Remove/install air conditioner housing · ar8330s5200e · Mercedes-Benz WIS

AR83.30-S-5200E

Remove/install air conditioner housing

29.05.2020

Model	447
	with code HH4 (THERMOTRONIC automatic climate control)
Model	447
	with code HH9 (Air conditioner, automatic heater control)
Model	448

Modification notes

19.02.2020	Work procedure revised	The whole document
28.05.2020	Method modified	Operation steps 20.1, 20.2

Shown on model 447 with ENGINE 651

2	Coolant hoses
3	Refrigerant lines
4	Nut

S83.30-A070-06

Shown on model 447 with engine 622.9

10	Bracket
11	Nuts

S83.30-A071-01

S83.25-4531-09

Shown on model 447 with code HZ0 (Electrical auxiliary heater)

1	AC housing	7	Nuts	N33/4	PTC heater booster control unit
5	Electrical connector	8	Electrical connector	N154	Automatic air conditioning (KLA) control unit
6	Electrical wiring harness	9	Drain hoses

 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Typ 447 mit Motor 780	AS00.00-Z-0035-01A
 Danger	Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures	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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.	AS83.00-Z-0007-01A
 Warning	Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts	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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.	AS83.00-Z-0006-01A
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
Topical note	General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment	Typ 447 mit Motor 780	AH00.00-Z-0300-01A
Topical note	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on handling refrigerant R1234yf		AH83.30-P-0003-02A
	Notes on handling refrigerant R134a		AH83.30-N-0003-01A
 	Remove/install
1	Discharge air conditioning system.	Model 447 except code HX1 (R-1234yf refrigerant), model 448	AR83.30-S-1760E
		Model 447 with code HX1 (R-1234yf refrigerant)	AR83.30-S-1760EF
2	Remove air filter housing.	Model 447 with engine 274, 622.8, 651, model 448
		Model 447 with engine 651	AR09.10-S-1150E
		Model 447 with engine 622.8	AR09.10-S-1150EF
		Model 447 with engine 274, model 448	AR09.10-S-1150EG
3	Remove engine cover.	Model 447 with engine 654.9
			AR01.10-S-2405EA
4	Remove the fuel injection system control unit.	Model 447 with engine 622.9
			AR07.08-S-7008EF
5	Remove bracket (10).	Model 447 with engine 622.9
		 For this purpose, remove nuts (11).
6.1	Drain off coolant.	Model 447 with engine 654.9, model 447 with engine 780
		Model 447 with engine 654.9	AR20.00-S-1142E
		* Applies to Europe only
		

		Model 447 with engine 780.701	AR08.50-S-0021F
		Model 447 with engine 780.702	AR08.50-S-0022G
6.2	Clamp off coolant hoses (2).	Model 447 with engine 274, 622, 651, model 448
		 Clamp	*000589543700
7	Remove coolant hoses (2).	 Collect escaping coolant using suitable vessel.
		 Installation: Check clamps for damage.
		 Commercially available devices/tools Collecting pan
		 Hose clamp pliers	*454589003700
		If there is damage,
		
		replace damaged clamps.
8	Remove nut (4).	 Model 447 with engine 274, 622, 651, 654 with code HH4 (THERMOTRONIC automatic climate control) Model 447 with engine 274, 622, 651, 654 with code HH9 (Air conditioner, automatic heater control) Model 448Nut, refrigerant line to expansion valve	*BA83.30-N-1001-01A
		 Model 447 with engine 780.701/702 with code HH9 (Air conditioner, automatic heater control) Model 447 with engine 780.702 with code HH4 (THERMOTRONIC automatic climate control)Nut, refrigerant line to expansion valve	*BA83.30-N-1012-01FA
9	Remove refrigerant lines (3) from expansion valve.	Model 447 with engine 274, 622, 651, 654, model 448
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Seal refrigerant lines (3) and connections on expansion valve.
		 Installation: Replace sealing rings and moisten with compressor oil.
		 Assembly tool	*000589936300
		 Record plug	*129589009100
10	Remove crossmember underneath the instrument panel.		AR68.10-S-1120E
11	Disconnect electrical connector (5).
12	Remove automatic air conditioning (AAC) control unit (N154) and place to one side with attached electric lines.	Model 447.8 , model 448.8
			AR83.30-S-6600E
13	Remove electrical wiring harness (6) from PTC heater booster control unit (N33/4).	Model 447 with code HZ0 (Electric auxiliary heater)
		 To do so, remove nuts (7).
		 Note installation position of electrical wiring harness (6).
		 Installation: Check retaining clips of electrical wiring harness (6) for damage.
		 Nut, wiring harness to PTC heater booster	*BA54.18-N-1001-02A
		If damage is detected,
		
