64 51 591 Removing and installing / replacing evaporator

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

Heater/air conditioner removed,

refer to 64 11 205 REMOVING AND INSTALLING / REPLACING HEATER (AUTOMATIC AIR CONDITIONER)

Unfasten screws and remove left and right footwell air outlets.

Fig 1: Removing Left And Right Footwell Air Outlets

G03154808

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and remove evaporator cover.

Fig 2: Removing Evaporator Cover

G03154809

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten clips and remove cover for evaporator tubes.

Fig 3: Removing Evaporator Tubes Cover

G03154810

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten clips and remove footwell vent outlet.

Fig 4: Removing Footwell Vent Outlet

G03154811

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and remove cover from heater core.

Fig 5: Removing Cover From Heater Core

G03154812

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws and remove lower section of housing

Fig 6: Removing Lower Section Of Housing

G03154813

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screw, pull tubes slightly apart and remove expansion valve.

Fig 7: Removing Expansion Valve

G03154814

Courtesy of BMW OF NORTH AMERICA, INC.

Remove evaporator.

CAUTION: Do not bend cooling slats: clean with slat comb and straighten.

Fig 8: Removing Evaporator

G03154815

Courtesy of BMW OF NORTH AMERICA, INC.