Removing Evaporator (Chiller)

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NOTE: Danger of scalding

Coolant can be very hot.
Coolant may be pressurized.

→ Only remove the heater when the cooling system has cooled down.

→ By carefully opening the catch on the reservoir, make sure that the cooling system is depressurized.

NOTE: Danger of slipping due to emerging coolant

The emerging coolant will make the floor of the workshop slippery and may cause people to slip and fall over.

→ Collect emerging coolant in a suitable pan.

Clamp off coolant hoses -1- using hose clamping pliers Nr.192 .

Fig 1: Clamping Off Coolant Hoses
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disconnect coolant hoses -1- on the evaporator.
1. 2.1. Loosen fastening screws for the three coolant line holders -1- and remove all holders.
  
  Fig 2: Removing Coolant Line Holders
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Loosen spring band clamp -2- and pull coolant line off the coolant hose -arrow- .
  
  Fig 3: Removing Coolant Line Holders
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 2.3. Loosen spring band clamps -1- at the evaporator using assembly pliers Nr.72 Pos.1 and pull off coolant hoses.
  
  Fig 4: Loosening Spring Band Clamps On Evaporator
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Disconnect electric plug connection -1- from the expansion valve.

Fig 5: Disconnecting Electric Plug Connection On Expansion Valve
Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Information

Before re-installing the component, check the O-rings of the refrigerant lines for damage and replace them if necessary.

Wet the O-rings of the refrigerant lines with refrigerant oil.

Close off all lines and connections using suitable stoppers during removal.

Do not open the stoppers for the lines and connections until shortly before installation.
Loosen fastening screws -1- for the refrigerant lines at the expansion valve and pull off refrigerant lines.
1. 4.1. If the evaporator has to be replaced, the expansion valve on the evaporator must also be converted.
  To do this, loosen the two fastening screws used to secure the expansion valve to the evaporator.
  
  Fig 6: Disconnecting Refrigerant Lines At Expansion Valve
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Loosen fastening nuts -1- and remove evaporator.
1. 5.1. If the evaporator has to be replaced, then the four decoupling elements must be converted or replaced.
  
  Fig 7: Fastening Nuts On Evaporator
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.