on transmission tunnel.
31. Slide evaporator housing with heater box against front wall while introducing heater pipes through front wall.






32. Fasten evaporator housing with heater box by means of lefthand upper angle bracket and screw (44) to front wall.






33. Fasten evaporator housing with heater box by means of righthand upper angle bracket and nuts (42 and 43) to front wall.






34. Mount lower angle bracket with screws (41).






35. Plug 2-point plug to switchover valve (14).






36. Mount condensate drain hoses (97).






37. Connect refrigerant lines (66 and 67) to expansion valve (35) while checking O-ring and moistening threads with refrigerant oil. (Refer to section "Removal and installation of expansion valve").






38. Mount housing to expansion valve (35).






39. Connect electric plug (refer to arrow) and clip into fastening holder (40).






40. Install electric lines on cable connector.






41. Plug 2-point plug to temperature sensors (6 and 7).
42. Plug air duct for fresh air, nozzle left and right to heater box.






43. Install main cable harness on heater box and attach with cable straps (refer to arrow).






44. Install electric lines on blower housing and attach with cable straps (refer to arrow).






45. Mount stiffening strut (38) with screws (37).






46. Plug vacuum lines to air volume switch (4).






47. Plug 2-, 5- and 6-pole couplings on temperature dials (2, 3 and 13), as well as 2-pole coupling on air flow sensor switch and air distributing switch (4 and 24).






48. Plug 12-point plug to electronic switchgear (9).
49. Mount air ducts left and right for rear passenger compartment heater.
50. Mount heater hoses.
51. Install ABS control unit.
52. Fill-in coolant and check cooling system for leaks.
53. Install center console.
54. Install instrument panel.






55. Install foot mats into footwell at front left and right.
56. Evacuate air-conditioning system, refill and check for function and leaks. Testing and Inspection