Overhaul

Heating And A/C Unit (With Heater Core And Evaporator), Disassembly And Assembly







1 - Seal
- Seals intake duct against air intake plenum.
- Check and replace if damaged.
2 - Air flap
- Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.
3 - Grommet
4 - Lever
5 - Air distribution housing, upper part
- Assembly See Fig. 1.
- Installing seal at refrigerant pipes See Fig. 2.
6 - Fresh/recirculation flap
- Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.
7 - Evaporator
- Installing seal at refrigerant pipes See Fig. 2.
- Installing seal See Fig. 3.
- Removed evaporator contains refrigerant oil that must be accounted for in refrigerant system when evaporator replacement is necessary.
8 - Pivot bushing
- Lightly lubricate with grease G 052 745 A3 or equivalent.
9 - Air distribution housing, lower part
- Assembly See Fig. 1.
- Installing seal at refrigerant pipes See Fig. 2.
10 - Screw
11 - Pivot bushing
- Lightly lubricate with grease G 052 745 A3 or equivalent.
12 - Central flap lever
13 - Screw
14 - Temperature flap lever
15 - Central flap
- Note installation position (shorter section of flap faces up).
16 - Footwell/defroster flap
- Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.
17 - Temperature flap
18 - Seal
- Installing seal at refrigerant pipes See Fig. 2.
19 - Threaded bracket
20 - O-Ring
21 - O-Ring
22 - Expansion valve
- Removing and installing refrigerant pipes.
- Removing and installing insulation.
23 - Bolt
- Tightening torque: 8 Nm (71 in lb).
24 - Air deflector







Fig. 1 Air distribution housing, assembly
- Secure both halves of the housing with screws -A- at locations (example) -B-.







Fig. 2 Refrigerant pipe seal at evaporator, installing
Evaporator refrigerant pipes -C- must be completely encapsulated by seal -A- between both halves of the air distribution housing -B-

- After securing both halves of the housing, apply silicone seal as necessary at any open locations. Housing must be completely sealed against entry of hot air from the engine compartment or warm air from the passenger compartment, otherwise, cooling efficiency will be affected.







Fig. 3 Evaporator seal, installing
- Evaporator -A- must be sealed (top and sides with gasket -B-) against the air distribution housing

NOTE: A gap must remain in the seal on the bottom of the evaporator to allow water to drain.