		Replace damaged retaining clips.
14	Remove and disconnect electrical connector (8) from air conditioner housing (1).
15	Remove electrical wiring harness (6) from air conditioner housing (1).	 Note installation position of electrical wiring harness (6).
		 Installation: Check retaining clips of electrical wiring harness (6) for damage.
		If damage is detected,
		
		Replace damaged retaining clips.
16	Remove drain hoses (9) from air conditioner housing (1).	 The number of drain hoses (9) varies depending on the given vehicle equipment.
		 Installation: Make sure that drain hoses (9) are seated correctly on air conditioner housing (1).
17.1	Remove air conditioner housing (1).	Model 447 with engine 274, 622, 651, 654, model 448
		 Aid of helper required.
17.2	Carefully release air conditioner housing (1) from ends of refrigerant lines (3) and remove.	Model 447 with engine 780
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Seal refrigerant lines (3) and connections on expansion valve.
		 Installation: Make sure that the ends of the refrigerant lines (3) insert properly into the corresponding openings of the expansion valve. Replace sealing rings and moisten with compressor oil.
		 Helper required.
		 Assembly tool	*000589936300
		 Record plug	*129589009100
18	Convert detachable parts on air conditioner housing (1).	If air conditioner housing (1) is replaced.
19	Install in the reverse order.
20.1	Bleed cooling circuit.	Model 447 with engine 274, 622, 651, 654, model 448
		Model 447 with engine 622.8	AR20.00-S-1142-03EH
		Model 447 with engine 654.9	AR20.00-S-1142-03E
		Model 447 with engine 274, 622.9, 651, model 448 with engine 274	AR20.00-S-1142-04E
	Service Information: Coolant	Model 447 with engine 274, 622, 651, 654	SI20.00-S-0001B
		 Engine 274 in models 447, 448Coolant	*BF20.00-N-1001-01K
		 ENGINE 654.9 in MODEL 447Engine cooling system	*BF20.00-N-0001-01EA
		 Model 447 with engine 622.851/951, 651.950Coolant	*BF20.00-N-1001-01A
		 Cooler vacuum filling device	*285589002100
		 Test cap	*210589009100
		 Typ 447 mit Motor 622.8 Electric vacuum pump	*285589022100
		 Typ 447 mit Motor 622.8 NTKL Adaption	*285589012100
20.2	Fill and bleed coolant circuit.	Model 447 with engine 780
		* Applies to Europe only
		

		Model 447 with engine 780.701	AR08.50-S-0021F
		Model 447 with engine 780.702	AR08.50-S-0022G
	Check
21	Check coolant circuit for leak tightness.	Model 447 with engine 274, 622, 651, model 448 with engine 274	AR20.00-S-1010E
		Model 447 with engine 654.9	AR20.00-S-1011E
		* Applies to Europe only
		

		Model 447 with engine 780	AR08.50-S-0011F
 Warning	Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.	Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.	AS49.00-Z-0001-01A
 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
22.1	Run engine for approx. 4 min at idle speed and check all systems relevant for the proper operation of the air conditioning system.	Model 447 with engine 274, 622, 651, 654, model 448
22.2	Check function of air conditioning system or cooling system for high-voltage on-board electrical system using diagnostic device.	Model 447 with engine 780
			AD00.00-S-2000-04E

