Remove/install air conditioner housing

AR83.30-P-5200Q

12.06.2019

Model

209

Shown on air conditioner housing of comfort automatic air conditioning

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

P83.40-2376-06

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

P83.40-2377-06

P83.40-2253-08

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

 	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		AR88.40-P-1000Q
2	Reduce pressure in cooling system
3.1	Remove engine compartment paneling	Vehicles with gasoline engine
			AR61.20-P-1105P
		 Only front section of engine compartment lining.
3.2	Remove bottom section of soundproofing	Vehicles with diesel engine
			AR94.30-P-5300P
		 Only front section of noise encapsulation.
4	Drain coolant at radiator	Engine 112, 113	AR20.00-P-1142PV
		Engine 156	AR20.00-P-1142TMG
		Engine 271	AR20.00-P-1142PR
		Engine 272, 273	AR20.00-P-1142QB
		Engine 612, 646	AR20.00-P-1142HB
		Engine 642	AR20.00-P-1142PI
5	Move driver and front passenger seats all the way back
6	Remove cross member under instrument panel	Model 209.3	AR68.10-P-1120Q
		Model 209.4	AR68.10-P-1120QA
7	Remove accelerator pedal
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	Vehicles with receiver drier at side	AR83.30-P-6521P
		Vehicles with receiver drier at bottom	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. Observe additional oil quantity after replacing parts.
13	Unscrew nut (1)	 Nut on expansion valve	*BA83.30-P-1001-01D
14	Remove pressure lines together with retaining plate (2)	 Installation: Replace O-rings and coat with refrigerant compressor oil, in order to prevent leaks.
		 Plug openings.
		 Record plug	*129589009100
15	Pull hose clamp (3) off fitting	 Installation: Install hose clamp (3) using hose clamp pliers at an angle of 45° (picture A).
16	Disconnect heating water feed hose (4)	 Seal off opening.
		 Record plug	*129589009100
17	Pull hose clamp (5) off fitting	 Installation: Install hose clamp (5) with hose clamp pliers at an angle of 45° (picture B).
18	Disconnect heating water return hose (6)	 Seal off opening.
		 Record plug	*129589009100
19	Remove condensation drain hoses (7)
20	Disconnect coupling (8) from evaporator temperature sensor (B10/6)
21	Pull air conditioner housing away from firewall slightly
22	Remove cockpit wiring harness (9) from air conditioner housing
23	Remove air conditioner housing
Topical note	Notes on removing and installing the air conditioner housing		AH83.30-P-0006-01GM
		Long-life grease	*BR00.45-Z-1001-06A
24	Install in the reverse order
25	Perform basic programming		AR00.19-P-0200Q
26	Read out fault memory using Star Diagnosis
27	Carry out function check

 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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