Check evaporator for leaks

AR83.30-P-5550Q

02.07.2019

Model	164, 166, 197, 199, 204, 207, 209, 211, 212, 216, 218, 219, 221, 230, 240, 245 (except 245.286), 251, 292
Model	169 (except 169.090), 171
	with code 580 (Air-conditioning system)
Model	169 (except 169.090), 171
	with code 581 (Automatic air conditioning)

Shown on model 203

1	Adapter
2	Sealing ring
3	Retaining plate
4	Evaporator intake connection
5	Evaporator pressure fitting
6	Sealing ring

P83.30-3445-05

 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.Model 164, 197, 199, 204, 207, 209, 211, 212, 216, 218, 219, 221, 230, 240, 245 (except 245.286), 251 Model 166, 292 except code 2U8 (Alternative refrigerant) Model 169 (except 169.090), 171 with code 580 (Air-conditioning system) Model 169 (except 169.090), 171 with code 581 (Automatic air conditioning)	AS83.00-Z-0006-01A
 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.Model 166, 292 with code 2U8 (Alternative refrigerant)	AS83.00-Z-0007-01A
Topical note	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
Topical note	Procedure for a damaged or leaky air conditioning system		AH83.30-N-0004-01A
	Notes on handling refrigerant R1234yf	Model 166, 292 with code 2U8 (Alternative refrigerant)	AH83.30-P-0003-02A
	Notes on handling refrigerant R134a	Model 164, 197, 199, 204, 207, 209, 211, 212, 216, 218, 219, 221, 230, 240, 245 (except 245.286), 251 Model 166, 292 except code 2U8 (Alternative refrigerant) Model 169 (except 169.090), 171 with code 580 (Air-conditioning system) Model 169 (except 169.090), 171 with code 581 (Automatic air conditioning)	AH83.30-N-0003-01A
	Remove
1	Remove expansion valve	Model 171.4 with code 580 (Air-conditioning system) Model 171.4 with code 581 (Automatic air conditioning)	AR83.30-P-5520V
		Model 204, 207, 212, 218	AR83.30-P-5520CW
		Model 164 with code 580 (Air-conditioning system) Model 164 with code 581 (Automatic air conditioning) Model 164 with code 582 (Rear air conditioner)	AR83.30-P-5520GZ
		Model 166, 292	AR83.30-P-5520GQ
		Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 580 (Air-conditioning system) Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 581 (Automatic air conditioning)	AR83.30-P-5520AK
		Model 197	AR83.30-P-5520RQ
		Model 199	AR83.30-P-5520SLR
		Model 209 with code 580 (Air-conditioning system) Model 209 with code 581 (Automatic air conditioning)	AR83.30-P-5520Q
		Model 211.0/2/6	AR83.30-P-5520T
		Model 219.3	AR83.30-P-5520TX
		Model 216.3, 221.0/1	AR83.30-P-5520SX
		Model 230.4	AR83.30-P-5520R
		Model 240Front air conditioning	AR83.30-P-5520H
		Model 240Rear-end air conditioning	AR83.30-P-5520HA
		Model 251 with code 580 (Air-conditioning system) Model 251 with code 581 (Automatic air conditioning)	AR83.30-P-5520RT
	Check
2.1	Install adapter (1) with adapter hose in place of expansion valve with new sealing rings (2, 6)	Model 164, 166, 197, 199, 204, 207, 209, 211, 212, 216, 218, 219, 221, 230, 251, 292 Model 171 with code 580 (Air-conditioning system) Model 171 with code 581 (Automatic air conditioning) Model 240Front air conditioning
		 Model 216 Model 221Bolt, expansion valve to retaining plate	*BA83.30-P-1003-01K
		 Model 219Screw/bolt, expansion valve to retaining plate	*BA83.30-P-1005-01H
		 Model 164.1/8, 166, 251, 292Bolt, expansion valve to retaining plate	*BA83.30-P-1006-01J
		 Model 171 (except 171.473) with code 580 (Air-conditioning system) Model 171 (except 171.473) with code 581 (Automatic air conditioning) Model 171.473 with code 580 (Air-conditioning system) Model 171.473 with code 581 (Automatic air conditioning) Model 209Bolt, expansion valve	*BA83.30-P-1002-01D
		 Model 197Nut on expansion valve	*BA83.30-P-1009-01M
		 Model 199, 204, 207, 211, 212, 218, 230 Model 240 Front air conditioningScrew/bolt on expansion valve	*BA83.30-P-1002-01A
		 Adapter	*463589016300
		 Adapter hose	*140589516301
2.2	Install adapter (1) in place of expansion valve with new sealing rings (2, 6)	Model 169 (except 169.090) with code 580 (Air-conditioning system) Model 169 (except 169.090) with code 581 (Automatic air conditioning) Model 240 Rear-end air conditioningModel 245.2 (except 245.286)
		 Model 169 (except 169.090) with code 580 (Air-conditioning system) Model 169 (except 169.090) with code 581 (Automatic air conditioning) Model 245 (except 245.286)Bolt, expansion valve	*BA83.30-P-1001-01G
		 Model 240 Rear-end air conditioningScrew/bolt on expansion valve	*BA83.30-P-1002-01A
		 Test adapter	*140589516300
3	Connect leak tester to adapter (1)
	000 588 19 21 00 Leak tester		WS83.00-P-0035B
4	Fill evaporator with forming gas and check for leaks	 The system pressure must be maintained for at least 4 h.
		 The leak tester operator's manual must be observed.
		 Temperature changes during the pressure test can cause pressure surges, e. g. due to weather changes, transition from day to night, cooling down of engine compartment. Consistent ambient conditions must be strictly ensured.
		Pressure drop in refrigerant circuit filled with test gas	*BE83.30-P-1001-04A
		If a problem arises
		
