Evaporator Housing

Evaporator Housing

• Evaporators with a 40 mm (1.6 in.) block depth - A - (air conditioner part number "8K_ 820 005") are being installed from start of production through the change-over from MY 12. These evaporators can be replaced with the air conditioner still installed. Refer to => [ Evaporator, A/C Unit Installed ] Evaporator, A/C Unit Installed. From MY 12, Evaporators with a block depth - A - of approximately 50 mm (2 in.) are being installed (air conditioner part number "8T_ 820 005") as a running change depending on the vehicle version. These evaporators can be replaced only with the air conditioner removed together with the evaporator housing. Refer to Electronic Parts Catalog (ETKA).






• Replace the evaporator and the evaporator housing if the evaporator is not available as a single part, or if for other reasons it must be replaced together with the evaporator housing (it is necessary to remove the air conditioner in order to replace the evaporator). Refer to Electronic Parts Catalog (ETKA).

• There is a label - A - on the outside of the A/C unit with a part - B - that tells which version is installed. Refer to Electronic Parts Catalog (ETKA).






• The part number - B - on the decal - A - can be read when the CD changer is removed (depending on the vehicle equipment level). Refer to Electronic Parts Catalog (ETKA).

Removing

- Remove the A/C unit. Refer to => [ A/C Unit ] A/C Unit.

• The following illustrations show a "Basis" air conditioner. The location of certain components on the "Comfort" air conditioner may differ (for example, the location and number of motors).






- Remove the bolt - B -, unlock the tabs and remove the bracket - A -.

- Remove the bolts - E -, unlock the tabs and remove the bracket - A -.

- Remove the clamps - F - and the coolant pipes - G -.

• Be careful not to drop the seals - B - into the heater core or air conditioner when removing the coolant pipes - A -.






• Do not re-use the seals - B - and clamps - D -. Refer to Electronic Parts Catalog (ETKA).

- Remove the bolts - A - (above the left radiator housing - C - on the evaporator housing - B -).






• Left radiator housing, removing and installing - C -, refer to => [ Left Heater Core Housing with Temperature Doors ] Left Heater Core Housing With Temperature Doors.

- Remove the right radiator housing - H -. Refer to => [ Right Heater Core Housing, Motor Mounting Plate Removed ] Right Heater Core Housing, Motor Mounting Plate Removed or => [ Right Heater Core Housing and Right Motor Mounting Plate ] Right Heater Core Housing and Right Motor Mounting Plate.






- Remove the heater core - I - and the honeycomb / auxiliary heater heating element (Z35). Refer to => [ Heater Core Removing and Installing ] Heater Core Removing and Installing.

• It is not really necessary to remove the heater core - I - and the honeycomb / auxiliary heater heating element because these parts still fit loosely inside the left radiator housing. It is easy to remove them.

- Remove the evaporator housing - A - from the left radiator housing - B - / air distribution housing - C -.






• Currently the evaporator housing is not disassembled any further. For the evaporator housing construction, refer to => [ Evaporator Housing ] Evaporator Housing.

Installing

Installation is done is reverse order, observe the following:

- Check the evaporator housing - A -, left radiator housing - B - and air distribution housing - C - for dirt and damage and clean or replace if necessary.

- Assemble the evaporator housing - A - and the left radiator housing - B - / air distribution housing - C -.

• Push the guides - D - (top and bottom) on the evaporator housing - A - into the grooves - E - in the left radiator housing - B -.

- Install the bolts - A - (above the left radiator housing - C - on the evaporator housing - B -).






- Install the heater core - I - and honeycomb / auxiliary heater heating element. Pay attention to the installed position. Refer to => [ Heater Core Removing and Installing ] Heater Core Removing and Installing.






- Install the right radiator housing - H -. Refer to => [ Right Heater Core Housing, Motor Mounting Plate Removed ] Right Heater Core Housing, Motor Mounting Plate Removed or => [ Right Heater Core Housing and Right Motor Mounting Plate ] Right Heater Core Housing and Right Motor Mounting Plate.

- Check both connections - C - on the heater core and the coolant pipes - A - for dirt and damage and clean or replace them if necessary.






- Coat both connections - C - on the heater core and coolant pipes - A - lightly with silicone grease.

• The silicone grease part number is G 000 405 A2. Refer to Electronic Parts Catalog (ETKA).

- Moisten the new seals - B - with coolant (or coat them lightly with silicone grease) and then push them onto the coolant pipes - A -.

- Position the coolant pipes - A - on the evaporator housing and push them into the connections - C - in the heater core - arrow -.

Risk of leaks from the heater core.

• Squeezed O-ring seals, sharp-edged or coolant pipes/clamps that have not been inserted completely may lead to leaks.

- Install the new coolant pipe clamps - F - on the connection - C - on the heater core as illustrated (push them all the way on - arrow -).

• Do not re-use removed seals - B - and clamps - D -. Refer to Electronic Parts Catalog (ETKA).

• If a replacement heater core - C - is being installed instead of the heater core shown above (standard production version), then install the coolant pipes as described for this version of the heater core. Refer to => [ Heater Core Removing and Installing ] Heater Core Removing and Installing.






- Install the remaining components for the air conditioner.

- Installing the heater and A/C unit, refer to => [ A/C Unit ] A/C Unit.