AR83.30-P-5200AK Remove/install air conditioner housing 22.2.

11
MODEL 169.0 /3, 245.2 (except 245.286)
with CODE (580) Automatic air conditioning
with CODE (581) Comfort automatic air conditioning

P83.30-4009-09

Illustrated on model 169

1 AC housing 4 Nut 8 Coolant hoses
2 Filter housing 5 High pressure pipe 28 Web
3 Wiring harness 6 Expansion valve 29 Partition wall
7 Low pressure pipe

P83.30-4222-09

Shown on model 169 with code (580)

Automatic air conditioning
1 AC housing 14 Floor Covering 20 Right air duct cover
9 Insulation mat 15 Bolts 21 Right air duct
10 Air distributor housing 16 Left air duct cover 22 Screw
11 Firewall 17 Left air duct 24 Shift lock cable
12 Cable tie 18 Floor Covering (with transmission 722.8)
13 Wiring harness 19 Bolts

© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing Page 1 of 6
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning
 P83.30-4223-09

Shown on model 169 with code (580)

Automatic air conditioning
1 AC housing M16/21 Fresh air/air recirculation flap M2/14 Blend air flap actuator motor
23 Connector actuator motor (with code (580) Automatic air
25 Nuts (with code (581) Comfort conditioning)
26 Condensation drain hose automatic air conditioning) R14 Blower motor series resistor
M16/7 Air recirculation flap actuator group
A32m1 Blower motor (with code (580) Automatic air (with code (580) Automatic air
B10/6 Evaporator temperature sensor conditioning) conditioning)
B11/12 Dew point sensor M2/7 Right blend air flap actuator
(with code (581) Comfort
automatic air conditioning)

Illustrated on model 169

1 AC housing
6 Expansion valve
27 Support
29 Partition wall
30 Screw
31 Sealing

P83.30-4224-06

© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing Page 2 of 6
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning
Shown on model 169.090 with engine 780.992