		Replace evaporator
		Model 166, 292	AR83.30-P-5540GQ
		Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 580 (Air-conditioning system) Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 581 (Automatic air conditioning)	AR83.30-P-5540AK
		Model 164 with code 580 (Air-conditioning system) Model 164 with code 581 (Automatic air conditioning) Model 164 with code 582 (Rear air conditioner)	AR83.30-P-5540GZ
		Model 171.4 with code 580 (Air-conditioning system) Model 171.4 with code 581 (Automatic air conditioning)	AR83.30-P-5540V
		Model 197	AR83.30-P-5540RQ
		Model 204, 207, 212, 218	AR83.30-P-5540CW
		Model 209 with code 580 (Air-conditioning system) Model 209 with code 581 (Automatic air conditioning)	AR83.30-P-5540P
		Model 211.0/2/6	AR83.30-P-5540T
		Model 219.3	AR83.30-P-5540TX
		Model 216.3, 221.0/1	AR83.30-P-5540SX
		Model 230.4	AR83.30-P-5540R
		Model 251 with code 580 (Air-conditioning system) Model 251 with code 581 (Automatic air conditioning)	AR83.30-P-5540RT
5	Disconnect leak tester from adapter (1)
	000 588 19 21 00 Leak tester		WS83.00-P-0035B
6.1	Remove adapter (1) and adapter hose	Model 164, 166, 197, 199, 204, 207, 209, 211, 212, 216, 218, 219, 221, 230, 251, 292 Model 171 with code 580 (Air-conditioning system) Model 171 with code 581 (Automatic air conditioning) Model 240Front air conditioning
		 Adapter hose	*140589516301
		 Adapter	*463589016300
6.2	Remove adapter (1)	Model 169 (except 169.090) with code 580 (Air-conditioning system) Model 169 (except 169.090) with code 581 (Automatic air conditioning) Model 240 Rear-end air conditioningModel 245.2 (except 245.286)
		 Test adapter	*140589516300
	Install
7	Install expansion valve with new sealing rings (2, 6)	Model 164 with code 580 (Air-conditioning system) Model 164 with code 581 (Automatic air conditioning) Model 164 with code 582 (Rear air conditioner)	AR83.30-P-5520GZ
		Model 166, 292	AR83.30-P-5520GQ
		Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 580 (Air-conditioning system) Model 169.0 (except 169.090), 169.3, 245.2 (except 245.286) with code 581 (Automatic air conditioning)	AR83.30-P-5520AK
		Model 171.4 with code 580 (Air-conditioning system) Model 171.4 with code 581 (Automatic air conditioning)	AR83.30-P-5520V
		Model 197	AR83.30-P-5520RQ
		Model 199	AR83.30-P-5520SLR
		Model 204, 207, 212, 218	AR83.30-P-5520CW
		Model 209 with code 580 (Air-conditioning system) Model 209 with code 581 (Automatic air conditioning)	AR83.30-P-5520Q
		Model 211.0/2/6	AR83.30-P-5520T
		Model 219.3	AR83.30-P-5520TX
		Model 216.3, 221.0/1	AR83.30-P-5520SX
		Model 230.4	AR83.30-P-5520R
		Model 240Front air conditioning	AR83.30-P-5520H
		Model 240Rear-end air conditioning	AR83.30-P-5520HA
		Model 251 with code 580 (Air-conditioning system) Model 251 with code 581 (Automatic air conditioning)	AR83.30-P-5520RT
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 New sealing rings must be coated with compressor oil.

