64 51 591 Removing and installing/replacing evaporator

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

Necessary Preliminary Tasks:

Remove heater. Refer to 64 11 206 REMOVING AND INSTALLING OR REPLACING HEATER .
Remove heater core. Refer to 64 11 208 REPLACING HEATER CORE .
Remove expansion valve. Refer to 64 51 525 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE .
Remove rear compartment air duct. Refer to 64 11 213 REMOVING AND INSTALLING/REPLACING HEATER - A/C UNIT FAN .
Remove fan for heater/air conditioner. Refer to 64 11 213 REMOVING AND INSTALLING/REPLACING HEATER - A/C UNIT FAN
Remove servodrive of left fresh-air/recirculated-air flap. Refer to 64 11 803 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR LEFT FRESH-AIR/RECIRCULATED-AIR FLAP .

Carefully pull off bulkhead seals (1) from heater/air conditioner (2) so that there are no remaining parts left behind.

Installation:

Replace bulkhead seals (1).

Fig 1: Identifying Bulkhead Seals In Heater/Air Conditioner

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Release screws (1).

Press lock (2).

Remove pipe holder (3) complete with pipes (4).

Fig 2: Locating Pipe Holder Retaining Screws

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Release screws (1).

Fig 3: Identifying Housing Section Retaining Screws

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Release screws (1).

Installation:

Make sure flaps (2) are correctly seated in mountings (3).

Fig 4: View Of Flaps Seated In Mountings

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Release screws (1).

Remove upper housing section (2) in direction of arrow.

Installation:

Make sure upper housing section (2) is correctly seated on lower housing section.

Make sure flaps (3) are correctly seated in mountings (4).

Fig 5: Removing Upper Housing Section

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Release screws (1).

Release clip (2).

Remove cover (3) in direction of arrow.

Installation:

Make sure cover (3) is correctly seated.

Fig 6: Removing Cover

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IMPORTANT: Do not bend radiator fins. If necessary, clean or straighten radiator fins with slat comb.

Pull evaporator (1) in direction of arrow out of lower housing section (2).

Installation:

If Necessary, Replace Seal (3).

Make sure seal (3) is correctly seated in lower housing section (2).

Fig 7: View Of Evaporator

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Replacement:

Remove plate (2) and seal (3) from evaporator (3).

Fig 8: Locating Plate And Seal In Evaporator

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