Part 2
Installation InstructionsAir Conditioner - R134a 83.1
B. Installation of air conditioner unit
1 Remove passenger seat.
2 Remove right and left cover strip and remove loudspeaker covers.
3 Remove steering wheel.
4 Remove jacket tube casing (1).
5 Remove wooden strips (1 and 2).
NOTE: Remove plastic caps from side nozzles.
6 Remove Instrument cluster.
140 589 02 33 00
7 Remove center nozzle.
8 Remove glove compartment.
9 Remove side nozzles left and right.
10 Remove side parts
NOTE: For this Purpose release bolt on the inside.
11 Remove loudspeaker.
12 Remove rotary light switch.
13 Remove hand rail
14 Release all bolts on the instrument panel and remove.
15 Remove nozzles (1 and 2).
16 Remove pedal covering.
17 Take out foot mat and remove accelerator pedal.
18 Remove side panelling.
NOTE: For this purpose pull off carpeting a little and release screws beneath it (arrow).
19 Remove blower switch (1) and release nut beneath it.
20 Remove radio and pull out oddments tray(2).
21 Release bolts and pull out pushbutton panel somewhat.
NOTE: Mark all connectors to the corresponding pushbuttons and detach.
22 Unclip Bowden cables (1) for air distribution behind the switch panel.
23 Unclip Bowden cable for heater regulation at regulating valve.
24 Remove pushbutton panel.
25 Release cover and remove.
NOTE: Mark all connectors to the corresponding pushbuttons and detach.
26 Push back cover of parking brake lever slightly and remove.
27 Unscrew 4 bolts on housing.
28 Remove ashtray and unscrew two bolts, then remove housing.
29 Release console and remove.
30 Release bottom section of instrument panel and remove.
NOTE:
- Unclip headlamp range control unit and put aside.
- Make sure that the lines are not bent.
- Never open the unit.
31 Remove frame for middle console.
32 Remove nozzles left and right.
33 Release all bolts of oddments tray (1) and remove.
NOTE: Slightly lift oddments tray, disconnect heater pipes and remove tray.
34 Remove terminal strip.
35 Detach heater hoses from heater unit.
36 Detach recirculating air flap.
37 Unscrew fastening bolts of heater unit.
38 Release bolts on the inside right and left and completely remove heater unit.
NOTE: Carefully release heater unit from the fire wall. "silicon adhesive"
39 Reposition regulating valve and Bowden cables. (from heater unit to air conditioner unit)
40 Close hole (1) with plug and additionally seal.
41 Remove adhesive residue from the sealing surface (2).
42 Install pressure line (1) and fasten with clip.
NOTE:
- Use copper sealing rings at the through-hole of the fire wall (outside and inside).
- Coat thread of lines with refrigerant oil.
43 Cut off Insulating matting in the area of the expansion valve.
44 Remove plugs and insert grommets 460 997 52 81 with sealing compound.
NOTE: Cut out holes in the insulating matting corresponding to the bores. (One Insulating matting is omitted)
45 Install air conditioner unit and secure with 4 bolts.
NOTE:
- Additionally coat the sealing surface to the fire wall with sealing compound e.g. Diko transparent.
- Press plugs N 915042 005000 into the two no longer used weld nuts on the left and right of the air conditioner unit.
46 Insert both condensation drain pipes into the grommets.
47 Attach air distributor (1) left and right as well as cover (2).
48 Attach water hoses to regulating valve.
49 Screw Intake line (3) and pressure line (1) on expansion valve and tighten.
NOTE: Coat thread with refrigerant oil.
50 Install auxiliary cable harness, refer to section D.
51 Install oddments tray.
NOTE: Attach heating pipes.
52 Install frame for center console.
NOTE: Pay attention to cable routing.
53 Attach instrument panel bottom section left and right.
NOTE: When screwing in the bolts make sure that none of the electric lines are damaged.
54 Install center console.
55 Install housing.
56 Attach cover for parking brake lever.
57 Attach Bowden cable for heater control at regulating valve.
58 Install temperature regulator, air conditioner, connect and plug in lamp.
Connections: 1 bl from fan to terminal 3
1 blk/1l from auxiliary cable harness to terminal 4
59 Attach all connectors corresponding to their marking.
60 Attach Bowden cables for air distribution behind the control panel.
61 Attach air nozzles.
62 Install air nozzles and adapters for side nozzles left and right.
63 Attach blower switch.
64 Secure pushbutton panel.
65 Install radio and insert oddments tray.
NOTE: The further installation is carried out in the same manner in reverse order to Pos. 13 to Pos. 1.