Evaporator Core: Service and Repair

Evaporator, replacing

Removal

Evaporator
Remove the dashboard. See (engine B5254T4) or Dashboard, replacing Dashboard, Replacing (other engines).
The climate control unit. See Climate control unit, replacing, L.H.D, R.H.D Service and Repair.





Remove:
- the inner and outer seals for the pipe lead-ins.





Remove:
- the retaining clip and pipe from the heat exchanger.





Remove:
- the sensor.





Remove:
- the 4 screws for the air cleaner (ACL) and cover.





Remove:
- the 3 screws for the central electrical unit.
Fold out the central electrical unit. Remove the seal





Remove:
- the blower fan motor cover, (1 screw)
- the blower fan motor (4 screws).





Remove:
- the screw for the bracket for the recirculation motor.

Loosen:
- the catches for the divisions of the upper and lower sections using a screwdriver and pipe wrench as illustrated. Start at one end.




- Lift off the lower section
- Lift out the evaporator.





Remove:
- the expansion valve, (2 screws)
- the expansion valve block
- the seal.

Installation

Evaporator

Install:
Note! Use new O-rings lubricated with compressor oil.

- O rings on the evaporator pipe
- the expansion valve.
- Position the evaporator in the upper fan housing
- Check that the seal sits in the correct groove at the expansion valve
- Install the lower fan housing. Press so that the mounting lugs are in line with the upper half
- Ensure that the mounting lugs line up
- Check that the seal sits in the correct groove at the expansion valve
- Press the upper fan housing into the lower
- Check that the upper fan housing is secured to the lower
- Install new retaining clips around the fan housing to ensure a good seal.

Install:
- the central electrical unit seal
- the central electrical unit. Screw it into place
- the air cleaner (ACL) and cover
- new inner and outer seals for the pipe lead-ins around the heat exchanger-refrigerant pipes.

Install:
- the climate control unit. See Climate control unit, replacing, L.H.D, R.H.D Service and Repair
- the dashboard in the car. See (engine B5254T4) or Dashboard, replacing Dashboard, Replacing (other engines).