The evaporator's low-pressure pipe

The evaporator's low-pressure pipe

To remove

Important

The evaporator's low-pressure pipe must be cut during removal. The spare is a hose in two parts.

1.	Place the car on a lift.

2.	Remove the grille.

3.	Drain the AC system of refrigerant.

4.	Remove the battery.

5.	Remove the bolt in the bracket securing the battery cable holder.

6.	Remove the main fuse box.

7.	Remove the compressor's low-pressure pipe from the holder on the front cross-member.

8.	Remove the clip holding the low-pressure side's service connection.

9.	Remove the evaporator's low-pressure pipe from the holder on the wheel housing. Important Both the receiver and the compressor oil absorb moisture from the air which cannot be removed. All connections which are opened should therefore be plugged immediately.

10.	Remove the nut which securing the evaporator's low-pressure pipe to the service connection.

11.	Plug the openings.

12.	Remove the evaporator's low-pressure pipe from the holder on the bulkhead wall.

13.	Unscrew the high-pressure pipe from the PAD connection adjacent to the lead-through in the bulkhead wall.

14.	Plug the openings.

15.	Remove the bolt securing the PAD connection.

16.	Plug the openings.

17.	Raise the car. Cut the low-pressure pipe through the wheel housing as shown.

18.	Lower the car and lift out the pipe sections.

To fit

1.	Fit the rear end of the low-pressure pipe in place from above.

2.	LHD cars: Raise the car.

3.	Lubricate new O-rings with synthetic vaseline and fit them in place at the expansion valve or block.

4.	Tighten the bolt securing the block or fit the PAD connection and pipes in place and tighten the bolt. Tightening torque, block: 20 Nm (14.8 lbf ft) Tightening torque, PAD connection: 9 Nm (6.6 lbf ft)

5.	LHD cars: Lower the car.

6.	Remove the bolt securing the pipe between the power steering fluid reservoir and the servo pump.

7.	Remove the power steering fluid reservoir's pipe from the holder under the battery tray.

8.	Cars with a turbo engine:

8.a.

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

8.b.

{blc}Remove the expansion tank retaining bolt.

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

10.	Cars with automatic transmission:

10.a.

Remove the nut securing the selector lever to the gearbox.

10.b.

{blc}Remove the two bolts securing the gear selector's bracket to the gearcase.

11.	Fit the front part of the evaporator's low-pressure pipe in place.

12.	Lubricate new O-rings with synthetic vaseline and fit them to both ends of the front part of the low-pressure pipe.

13.	Insert both ends of the pipe.

14.	Tighten both ends of the pipe. Tightening torque: 34 Nm (25.1 lbf ft)

15.	Cars with block connection on the bulkhead wall: Lubricate a new O-ring with synthetic vaseline and fit it on the high-pressure pipe.

16.	Cars with block connection on the bulkhead wall: Screw the high-pressure pipe to the block. Tightening torque: 20 Nm (14.8 lbf ft)

17.	Fit the evaporator's low-pressure pipe in the holders on the bulkhead wall and wheel housing.

18.	Fit the low-pressure side's service connection in place and press on the clip.

19.	Cars with automatic transmission:

19.a.

Tighten the nut securing the gear selector lever to the gearbox.

19.b.

Tighten the two bolts securing the gear selector lever's bracket to the gearcase.

20.	Fit the compressor's low-pressure pipe in the holder on the subframe.

21.	Refit the hose between the power steering fluid reservoir and the servo pump. Secure the hose in the clip and tighten the screw.

22.	Refit the main fuse box.

23.	Tighten the bolt securing the bracket for the battery cable holder.

24.	Refit the battery.

25.	Cars with a turbo engine:

25.a.

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

25.b.

Refit the expansion tank and tighten the screw.

26.	Fill up with compressor oil, carry out vacuum pumping of the AC system and fill up with refrigerant.

27.	Refit the grille.