35 Electrical connector

P83.70-5406-01

 Remove/install
 Danger! Risk of death when touching components
on vehicles with high-voltage on-board
electrical system
 Danger! Risk of explosion from welding or soldering Never perform welding work on or near a
work on sealed air conditioning system. Risk closed air conditioning system. No smoking
of poisoning caused by inhaling overheated or open flames. Wear safety glasses and
refrigerant vapors. Risk of injury to skin
and eyes caused by contact with liquid
refrigerant.
 Note on the -voltage on-board electrical
system
 Conduct if air conditioning system is
damaged or leaking
 Protect air conditioning circuit and
components from moisture when carrying out
repair work
 Notes on coolant
 Notes on handling refrigerant R134a
1 Carry out disconnection of high-voltage
system
2 Remove air filter housing
3 Drain coolant from radiator
4 Drain air conditioning system
5 Remove water collector
6 Lift up filter housing (2) and remove from air
conditioner housing (1)
7 Loosen wiring harness (3) on air conditioner
housing (1)
8 Remove battery
9.1 Unscrew nut (4)
9.2 Unscrew both nuts of A/C lines at expansion
valve (6)
10 Remove high pressure line (5) from
expansion valve (6)
11 Seal opening on high pressure line (5) using
suitable stop plug
© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning
Do not touch components and open lines of AS54.00-Z-0001-01A
the high-voltage on-board electrical system.
Persons who are carriers of electronic
implants (e.g. cardiac pacemakers), must not
carry out any work on high-voltage on-
board electrical systems.
AS83.00-Z-0001-01A
protective gloves. Work only in well
ventilated areas. Carry out repair work on
the air conditioning system circuit only after
the system has been drained.
AH54.00-P-0010-01A
AH83.30-N-0004-01A
AH83.30-N-0005-01A
AH20.00-N-2080-01A
AH83.30-N-0003-01A
Model 169.090 AR54.10-P-1150EZ
With engine 266.9 AR09.10-P-1050AK
 The drain plug on the radiator is
accessible from the top via the engine
compartment on engines 266.920/940/960.
Engine 266.920/940/960 AR20.00-P-1142AK
Engine 266.980 AR20.00-P-1142BK
Engine 640.940/941/942 AR20.00-P-1142AL
Engine 780.992 AR20.00-P-1142EZ
 Installation: Evacuate, refill and check
air conditioner for leaks and proper
operation.
Model 169, 245 (except 169.090) AR83.30-P-1760AK
Model 169.090 AR83.30-P-1760EZ
AR83.25-P-1402AK
 Installation: Ensure that the filter
housing (2) is properly seated on the air
conditioner housing (1).
Model 169.090 AR54.10-P-0005AK
Model 169, 245 (except 169.090)
 *BA83.30-P-1002-01G
Model 169.090
 *BA83.30-P-1005-01O
 *BA83.30-P-1006-01O
 Installation: Replace sealing ring of
high-pressure line (5) and moisten with
compressor oil.
 The opening of the high pressure line (5)
must be sealed, as otherwise penetrating dirt
and moisture can damage the components
connected to the refrigerant circuit.
Page 3 of 6
12 Remove low-pressure line (7) from expansion  Installation: Renew sealing ring of low-
valve (6) pressure line (7) and wet with compressor
oil.
13 Close opening of low-pressure line (7) and  The opening of the low-pressure line (7)
openings of expansion valve (6) using and openings of the expansion valve (6)
suitable stop plugs must be sealed, as otherwise any penetrating
dirt and moisture can damage components
connected to the refrigerant circuit.
14 Release safety clamps of coolant hoses (8) Model 169, 245 (except 169.090)
using suitable screwdriver
 Release safety clamps of coolant hoses
(8) using suitable screwdriver in the direction
of the right side of the vehicle, away from
expansion valve (6).
15 Detach coolant hoses (8) from respective Model 169, 245 (except 169.090)
connection fitting
 Collect escaping coolant.
 Installation: Observe installation location
of coolant hoses (8).
16 Close connection fittings of coolant hoses (8) Model 169, 245 (except 169.090)
using suitable caps
 This helps to prevent the interior of the
vehicle from being soiled when removing the
air conditioner housing (1).
17 Remove crossmember under the dashboard AR68.10-P-1120AK
18 Pull out damping mat (9) between air
distributor housing (10) and firewall (11) and
take out of vehicle
19 Disconnect electrical connector (35) Model 169.090
20 Cover both couplings of electrical connectors Model 169.090
(35)
 Set of protective covers *001589019100
21 Separate cable tie (12)  Installation: Replace cable ties (12).
22 Unhook electric wiring harness (13) from left
and right of air distributor housing (10)
23 Remove accelerator pedal sensor On model 245.2 AR30.12-P-1321AK
24 Fold floor covering (14) to the side
25 Remove left blend air flap actuator motor On vehicles with code (581) Comfort AR83.10-P-2002AK
automatic air conditioning
26 Remove bolts (15) on left air duct cover (16)
using cordless drill/driver
27 Remove left air duct cover (16) from air  Installation: Ensure that the left air duct
conditioner housing (1) cover (16) is properly seated on the air
conditioner housing (1), in the left air duct
(17), and on the air distributor housing (10).
28 Fold floor covering (18) to one side and
remove bolts (19) from right air duct cover
(20) using cordless drill/driver
29 Remove right air duct cover (20) from air  Installation: Ensure that the right air
conditioner housing (1) duct cover (20) is properly seated on the air
conditioner housing (1), in the right air duct
(21), and on the air distributor housing (10).
30 Lead cables of defroster flaps and cable of On vehicles with code (580) Automatic air
footwell flaps out of retaining tab on right air conditioning
duct cover (20)
31 Disconnect electrical connector from left and On vehicles with code (581) Comfort
right defroster flaps actuator motor automatic air conditioning
 See:
Remove/install actuator motor for left and AR83.10-P-2009AK
right defroster flaps
32 Disconnect electrical connector from left and On vehicles with code (581) Comfort
right footwell flaps actuator motor automatic air conditioning
 See:
Remove and install left and right footwell flap AR83.10-P-2008AK
actuator motor
33 Disconnect electrical connector from center On vehicles with code (581) Comfort
air outlet flap actuator motor automatic air conditioning
 See:
Remove/install center air outlet flap actuator AR83.10-P-2019AK
motor
34 Unscrew bolt (22) and remove air distributor  Installation: Ensure that air distributor
housing (10) from air conditioner housing (1) housing (10) is properly seated on air
conditioner housing (1).
35 Disconnect electrical connector from blower On vehicles with code (580) Automatic air
motor (A32m1) conditioning
© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing Page 4 of 6
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning
36 Disconnect electrical connector from blend
air flap actuator motor (M2/14) or from right
blend air flap actuator motor (M2/7)
37 Disconnect electrical connector from blower On vehicles with code (580) Automatic air
motor series resistor group (R14)
38 Release plug (23) from air conditioner
housing (1) and remove
39 Remove ground line, positive lead from PTC On vehicles with engine 640.9
heater booster and disconnect electrical
connector from PTC heater booster
40 Disconnect electrical connector from rear
shutoff flap actuator motor
41 Disconnect electrical connector from
evaporator temperature sensor (B10/6) and
from dew point sensor (B11/12)
42 Remove wiring harness to evaporator
temperature sensor (B10/6) and to dew point
sensor (B11/12) from air conditioner housing
(1)
43 Disconnect electrical connector from fresh
air/air recirculation flap actuator motor
(M16/21) or from air recirculation flap
actuator (M16/7)
44 Unclip shift lock cable (24) from air
conditioner housing (1)
45 Unscrew nuts (25) on left and right of air
conditioner housing (1)
46 Separate condensate water drain hose (26)
from air conditioner housing (1)
47 Lift up rear of air conditioner housing (1) and  Installation: Observe proper seating of
lead out of left air duct (17) and right air
duct (21)
48 Lead air conditioner housing (1) out of
mounting (27) on partition wall (29)
49 Disconnect electrical connectors from blower On vehicles with code (581) Automatic air
regulator
50 Take air conditioner housing (1) out of the
vehicle interior with the aid of an assistant
51 Remove screws/bolts (30) and remove
expansion valve (6)
52 Remove air distributor housing (10) from new
air conditioner housing (1)
53 Separate sealing (31) from air conditioner
housing (1)
54 Install in the reverse order
55 Put high-voltage system back into operation
© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning
conditioning
 See:
Remove/install PTC heater booster AR83.70-P-8000AK
On vehicles with code (581) Comfort
automatic air conditioning
 See:
Remove/install rear shutoff flap actuator AR83.30-P-2008AK
motor
 Installation: Observe proper routing of
wiring harness to evaporator temperature
sensor (B11/12) and dew point sensor
(B10/6).
With transmission 722.8
Model 169, 245 except 169.090 *BA83.30-P-1010-01G
Type 169.090
 Installation: Observe proper seating of
condensate water drain hose (26) on
connection fitting of air conditioner housing
(1), otherwise the condensate cannot drain
and reaches the vehicle interior.
air conditioner housing (1) in left air duct
(17) and in right air duct (21).
 Installation: Observe correct seating of
air conditioner housing (1) in mounting (27)
on partition wall (29).
The shoulder (28) on the front end of the air
conditioner housing (1) has to make contact
with the partition wall (29), which has to be
visible from the outside.
conditioning
 See:
Remove and install electronic blower control AR83.25-P-1220AK
unit
 When removing or installing the vehicle's
air conditioner housing (1) always do so with
an assistant, in order to avoid any damage
to the interior and the air conditioner housing
(1).
When replacing the air conditioner housing
(1).
 Installation: Tighten bolts (30)
alternately, as otherwise the expansion valve
(6) will be tilted relative to the connection
fitting.
 Installation: Replace sealing rings of
connection fittings for expansion valve (6)
and moisten with compressor oil.
Model 169, 245 except 169.090 *BA83.30-P-1001-01G
Type 169.090 *BA83.30-P-1004-01O
When replacing the air conditioner housing
(1).
 Installation: The sealing (31) has to be
replaced whenever the air conditioner
housing (1) is replaced.
Model 169.090 AR54.10-P-1150EZ
Page 5 of 6
  After completing the work, attach initial
startup event log together with the
disconnection log to the vehicle file.
56 Synchronize the actuator motors  Menu item, Actuation, Normalization of
actuator motors.
 Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04AK
fault memory

 Air conditioning

Number Designation Model

169, 245

BA83.30-P-1001-01G Expansion valve bolt Nm 8

BA83.30-P-1002-01G Nut, low- and high-pressure lines to expansion Nm 8

valve

BA83.30-P-1010-01G Nut, air conditioner housing to firewall Nm 8

 Air conditioning

Number Designation Model

169.090

BA83.30-P-1004-01O Screw/bolt, air conditioning expansion valve Nm 8

BA83.30-P-1005-01O Nut, low-pressure line to refrigerant compressor Nm 20

BA83.30-P-1006-01O Nut, high-pressure line to refrigerant compressor Nm 20

001 589 01 91 00
Set of protective covers

© Daimler AG, 1/4/10, G/07/15, ar83.30-p-5200ak, Remove/install air conditioner housing Page 6 of 6
MODEL 169.0 /3, 245.2 (except 245.286) with CODE (580) Automatic air conditioning with CODE (581) Comfort automatic air conditioning