Remove/install air conditioner housing

AR83.30-P-5200P

12.06.2019

Model	203
	with code 580 (Air-conditioning system)
Model	203
	with code 581 (Automatic air conditioning)

P83.40-2251-09

Shown on air conditioner housing of comfort automatic air conditioning, code 580a

10	Instrument panel carrier		14	Air duct to left rear compartment		15	Air duct to right rear compartment
13	AC housing

P83.40-2252-09

1	Nut	4	Hot water feed hose	6	Hot water return hose
2	Retaining plate	4a	Fitting for heating water feed hose	6a	Fitting for heating water return hose
3	Hose clamp	5	Hose clamp

P83.40-2253-08

7	Condensation drain hoses		9	Cockpit wiring harness		B10/6	Evaporator temperature sensor
8	Clutch

P83.40-2254-09

Seal

Guide

 	Remove/install
 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
 Danger	Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by 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 drained.	AS83.00-Z-0001-01A
Topical note	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
Topical note	Notes on coolant		AH20.00-N-2080-01A
Topical note	Procedure for a damaged or leaky air conditioning system		AH83.30-N-0004-01A
	Notes on handling refrigerant R134a		AH83.30-N-0003-01A
1	Open hood
2	Reduce pressure in cooling system
3.1	Detach lower engine compartment paneling	Engine 111, 112, 271, 612.990
			AR61.20-P-1105P
		 Detach front trim only.
3.2	Remove bottom section of soundproofing	Engine 611, 612 (except 612.990), 646
			AR94.30-P-5300P
		 Remove front lower section only.
4	Drain coolant at radiator	Drain/pour in coolant ENGINE 611, 612, 646	AR20.00-P-1142HB
		Drain/pour in coolantEngine 111, 271	AR20.00-P-1142PR
		Drain/pour in coolantEngine 112	AR20.00-P-1142PV
5	Move driver and front passenger seats all the way back
 Danger	Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
6	Remove dashboard carrier		AR68.10-P-1111P
Topical note	Notes on battery		AH54.10-P-0001-01A
7	Remove accelerator pedal		AR30.12-P-1321P
8	Fold back floor covering at front left	 The air duct to the left rear compartment (14) must be accessible.
9	Remove air duct to left rear compartment (14)
10	Fold back floor covering at front right	 The air duct to the right rear compartment (15) must be accessible.
11	Remove air duct to right rear compartment (15)
12	Remove receiver drier	Up to 23.04.04	AR83.30-P-6521P
		As of 24.04.04	AR83.30-P-6521PA
		 Installation: The receiver drier must be replaced every time the refrigerant circuit is opened, in order to guarantee correct operation of the air conditioning system.
13	Unscrew nut (1)	 Nut on expansion valve	*BA83.30-P-1001-01D
14	Remove pressure lines together with retaining plate (2)	 Seal openings in order to prevent foreign objects entering.
		 Installation: Replace sealing rings and coat with compressor oil.
		 Record plug	*129589009100
15	Pull off hose clamp (3)	 Installation: Install hose clamp (3) using hose clamp pliers at an angle of 45° (picture A).
		 Hose clamp pliers (length 210 mm; clamping range 80 mm)
16	Disconnect heating water feed hose (4) from fitting for heating water feed hose (4a)	 Seal opening in order to prevent foreign objects entering.
		 Record plug	*129589009100
17	Pull off hose clamp (5)	 Installation: Install hose clamp (5) using hose clamp pliers at an angle of 45° (picture B).
		 Hose clamp pliers (length 210 mm; clamping range 80 mm)
18	Disconnect heating water return hose (6) from fitting for heating water return hose (6a)	 Seal opening in order to prevent foreign objects entering.
		 Record plug	*129589009100
19	Remove condensation drain hoses (7)
20	Disconnect coupling (8) from evaporator temperature sensor (B10/6)
21	Pull air conditioner housing (13) away from firewall slightly	 Installation: Moisten seal (11) on air conditioner housing air intake (13) with soapy water. Do not oil the seal (11). Ensure that the seal (11) is seated correctly on the air conditioner housing air intake. Grease the guides (12).
		Long-life grease	*BR00.45-Z-1001-06A
22	Remove cockpit wiring harness (9) from air conditioner housing (13)
23	Remove air conditioner housing (13)	 Remove air conditioner housing with aid of a helper. Avoid damage in the interior and on the air conditioner housing.
24	Install in the reverse order
25	Read out fault memory and erase
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
26	Synchronize actuator motors	 STAR diagnostic tool.

 Air conditioning

Number	Designation		Model 203, 209
BA83.30-P-1001-01D	Nut on expansion valve	Nm	8

129 589 00 91 00

Record plug

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51 11

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