Housing Assembly HVAC: Service and Repair

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



























DANGER:
- Danger of severe burns to skin and eyes from hot coolant spewing out. Coolant is toxic when swallowed
- Open cooling system only when coolant temperature is below 90 degrees C. Open cover slowly and reduce pressure. Do not fill beverage containers with coolant. Wear protective gloves, protective clothing and protective goggles.

1 Release pressure in cooling system

NOTE: For this purpose, turn radiator cap to catch "1" and close again.

2 Drain coolant, refill

DANGER:
- Explosion hazard when performing welding or brazing work on closed air conditioning. Poisoning hazard from inhaling overheated refrigerant vapors. Injury hazard from skin and eye contact with liquid refrigerant.
- Do not perform any type of welding work on closed air conditioning system or in its vicinity. Smoking and open flame prohibited. Wear protective goggles and protective gloves, work only in well-ventilated rooms. Perform repair work on air conditioning circuit only with system emptied.

3 Empty air conditioning (recycle), evacuate, charge, check for leaks

CAUTION:
- Add quantity of compressor oil removed to refrigerant circuit when charging air conditioning (new oil).
- Protect air conditioning circuit and components from moisture during repair work.

4 Remove wiper system (1)
5 Remove air collection box and water collector (3)
6 Disconnect pressure lines from expansion valve (4)

CAUTION: Plug openings (parts kit)

7 Remove hose clamp (5) and pull off coolant feed hose (6)
8 Remove hose clamps (7) and pull off coolant return hoses (8)

NOTE: Installation: Do not mix up coolant return hoses.

9 Remove instrument panel (9)

NOTE: Installation: Perform function check before installing instrument panel.

10 Remove air ducts (11) for rear/stowage compartment ventilation
11 Remove front floor covering on left (12)
12 Remove front floor covering on right (13)
13 Remove left/right rear air ducts (14)
14 Remove air ducts for side vents and footwell on left (16)
15 Remove air ducts for side vents and footwell on right (17)
16 Disconnect connector for front passenger airbag (R12/4)
17 Disconnect blower motor connector (M2x1)
18 Disconnect connector for electronic ignition switch (15)
19 Disconnect connector for actuator motor electronic circuitry (20)
20 Disconnect connector for left heater core temperature sensor (19)
21 Disconnect connector for right heater core temperature sensor (18)
22 Disconnect connector for evaporator temperature sensor (B10/6x1)
23 Unscrew screws (21) for jacket tube
24 Unscrew screws (22) on left A-pillar
25 Unscrew screws (23) on fire wall
26 Unscrew nut (24) on A/C housing
27 Unscrew screw (25) on left transmission tunnel
28 Unscrew screws (26) on right A-pillar
29 Unscrew screws (28), remove line duct (29) with wiring harness
30 Unscrew nuts (27) on A/C housing
31 Separate all cable straps on cross tube (30)

NOTE: Installation: Use new cable straps.

32 Remove cross tube (30) and lay down on front seats
33 Remove A/C housing
34 Remove receiver/drier
35 Install in opposite order.

NOTE: Installation: After completing work, correct coolant level and check for leakage.