Air conditioning

Number	Designation			Model 118, 164, 166, 167, 169, 171, 177, 190, 197, 199, 204, 205, 207, 209, 211, 212, 216, 218, 219, 221, 230, 238, 240, 245, 247, 251, 253, 257, 290, 292, 293 Model 213, 217, 222 except code 1U6 (R744 refrigerant)
BE83.30-P-1001-04A	Pressure drop in refrigerant circuit filled with test gas	Test pressure	bar	15
		Test period	h	4
		Permissible fluctuation of ambient temperature	°C	2
		Pressure drop	bar	0

 Air conditioning

Number	Designation		Model 169 (except 169.090), 245 (except 245.286)
BA83.30-P-1001-01G	Bolt, expansion valve	Nm	8

 Air conditioning

Number	Designation		Model 199	Model 204
BA83.30-P-1002-01A	Screw/bolt on expansion valve	Nm	8	5,5

 Air conditioning

Number	Designation		Model 207	Model 211
BA83.30-P-1002-01A	Screw/bolt on expansion valve	Nm	5,5	8

 Air conditioning

Number	Designation		Model 212	Model 218
BA83.30-P-1002-01A	Screw/bolt on expansion valve	Nm	5,5	5,5

 Air conditioning

Number	Designation		Model 230	Model 240
BA83.30-P-1002-01A	Screw/bolt on expansion valve	Nm	8	8

 Air conditioning

Number	Designation		Model 171 (except 171.473)	Model 171.473
BA83.30-P-1002-01D	Bolt, expansion valve	Nm	4	4

 Air conditioning

Number	Designation		Model 203, 209
BA83.30-P-1002-01D	Bolt, expansion valve	Nm	10

 Air conditioning

Number	Designation		Model 221	Model 216
BA83.30-P-1003-01K	Bolt, expansion valve to retaining plate	Nm	5	5

 Air conditioning

Number	Designation		Model 219
BA83.30-P-1005-01H	Screw/bolt, expansion valve to retaining plate	Nm	5

 Air conditioning

Number	Designation		Model 164.1	Model 164.8
BA83.30-P-1006-01J	Bolt, expansion valve to retaining plate	Nm	5	5

 Air conditioning

Number	Designation		Model 166	Model 251
BA83.30-P-1006-01J	Bolt, expansion valve to retaining plate	Nm	5	5

 Air conditioning

Number	Designation		Model 292
BA83.30-P-1006-01J	Bolt, expansion valve to retaining plate	Nm	5

 Air conditioning

Number	Designation		Model 197
BA83.30-P-1009-01M	Nut on expansion valve	Nm	8

463 589 01 63 00

Adapter

140 589 51 63 01

Adapter hose

140 589 51 63 00

Test adapter

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