OEM A/C Evaporator Defects

[Flyer1]

An FYI for the forum in case this info helps someone else.

Hope no one else encounters this problem as its a huge pain to repair.

I haven't found many other reports about evaporator leaks, but I've had to replace two of them in my 2004 X3 3.0. The one that came with the SAV from the factory lasted ~3 years, the one I got from BMW lasted ~2 years. (I just replaced it) I'm not sure if this is indicative of a possibly more widespread problem, or I was just unlucky. I plan to contact BMW NA to see if I can get them to reimburse me for the new part. (~$500) Discussing my problem over the phone with a gentelman in the parts department at Circle BMW (where I mail ordered both evaporators from) he stated BMW gives a 2-year warranty on parts. This was in contrast to the disclaimer on their invoice that claims parts are as-is.

I did the replacement myself. The first time the leak occured in 2007 the dealer quoted $1400 just in labor. So its over a $2k job for labor plus a new evaportor, expansion valve and receiver dryer if you have the dealer do the work. It's a lot of work. I spent ~30 hours the first time, ~20 the second since I was familiar with the job.

I'll try to post some pics later that show the leak check dye that shows where the evaporator leaked.