For 1990-2009 cars

### Removal Procedure

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the block connector and refrigerant lines from the expansion valve.

2.1. | Remove the bolt.

2.2. | Disconnect the refrigerant lines.

Note: If installation is postponed, close off lines and connections.

3. Remove the thermostatically controlled expansion valve (TXV) (1).

Insert the bolt, block connector refrigerant line, in expansion valve (2) and remove the expansion valve.

4. Remove the expansion valve retaining plate.
5. Remove the air inlet screen. Refer to Air Inlet Screen Replacement.
6. Remove the recirculating air valve housing, outside.

6.1. | Remove the 4 bolts (1).

6.2. | Remove the recirculating air valve housing grille (3).

6.3. | Remove the bolt for recirculating air valve housing (2).

7. Remove the instrument panel (I/P) compartment.

7.1. | Remove the 4 bolts (1).

7.2. | Disconnect the wiring harness plug.

8. Remove the insulator panel.

Remove the 2 retainers (3).

9. Remove the air duct.

Remove the body-bound rivet (2).

10. Remove the heater fan motor (2).

10.1. | Disconnect the 2 wiring harness plugs (1) from the series resistor.

10.2. | Release the clip.

10.3. | Remove the 5 bolts.

11. Detach and remove the recirculating air valve housing (2).

11.1. | Remove the 2 bolts (3).

11.2. | Disconnect the wiring harness plug for mixed air valve servo motor.

11.3. | Release and disconnect the wiring harness plug.

12. Remove the bolt for recirculating air valve housing

Remove the bolt (2).

13. Remove the pollen filter service flap and pollen filter.

Remove the 3 bolts (3).

Note: Only for vehicles with radio cooling.

14. Disconnect the radio cooling (1) and remove.
15. Cut the air distributor housing.

Cut the air distributor housing at groove (dotted line) using a suitable tool.

Note: Press the recirculating air valve housing upwards.

16. Remove the evaporator core.

### Installation Procedure

1. Insert the evaporator core.
2. Position the seal in the evaporator cover.
3. Prepare the evaporator cover.

Cut the 2 plastic webs (1) using a suitable tool.

Note: Only for vehicles with radio cooling.

4. Connect the radio cooling to evaporator cover.

4.1. | Place the cut evaporator cover (1) on new cover (3), and use a pencil to mark the hole for radio cooling.

4.2. | Using a suitable tool, cut a hole (2) for radio cooling.

4.3. | Glue the radio cooling in place on both sides.

4.4. | Use adhesive mastic.

Caution: Refer to Fastener Caution in the Preface section.

5. Attach the evaporator cover.

Install the radio cooling.

Tighten
Tighten the 4 bolts to 2.5 N·m (22 lb in).

6. Insert the pollen filter and attach pollen filter cover.

Tighten
Tighten the 3 bolts to 2.5 N·m (22 lb in).

7. Install the bolt for recirculating air valve housing.
8. Insert and tighten the recirculating air valve housing.

Tighten
Tighten the 2 bolts to 5 N·m (44 lb in).

9. Connect the wiring harness plug to recirculating air valve servo motor.
10. Install the heater fan motor.

10.1. | Connect the clip.

Tighten
Tighten the 5 bolts to 8 N·m (71 lb in).

10.2. | Connect the 2 wiring harness plug.

11. Install the retaining plate TXV.
12. Install the air inlet screen. Refer to Air Inlet Screen Replacement.
13. Install the TXV.

13.1. | Use new sealing rings, before installation moisten only green colored sealing rings with mineral oil and insert.

13.2. | Install service threaded rods (2) into retaining clip (1) to guide expansion valve.

13.3. | Push expansion valve onto service threaded rods until the refrigerant lines lie in the expansion valve.

13.4. | Replace the threaded rods in succession with the fixing bolts.

Tighten
Tighten the expansion valve to 6 N·m (53 lb in).

14. Install the block connector.
15. Use new seal rings, before installation moisten only green colored seal rings with mineral oil and insert.

Tighten
Tighten the block connector bolt to 7 N·m (62 lb in).

16. Install the air duct for footwell right side.

Connect the clip.

17. Install the I/P compartment.
18. Connect the wiring harness plug.

Tighten
Tighten the 4 bolts to 4 N·m (35 lb in).

19. Install the insulator panel.

Tighten the 2 retainers.

20. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.