AR83.30-P-5200GH Remove/Install AC Housing

Remove And Install Evaporator Housing











DANGER:
- Risk of explosion from welding or soldering work on closed air conditioning system. Risk of poisoning. Inhaling overheated refrigerant vapors may be toxic. Risk of injury, Contact with liquid refrigerant may result in injury to the skin and eyes.
- Do not carry out any welding work on the closed air conditioning system or in the surrounding area. No smoking or open flames. Wear eye protection 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.

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

DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Drain coolant
2 Loosen brake line on the front of radiator

NOTE: Only required for right-hand steering.

3 Loosen ignition cable on the front of the radiator

NOTE: Only required on right-hand drive vehicles with engine 111/112/113.

4 Release coolant overflow from battery shield
5 Disconnect upper coolant hose from electric coolant pump

NOTE: Loosen damp on coolant hose, top.

6 Unscrew nuts from expansion reservoir on firewall
7 Remove expansion reservoir from firewall and put to one side
8 Disconnect coolant delivery/return hoses for heat exchanger (17)

NOTE: Loosen hose clamps on coolant hoses for heat exchanger supply and return.

9 Discharge air conditioning system

NOTE: Installation: Evacuate, refill air conditioning system and check for proper operation and tightness.

10 Unscrew self-locking nut (16) on expansion valve (15)

NOTE: Replace self-locking nut.

11 Disconnect low pressure refrigerant line (13) and high pressure refrigerant line (14) from expansion valve (15)

NOTE: Installation: Replace sealing rings and moisten with compressor oil.

12 Remove instrument panel carrier (4)
13 Unclip ETC control module (N15/3)
14 Disconnect connector from blend air flap actuator (M16/8)
15 Disconnect connector from recirculated air flap actuator (M39)
16 Disconnect evaporator temperature sensor connector (810/6x1)
17 Disconnect series resistor connector (6)
18 Disconnect blower motor connector (5)
19 Remove air conditioning control module (N19)

NOTE: only upto 31.08.01.

20 Unclip cable set at evaporator housing

NOTE: Installation: Ensure cable set is routed correctly.

21 Remove sound deadener (2)
22 Disconnect water drain hose from underside of AC housing (1)
23 Remove evaporator housing (1)

NOTE: Unclip evaporator housing from air distributor and remove upward.

24 Install in the reverse order
25 Inspect cooling system for leaks.