Remove/install air conditioner housing

AR83.30-P-5200A

Remove/install air conditioner housing

27.06.2019

Model

461 (except 461.331)

with code H02 (Air conditioning, manual)

Modification notes

06.04.2017

Safety note added

AS20.00-Z-0001-01A

03.04.2017

"Technical note" added

AH00.00-P-5000-01A

15.03.2017

Safety note changed

AS83.00-Z-0006-01A

15.03.2017

General note added

AH83.30-P-0005-01GW

18a

Fitting

91

Expansion valve

35

Drain hose

91a

Cover

36

Drain hose

91c

Nut

53

Pressure line

98

Heater control

54

Suction pipe

98a

Mounting clip

68a

Heater hose

98b

Heater control cable

68b

Heater hose

W29/7

Steering column ground point

g

Bolts

 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

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Topical note

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

AH83.30-N-0005-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

 

Remove/install

1

Disconnect ground line of battery.

Model 461.217/219/227/229/238/239/249/266/267/321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459
with code H02 (Air conditioning, manual)

AR54.10-P-0003G

Model 461.302/332/342/345
with code H02 (Air conditioning, manual)
Model 461.304/334/344/346/392
with code H02 (Air conditioning, manual)
Model 461.305/333/340/343
with code H02 (Air conditioning, manual)

AR54.10-P-0003GL

2

Remove refrigerant reservoir.

Model 461.217/219/227/229/238/239/249/266/267/321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459
with code H02 (Air conditioning, manual)
except code Y65 (Alternative refrigerant)

AR83.30-P-6520A

Model 461.302/304/305/332/333/334/340/342/343/344/345/346/392
with code H02 (Air conditioning, manual)

AR83.30-P-6520GM

 Replace the refrigerant reservoir each time the air conditioner housing is removed.

3

Drain off coolant.

Model 461 with engine 602.983
with code H02 (Air conditioning, manual)

AR20.00-P-1142GG

Model 461.304/334/344/346 with engine 642.975
with code H02 (Air conditioning, manual)
Model 461.305/333/340/343/392 with engine 642.884
with code H02 (Air conditioning, manual)

AR20.00-P-1142GX

4

Remove center console.

Model 461 (except 461.331)
as of model year 2014
with code H02 (Air conditioning, manual)

AR68.20-P-2000GQA

Model 461.217/219/227/229/238/239/249/266/267/321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459
up to model year 2014
with code H02 (Air conditioning, manual)

AR68.20-P-2000D

Model 461.302/304/305/332/333/334/340/342/343/344/345/346/392
up to model year 2014
with code H02 (Air conditioning, manual)

AR68.20-P-2000GL

5

Remove instrument panel.

Model 461.302/304/305/332/333/334/340/342/343/344/345/346/392
with code H02 (Air conditioning, manual)

AR68.10-P-1040GL

Model 461.217/219/227/229/238/239/249/266/267/321/322/323/326/327/328/329/335/336/337/338/341/365/366/367/368/401/402/403/404/405/450/451/452/454/455/456/458/459
with code H02 (Air conditioning, manual)

AR68.10-P-1000A

 Installation: Only install the instrument panel center section cover after installing the center console.

6

Detach blower hoses from fittings (18a) on air conditioner housing.

7

Detach air boxes on left and right of air conditioner housing and place to one side with rear passenger compartment air hoses still connected.

8

Detach heater hoses (68a, 68b) from heater box.

9

Seal opened hoses and connections.

 Record plug

*129589009100

10

Detach retaining clip (98a) and unhook heater control cable (98b) from lever of heater control (98).

11

Detach heater control cable (98b) from lever of heater control (98).

12

Detach cover (91a) from expansion valve (91).

13

Unscrew nut (91c) from expansion valve (91), remove lock washer and pull suction line (54) and pressure line (53) out of expansion valve (91).



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace the nut (91c).
Replace the sealing rings of the lines and moisten with compressor oil.

 Nut on expansion valve

*BA83.30-P-1001-01C

14

Seal opened hoses and connections.

 Record plug

*129589009100

15

Pull drain hoses (35, 36) out of drain grommets.

 Installation: Ensure that drain hoses (35, 36) are correctly seated in the drain grommets.

16

Unscrew ground line of blower motor (M2) from steering column ground point (W29/7) and expose.

17

Remove air recirculation flap in air box.

18

Remove screws (g) on air conditioner housing in engine compartment from firewall.

 Bolt, air conditioner housing to firewall/cockpit crossmember

*BA83.30-P-1013-01C

19

Remove air conditioner housing.


Do not use any tools to detach the air conditioner housing from the firewall.
Otherwise the air conditioner housing will be damaged.


Detach the air conditioner housing carefully.
Otherwise the pressure line (53), suction line (54) and expansion valve (91) will be damaged.

 Helper required.

 Installation: Clean the sealing surface on the firewall.

 Installation: Replace the seal on the heater box and moisten with sealant.

Universal sealant 205 ml

*BR00.45-Z-1004-01A

20

Install in reverse order.

 Air conditioning

Number

Designation

Model 461

BA83.30-P-1001-01C

Nut on expansion valve

Nm

10

 Air conditioning

Number

Designation

Model 461

BA83.30-P-1013-01C

Bolt, air conditioner housing to firewall/cockpit crossmember

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1004-01A

Universal sealant 205 ml

A 003 989 01 71