 Wiring harness

Number	Designation			Model 447, 448
BA54.18-N-1001-02A	Nut, wiring harness to PTC heater booster	M6	Nm	8
		M8	Nm	16

 Air conditioning

Number	Designation		Model 447 with engine 654	Model 447 with engine 622
BA83.30-N-1001-01A	Nut, refrigerant line to expansion valve	Nm	14	8

 Air conditioning

Number	Designation		Model 447 with engine 274, 651 Model 448 with engine 274
BA83.30-N-1001-01A	Nut, refrigerant line to expansion valve	Nm	8

 Air conditioning

Number	Designation		Model 447 with engine 780.701/702 with code HH9, Model 447 with engine 780.702 with code HH4
BA83.30-N-1012-01FA	Nut, refrigerant line to expansion valve	Nm	12

 Engine cooling system

Number	Designation				Engine 654.9 in model 447
BF20.00-N-0001-01EA	Engine cooling system	Filling capacity		Liter	10
		Antifreeze/water	to -37 °C	%	50/50
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-06A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-06A

 Engine cooling

Number	Designation			Engine 622.851 except code H12 (Auxiliary hot-water heater)	Engine 622.851 with code H12 (Auxiliary hot-water heater)
BF20.00-N-1001-01A	Coolant	Total filling capacity	Liter	10,0	13,0
		Corrosion/antifreeze down to -37 °C	Liter	5,0	6,5
		Corrosion/antifreeze down to -45 °C	Liter	5,5	7,25
		Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-06A	BB00.40-P-0325-06A
		Sheet		BB00.40-P-0326-06A	BB00.40-P-0326-06A
		Sheet		-	-

 Engine cooling

Number	Designation			Engine 622.951 except code H12 (Auxiliary hot-water heater)	Engine 622.951 with code H12 (Auxiliary hot-water heater)
BF20.00-N-1001-01A	Coolant	Total filling capacity	Liter	10,7	13,7
		Corrosion/antifreeze down to -37 °C	Liter	5,4	6,9
		Corrosion/antifreeze down to -45 °C	Liter	5,9	7,5
		Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-00A	BB00.40-P-0325-00A
		Sheet		BB00.40-P-0325-06A	BB00.40-P-0325-06A
		Sheet		BB00.40-P-0326-06A	BB00.40-P-0326-06A

 Engine cooling

Number	Designation			Engine 651.950 except code H12 (Auxiliary hot-water heater)	Engine 651.950 with code H12 (Auxiliary hot-water heater)
BF20.00-N-1001-01A	Coolant	Total filling capacity	Liter	10,4	13,4
		Corrosion/antifreeze down to -37 °C	Liter	5,2	6,7
		Corrosion/antifreeze down to -45 °C	Liter	5,7	7,4
		Sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-00A	BB00.40-P-0325-00A
		Sheet		BB00.40-P-0325-06A	BB00.40-P-0325-06A
		Sheet		BB00.40-P-0326-06A	BB00.40-P-0326-06A

 Engine cooling

Number	Designation			Engine 274 in model 447, 448
BF20.00-N-1001-01K	Coolant	Total filling capacity	Liter	10,4
		Corrosion/antifreeze down to -37 °C	Liter	5,2
		Corrosion/antifreeze down to -45 °C	Liter	5,7
		Sheet		BB00.40-P-0310-01A
		Sheet		BB00.40-P-0325-00A
		Sheet		BB00.40-P-0325-06A
		Sheet		BB00.40-P-0326-06A

000 589 93 63 00

Assembly tool

285 589 01 21 00

NTKL Adaption

000 589 54 37 00

Clamp

454 589 00 37 00

Hose clamp pliers

210 589 00 91 00

Test cap

129 589 00 91 00

Record plug

285 589 02 21 00

Electric vacuum pump

285 589 00 21 00

Cooler vacuum filling device

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