To replace the Alfa 156 evaporator, removing the dashboard is merely the first step. I cannot find a way to get the evaporator out without taking the entire airbox out.
Alfa 156 airbox
Taking out the airbox
To get the airbox out, I followed the 3 main steps:
- Disconnect the air conditioning and heater core pipe from the engine bay
- Remove the central bridge between the driver and passenger seats
- Disconnect all cables connecting to the airbox components, including sensors, blower motor, ventilation flap controllers.
To do the step 1 and 3, it needs more space and tools that I don’t have. So I replied on my mechanic finishing the new component refit.
For step 3, some preparation works can make the job easier:
- First, have a container to collect all the airbox screws, I said it before
- Second, it is very important to mark the connector destination and cable layout. It can save a lot of time when we reassemble the airbox.
- Foam sealing strip
- Third, prepare a 5.5 mm socket. That’s the size of screws holding the airbox together
Connectors and cables between the blower motor and the airbox
Screws holding the airbox together
New seal is needed
With the airbox revealed, we found the source of refrigerant leakage. It is between the evaporator and the expansion valve.
Refrigerant leakage
Removing the evaporator
To replace the evaporator, the airbox must be dismantled. One of the screws is hidden behind the evaporator housing partition that cannot be seen from the front view. It is a very strange arrangement and an awkward position to get access to.
Awkward airbox screw location
To get the evaporator out, I must remove the airbox top cover.
Old evaporator removed
Reassemble the airbox
Before putting in the new evaporator, I replaced all foam seal of the airbox.
Renew the airbox sealing
At the time my mechanic reassembled and putted the airbox back in place, I also cleaned the blower.
Cleaned blower
Before reinstalling the dashboard, my mechanic tested the air conditioning pressure for 24 hours to check if the new o-rings and the evaporator were installed properly.
Test the air conditioning system
I also connect the air conditioning control unit to test the cooling and ventilation functions prior to putting back the dashboard
Furthermore, I did a few other things with the dashboard removed.
Part 1 – Replacing Alfa 156 evaporator
November 2019
Goran Obradovic
Hi
Great instructions.
I have an issue with clogged AC drainage.
I wonder if you have a picture of where the water goes from the evaporator through the bulkhead to the drain in the engine compartment?
Which components should I mildly “attack” with any penetrating tools or force?
Car is an 156 2.5 V6 LHD 1999.
Best regards
Goran
icapcut.com
You’re on the right track!
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