Evaporator high-pressure pipe

Evaporator high-pressure pipe

Removing

Important

The evaporator high-pressure pipe must be cut when removing. The spare part is supplied as a two-sectioned pipe.

1.	Position the car on a lift.

2.	Remove the grille.

3.	Remove the left headlamp.

4.	Drain refrigerant from the A/C system, see .

5.	Remove the battery.

6.	Remove the bolt in the console that secures the battery cable holder.

7.	Remove the main fuse box. Important Both the receiver and the compressor oil absorb moisture from the air that cannot be removed. All connections that are opened must be plugged immediately.

8.	Remove the high-pressure pipe from the holder on the wheel housing.

9.	Remove the high-pressure pipe from the bulkhead bracket.

10.	Remove the bolt in the PAD-connection by the receiver dryer.

11.	Plug the openings.

12.	Move aside the high-pressure pipe.

13.	Remove the high-pressure pipe from the PAD-connection by the lead-through in the bulkhead.

14.	Plug the openings.

15.	Cut the pipe as shown in the illustration. Remove the pipe sections by lifting them up.

Fitting

1.	Fill compressor oil, see .

2.	Fit the rear section of the high-pressure pipe from above.

3.	LHD: Raise the car.

4.	Lubricate a new O-ring with synthetic vaseline and fit the O-ring on the high-pressure pipe.

5.	Tighten the high-pressure pipe to the PAD-connection. Tightening torque: 9 Nm (6.6 lbf ft)

6.	LHD: Lower the car.

7.	Remove the bolt that secures the power steering fluid reservoir.

8.	Remove the bolt that secures the pipe between the power steering fluid reservoir and the servo pump.

9.	Remove the power steering fluid reservoir pipe from the holder underneath the battery shelf.

10.	Remove the connectors by the radiator fan.

11.	Lift up the power steering fluid reservoir pipe and set it down on the battery shelf.

12.	Remove the clip securing the low-pressure side service connection.

13.	Cars with turbo:

13.a.

Remove the hose between the charge air cooler and the throttle body.

13.b.

Remove the expansion tank retainer bolt.

14.	Cars with manual gearbox: Secure the clutch pedal in the depressed position.

15.	Cars with automatic transmission:

15.a.

Remove the nut that secures the gearshift selector to the gearbox.

15.b.

Remove both bolts that secure the gearshift selector console to the gearbox housing.

16.	Fit the front section of the high-pressure pipe.

17.	Lubricate the new O-rings with synthetic vaseline and fit them on the pipes by the receiver dryer PAD-connection.

18.	Fit the pipes in the PAD-connection by the receiver dryer.

19.	Tighten the bolt that secures the pipes to the PAD-connection. Tightening torque: 9 Nm (6.6 lbf ft)

20.	Lubricate an O-ring with synthetic vaseline and fit it in the joint between the front and rear section of the high-pressure pipe.

21.	Join the front and rear section of the high-pressure pipe. Tightening torque: 11 Nm (8.1 lbf ft)

22.	Fit the high-pressure pipe in the brackets on the bulkhead and on the wheel housing.

23.	Fit the power steering fluid reservoir and tighten the bolt.

24.	Tighten the bolt securing the pipe for the power steering fluid reservoir.

25.	Fit the pipe for the power steering fluid reservoir in the holder underneath the battery shelf.

26.	Connect the connectors by the radiator fan.

27.	Fit the low-pressure side service connection and press on the clip.

28.	Cars with automatic transmission:

28.a.

Tighten the nut that secures the gearshift selector to the gearbox.

28.b.

Tighten both bolts that secure the gearshift selector console to the gearbox housing.

29.	Tighten the bolt in the console that secures the battery cable holder.

30.	Refit the battery.

31.	Cars with turbo:

31.a.

Refit the hose between the charge air cooler and the throttle body.

31.b.

Fit the expansion tank and tighten the bolt.

32.	Vacuum pump the A/C system and fill refrigerant, see .

33.	Refit the main fuse box.

34.	Refit the headlamp.

35.	Refit the grille.