BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

Evaporator Core & Expansion Valve

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REMOVAL & INSTALLATION



E30 3 Series
  1. Have the air conditioning system discharged by a qualified shop.
  2.  
  3. Disconnect the negative battery terminal. Remove the center console and the left side lower instrument panel trim next to the steering column.
  4.  
  5. Remove the glove compartment door and the inside trim.
  6.  
  7. Use a wrench to hold the expansion valve while removing the refrigerant lines from the evaporator core. Remove the 4 screws holding the cover panel. Remove the cover panel and the foam rubber.
  8.  
  9. Disconnect the wires and remove the bolts. Remove the temperature switch with the sensor without bending the sensor.
  10.  
  11. Pull the evaporator from the housing and disconnect the lines from the expansion valve using a wrench to hold the expansion valve.
  12.  

To install:
  1. Install the expansion valve on the evaporator core. Tighten the 5 / 8 in. line to 14.5 ft. lbs. (20 Nm), the 3 / 4 in. line to 28 ft. lbs. (39 Nm), the 7 / 8 lines to 30 ft. lbs. (42 Nm) and the 11 / 16 in. lines to 35 ft. lbs. (48 Nm).
  2.  
  3. Install the evaporator core in the housing and replace the temperature switch. Install the bolts and connect the wires. Install the foam rubber and the cover.
  4.  
  5. Connect the lines to the expansion valve. Tighten the 5 / 8 in. line to 14.5 ft. lbs. (20 Nm), the 3 / 4 in. line to 28 ft. lbs. (39 Nm), the 7 / 8 lines to 30 ft. lbs. (42 Nm) and the 11 / 16 in. lines to 35 ft. lbs. (48 Nm).
  6.  
  7. Install the glove compartment and trim panels. Install the center console and connect the negative battery terminal. Have the system charged by a qualified shop.
  8.  

E36 3 Series
  1. Have the air conditioning system discharged by a qualified shop.
  2.  
  3. Turn the ignition switch to the OFF position. Remove the air intake cowl weather-stripping. Remove the grill by gently prying out.
  4.  
  5. Remove the 2 screws inside the air intake cowl holding the electrical duct.
  6.  
  7. Remove the 2 screws holding the right side of the air intake cowl and remove the screw holding the left side. Pull the cowl out from above. It may be very hard to remove, but it will come out.
  8.  
  9. Remove the nut from the heater connection and pull off the connection. Blow air into the intake hose to force the coolant out of the heater core. This will prevent coolant from dripping onto the carpeting.
  10.  
  11. Remove the nut from the connection in the engine compartment.
  12.  
  13. Remove the braces on both sides of the unit. Remove the nut holding the refrigerant line flange to the evaporator core.
  14.  
  15. Place the dashboard vent grills above the glove compartment in the forward position and pull out. Remove the 6 screws holding the glove compartment and pull out.
  16.  
  17. Remove both A-pillar trim pieces by unclipping. Remove the lower dashboard trim piece at the right side. Remove the trim panel screw at the bottom left and pry the panel off.
  18.  
  19. Unbolt and lower the steering column. Remove the screws holding the instrument cluster and pull out. Disconnect the instrument cluster wiring.
  20.  
  21. Remove the hazard flasher switch directly behind the shifter opening and remove the screw. Remove the rear ashtray from the console and remove the screws. Remove the parking brake console. Remove the screws and the center console.
  22.  
  23. Remove the screws on both sides and remove the dashboard. Remove the control unit upwards and disconnect the plug. Remove the steering column reinforcement. Disconnect the wires and ducts. Remove the screws and the heater unit with the evaporator.
  24.  
  25. Remove the nuts and the evaporator core. Remove the nut and stud holding the expansion valve.
  26.  

To install:
  1. Install new O-rings on the expansion valve and flange. Attach the expansion valve to the evaporator core. Install the evaporator core. Install the heater unit and connect the wiring, ducts and steering column reinforcement. Install the control unit and the dashboard.
  2.  
  3. Install the center and brake handle consoles. Install the instrument cluster and the steering column.
  4.  
  5. Install the trim panels and the glove compartment. Install the vent grills. Connect the line flange with new O-rings. Install the bolts in the braces.
  6.  
  7. Install the heater line flange with new O-rings. Install the air intake cowl and connect the electrical duct. Install the grill in the cowl.
  8.  
  9. Have the system recharged by a qualified shop.
  10.  

E34 5 Series
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rubber insulator from the cowl. Remove the mounting bolts and the radiator expansion tank located under the windshield on vehicles equipped. Remove the intensive washing fluid reservoir, if necessary.
  4.  
  5. Remove the wire ties holding the cable to the cover. Remove the screws holding the housing cover and remove the cover.
  6.  
  7. Remove the nut and stud holding the refrigerant line flange. The nut is held with threadlocker and may need to be heated with a hot air gun before removal.
  8.  
  9. Remove the glove compartment and the inside trim. Remove the side trim panel. Remove the air duct.
  10.  
  11. Disconnect the electrical harness and set to the side. Remove the evaporator cover panel.
  12.  
  13. Remove the bolt and disconnect the line flange. Remove the screws and the expansion valve. Pull the evaporator core out from the housing.
  14.  

To install:
  1. Install the evaporator core. Install new O-rings on the flange and expansion valve. Install the expansion valve and the flange. Install the cover and connect the electrical harness.
  2.  
  3. Install the air duct, trim panels and the glove compartment.
  4.  
  5. Install new O-rings on the refrigerant line flange sand connect the flange. Use Loctite® 270 or equivalent threadlocker.
  6.  
  7. Install the blower cover and clip into place. Install the housing cover and replace the screws. Replace the cable wire ties.
  8.  
  9. Install the intensive washing fluid reservoir or the expansion tank, as equipped. Install the weather-stripping.
  10.  

 
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