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  #1  
Old 09-27-2012, 10:40 AM
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Join Date: May 2006
Location: Boston
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W109 3.5 Evaporator removal

I need help for removal of the underdash evaporator core. I need to change the expansion valve and clean out the evaporator core.

I removed the AC hoses (aeroquip) in the motor bay and I removed the AC fan at the lower right side but now I am stuck.
I find the black plastic housing clipped together but I have no idea how I get this evaporator out.
Martin

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W109 3.5   Evaporator removal-pict2560.jpg   W109 3.5   Evaporator removal-pict2561.jpg  
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  #2  
Old 09-27-2012, 03:09 PM
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You are looking at a 3 - 5 day project.
In short the entire dash comes out first, then a few more hours of the heater / ac unit.
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  #3  
Old 09-27-2012, 04:07 PM
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The evaporator is held in at the top by a couple of bolts. You have to remove the glovebox insert to be able to see and access those bolts. The whole evaporator box needs to be removed before you can access the evap coil and expansion valve.

John
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Old 09-28-2012, 01:49 AM
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Quote:
Originally Posted by 68_280SE View Post
The evaporator is held in at the top by a couple of bolts. You have to remove the glovebox insert to be able to see and access those bolts. The whole evaporator box needs to be removed before you can access the evap coil and expansion valve.

John
Hi John,
thanks, someone said before I have to remove the dash (puh) but from what I hear from you I can leave the dash in place and 'just' remove the glove box insert in order to access the evaporator box bolts?
I'll start removing the glove box then and hope to get access to the top bolts.
Martin
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  #5  
Old 09-28-2012, 01:00 PM
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update: I opened the glove box and the top dash pad (with wood bow and center grill removed). I moved the linear diffusor (from heating system) in order to get to the third evaporator bracket/screw
I removed 3 screws from the evaporator brackets. Evaporator is loose but won't come out.
The 2 copper fittings are still on the fire wall side.
I have a hard time to pull the fitting through the fire wall openings. Evap. won't move back.

Do I need to remove the plastic airducts in front of the evaporator? in order to push the evap. box backward to get the 2 copper fitting through the fire wall? See 3rd pic.
Please help me guide through this.

Martin
Attached Thumbnails
W109 3.5   Evaporator removal-pict2564.jpg   W109 3.5   Evaporator removal-pict2566.jpg   W109 3.5   Evaporator removal-pict2567.jpg   W109 3.5   Evaporator removal-pict2569.jpg   W109 3.5   Evaporator removal-pict2568.jpg  

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  #6  
Old 09-29-2012, 10:36 AM
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Location: Boston
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Any idea of how I finally get the evaporator through the firewall?
Do I need to kill the rubber sleeves where the copper lines/fitting go through?
Any memory left somewhere?
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  #7  
Old 09-29-2012, 05:10 PM
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Location: Atlanta, GA
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The copper evaporator pipes have to come out in towards the inside of the car. The only way I was able to do that was to remove the rubber grommets in the firewall where the pipes go through. Once the grommets are removed, then the openings in the firewall will be large enough for the fittings to go through.

John
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  #8  
Old 09-30-2012, 12:50 PM
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Quote:
Originally Posted by 68_280SE View Post
The copper evaporator pipes have to come out in towards the inside of the car. The only way I was able to do that was to remove the rubber grommets in the firewall where the pipes go through. Once the grommets are removed, then the openings in the firewall will be large enough for the fittings to go through.

John

Hi John
You are right, my grommets are shot, hard and brittle. Where the hell do I get good ones here in Oman??? This is the end of the world in a sense.

I have the evaporator out, as John said after removing the grommets.
I also had to remove the metal bracket on top of the evap. which also fixes the metal evaporator in the plastic case.
The rest of removal is easy, self explaining.I removed the small metal clips with circlip pliers. This opens the bottom and top part of the case and from there I removed the expansion valve and cleaned the metal evap. body outside and inside (carb cleaner and air for inside). Here are some pics.

Three questions I have:
1)What is this weird electrical part with the 2 springs inside the evap. case?
2) What is the long hollow ping that pierces the fins of the evaporator?
3) Who can send me 2 of these rummer grommets? I can pay with paypal.
Dimensions: sheetmetal hole dia. 30mm or less, 46 mm outer rubber dia
Number on the part: 180 007 0781. Please.
Attached Thumbnails
W109 3.5   Evaporator removal-pict2571a.jpg   W109 3.5   Evaporator removal-pict2575.jpg   W109 3.5   Evaporator removal-pict2576.jpg   W109 3.5   Evaporator removal-pict2580.jpg   W109 3.5   Evaporator removal-pict2583.jpg  


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