Remove/install AC housing

AR83.30-P-5200FF

Remove/install AC housing

11.5.06

 

Remove/install

 Danger!

Risk of explosion from welding or soldering work on closed air conditioning system. Risk of poisoning from inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.

AS83.00-Z-0001-01A



Conduct if air conditioning system is damaged or leaking

AH83.30-N-0004-01A



Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A



Notes on handling refrigerant R134a

AH83.30-N-0003-01A

1

Discharge air conditioning system

 Installation: Evacuate air conditioning and then fill.

AR83.30-P-1760FF

2.1

Remove water collector

Engine 639.9:

AR83.25-P-1402FF

3

Remove screw (2) and remove yoke plate (3) with cover (4)



*BA83.30-P-1001-01F

4

Pull refrigerant lines (1) out of expansion valve (16)

 Use suitable plugs to seal openings on refrigerant lines (1) and on the expansion valve (16).

 Installation: Replace sealing rings at refrigerant lines (1) and coat with compressor fluid when inserting.

5

Drain coolant

Engines 134.9, 135.9

AR20.00-P-1142FF

Engine 639.9

AR20.00-P-1142FG

6

Remove coolant hoses (5) from fittings (6)

 Collect escaping coolant with a suitable container and seal openings of fittings (6) with suitable plugs.

7

Detach cable tie (17) and unscrew concealed nut

8

Remove cross member under instrument panel

AR68.10-P-1120FF

9

Detach electrical wiring harnesses (7) from retaining clips in firewall area

10

Remove defroster outlet (15)

11.1

Mark electrical connector (12)

For vehicles with code (I77) Manual air conditioning

 Risk of being mixed up with electrical connector of blend air flap actuator motor.

12

Separate electrical connectors (8, 9, 12)

 Depending on the equipment variant used the connector (12) is connected to the blend air flap actuator or clipped onto the air conditioner housing (10).

13.1

Disconnect wiring harness from PTC heater booster

Engine 639.9:

AR83.70-P-8000-01FF

14

Remove bracket (13) on air conditioner housing (10) and detach electrical connector underneath

15

Disconnect electrical connector (14)

16

Remove air conditioner housing (10) and air recirculation unit (11) at firewall

17

Remove retaining clips of electrical wiring harnesses on air conditioner housing (10) and on the air recirculation unit (11)

18

Remove air recirculation unit (11) from air conditioner housing (10)

19

Remove air conditioner housing (10)

20.1

Remove blower motor, blend air flap actuator, blower motor series resistor group and evaporator sensor

When replacing the air conditioner housing (10).

21.1

Remove PTC heater booster

When replacing the air conditioner housing (10) with engine 639.9.

22

Install in the reverse order

Number

Designation

Model
454.0

BA83.30-P-1001-01F

Torx bolt, yoke plate to expansion valve

Nm

9