Remove/install air conditioner housing

AR83.30-P-5200RT

Remove/install air conditioner housing

16.2.12

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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 discharged.

AS83.00-Z-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A



Procedure for a damaged or leaky air conditioning system

All models

AH83.30-N-0004-01A



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

All models with air conditioning

AH83.30-N-0005-01A



Notes on handling refrigerant R134a

Air conditioning with refrigerant R134a

AH83.30-N-0003-01A

1

Open engine hood and raise to vertical position

AR88.40-P-1000RT

2

Discharge air conditioning system

 Installation: Refill air conditioning and check for proper operation and leaktightness.

AR83.30-P-1760RT

3

Remove partition wall between wheelhouse liners (2)

AR62.30-P-2400RT

4

Remove engine trim panel

Engine 642

5

Remove air filter (1)

Engine 113

AR09.10-P-1150RT

Engine 272, 273

AR09.10-P-1150GZA

Engine 156.980

AR09.10-P-1150GZS

Engine 642

AR09.10-P-1150RTB

 On engine 642, only the air filter on the left side of the vehicle must be removed.

6

Separate cable tie (4)

7

Remove bolts (3) from partition wall (6)

8

Unclip partition wall (6) upwards

 Installation: First, clip the clips (5) onto the installed partition wall and then clip on partition wall (6) from above.

9

Reduce pressure in cooling system

 Carefully open cap on coolant expansion reservoir and then reclose

10

Unclamp heating water hoses (7) with clamps

 Installation: Check fluid level in engine cooling system and corrosion/frost protection, correct if required.

 Clamping device

*000589543700

11

Remove hose clamps and pull off hot water hoses (7)

 Loosen clamps with hose clamp pliers

 Collect escaping coolant.

12

Plug hot water hoses connection fittings (7) with suitable caps

 This helps to prevent the interior of the vehicle from being soiled when removing the air conditioner housing (51).

13

Remove nut (8), push bracket (9) toward the front and remove high pressure line (10) as well as low-pressure line (11) from expansion valve

 Removal: Plug lines and expansion valve with plug

 Installation: Use new O-rings and moisten with refrigerant compressor oil



*BA83.30-P-1004-01J

 Set of stop plugs

*129589009100

14

Move the steering column in to the full extent and move out the driver seat to the full extent

15

Disconnect battery ground line

 Installation: Do not connect ground line of battery until at the very end of the overall work procedure.

AR54.10-P-0003RT

16

Remove center console

AR68.20-P-2000RT

17

Remove dashboard

AR68.10-P-1000RT

18

Remove jacket tube

AR46.10-P-0400RT

19

Remove sound deadening mats from air conditioner housing (51)

 2 sound deadening mats.

20

Remove booster blower motor (M2/1) underneath center console

AR83.30-P-5565RT

21

Detach air pipe (21) underneath center console toward the rear

22

Disconnect electrical connector from Keyless Go cockpit antenna (17)

 Vehicles with keyless go, code 889.

23

Remove connector (14) from air conditioner housing (51) toward right

24

Disconnect electrical connector for air conditioner housing (15)

25

Disconnect electrical connector from blower motor (19)

26

Disconnect electrical connector for right side outlet temperature sensor (13) and electrical connector for left side outlet temperature sensor (12)

27

Disconnect electrical connector (16) from evaporator temperature sensor

28

Disconnect electrical connector from radio (18)

29

Disconnect electrical connector (22) from restraint systems control unit (N2/7)

30

Remove right condensate water hose (42) and left condensate water hose (41) from air conditioner housing (51)

31

Pull out left insulation (48) and right insulation (49) below air conditioner housing (51) at side

32

Remove nuts of positive lead and negative line from PTC heater booster and remove positive lead and negative line from PTC heater booster

 Only on vehicles with engine 642.950

33

Unclip cockpit fuse box (F3) from bracket

34

Remove cable tie (23 to 38), remove guide (39) from bracket and lay wiring harness (40) down to side

 Removal: Carefully separate cable ties to prevent damaging the cables.

35

Remove bolts (45, 46, 47) and bolts (43, 44) and lift out air conditioner housing (51) with instrument panel carrier (52)

 Installation: Start with the bolts (47) so that the instrument panel carrier (52) is fixed in position.

 Installation: Ensure that air pipe guides (50) and guide (53) are seated correctly.



*BA68.10-P-1001-01C



*BA68.10-P-1002-01C



*BA68.10-P-1003-01C

36

Install in the reverse order

37

Perform basic programming

AR00.19-P-0200RT

Number

Designation

Model 251

BA83.30-P-1004-01J

Nut, low- and high-pressure lines to expansion valve

Nm

8

Number

Designation

Model 251

BA68.10-P-1001-01C

Bolt, instrument panel crossmember to firewall

Nm

30

BA68.10-P-1002-01C

Bolt, instrument panel crossmember to A-pillar

Nm

30

BA68.10-P-1003-01C

Bolt, instrument panel crossmember to transmission tunnel

Nm

30