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PRE-RELEASE

Evaporator's high and low-pressure pipes, Z19DTR

Evaporator's high and low-pressure pipes, Z19DTR

Important

The A/C receiver and the compressor oil absorb moisture from the air, which can then not be removed. Plug all connections that are opened immediately.


To remove


1. Put the car on a lift.

2. Drain the refrigerant from the A/C system, see Draining and filling the refrigerant .

3. Remove the windscreen wipers. Use the puller 85 80 144 Puller, windscreen wiper arm .

4. Remove the cover on the bulkhead partition space .

5. RHD: Remove the Windscreen wiper assembly .

6. LHD: Remove the fresh-air filter (A) and the fresh-air filter housing (B).


7. Unplug the mass air flow sensor connector (C).


8. Remove the hose between the turbo intake manifold and the air cleaner housing.

9. Remove the cover from the air filter housing (E).

10. Remove the filter (F).


11. Remove the lower part of the air filter housing (G). Press out the intake manifold (H) so that it becomes loose before the air filter housing is lifted out.


Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .


12. Unplug the pressure sensor connector (I). Take care that the pressure sensor is not damaged.


13. Detach the high and low pressure pipes' PAD connection (J) from the expansion valve. Plug the openings.


14. Detach the high and low pressure pipes' PAD connection (K) by the right-hand front structural member. Plug the openings.


15. Detach the evaporator's high and low pressure pipes from the clips (L) and the seal (M). Lift out the pipe.


To fit


1. Adjust the oil quantity in the A/C system. See Filling and adjusting the compressor oil .

2. Move the high and low pressure pipes into position, and secure the pipes in the clip (L) and the seal (M).

3. Replace the sealing washers and attach the high and low pressure pipes' PAD connection (J) to the expansion valve.

Tightening torque 18 Nm (13 lbf ft)


4. Replace the sealing washers and attach the high and low pressure pipes' PAD connection (K) by the right-hand front structural member.

Tightening torque 15 Nm (11 lbf ft)

Important

Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to Connectors, handling and inspection .



5. Plug in the pressure sensor connector (I).


6. Fit the lower part of the air filter housing (G). Make sure the intake manifold (H) is positioned correctly in the lower part of the air filter housing.


7. Fit the air filter (F).


8. Fit the cover for the air filter housing (E). Fit the hose (D) between the intake manifold and the turbo.


9. Plug in the mass air flow sensor connector (C).

10. LHD : Fit the fresh-air filter (A) and the fresh-air filter housing (B).


11. RHD : Fit the windscreen wiper assembly .

12. Fit Bulkhead partition space cover .

13. Fit the windscreen wipers

Tightening torque 20 Nm (15 lbf ft)

14. Vacuum pump and fill the A/C system with refrigerant R134a. See Draining and filling the refrigerant .

15. Test the A/C system. See A/C system performance test .


PRE-RELEASE