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Evaporator

Evaporator

Removing


Warning

When removing the fresh-air filter, fuse 22 in the instrument panel fuse box must be removed. The cooling fins on the fan control unit are live. Risk of personal injury and short circuit/fire!


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. Remove fuse 22.

Drain the refrigerant from the A/C system. See Draining and filling of refrigerant .

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 hatch bolts. Fold up the service hatch.


5. Remove the fresh-air filter and filter element or particle filter.

6. Remove the ventilation fan, see Ventilation fan .


7. Remove the expansion valve, see Expansion valve .

8. Cut the A/C pipes to the evaporator with a sheet metal cutter or air-driven jigsaw.

The pipes are accessible from the engine bay by the air recirculation flap.

9. Pull out the evaporator.


10. Cars with temperature sensor : Remove the temperature sensor from the evaporator.

11. Pull out the pipes from inside the cabin.

12. Vacuum pump the heating and ventilation unit to remove any cuttings.


Fitting



1. Cars with temperature sensor : Make a hole for the temperature sensor and its clip in the evaporator cooling fins, 60 mm from the bottom of the 11th fin (from the passenger side). Use a tool with a round tip, e.g. a cross-head screwdriver that is 4.5 mm in diameter.

Fit the temperature sensor in the evaporator.

2. Adjust the oil level in the compressor. See Filling and adjustment of compressor oil .

3. Insert the plugged pipe set from inside the cabin.

4. Position the filter retainer against the evaporator.

5. Push in the evaporator to the heating and ventilation unit.

6. Remove the plugs in the A/C pipes and fit the expansion valve, see 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 bay by the air recirculation flap.

Tightening torque: 8 Nm (5.9 lbf ft)

9. Fit the ventilation fan, see Ventilation fan .

10. Fit the fresh-air filter. When changing filter, see Replacing the fresh air filter .


11. Fit the service cover.

12. Fasten the wiring harness and cooler hose with cable ties.

13. Fit the side trim on the centre console.


Fit the glove box. See Glove box .

14. Evacuate the A/C system and fill with R134a refrigerant. See Draining and filling of refrigerant .

Fit fuse 22.