Removing and installing evaporator - ra83001400554x(0554)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Model 140

Fig 1: Identifying Evaporator Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Air conditioner unit	Remove.
Heat exchanger	Remove (paras. 1-3).
Charcoal canister	Remove (paras. 4-5).
All vacuum lines	Pull off vacuum elements and place to one side together with the valve block.
Blower	Remove (4 screws).
Actuator for bypass flap (charcoal canister)	Remove if fitted (2 screws), unclip actuating rod (arrow) and place actuator to one side.

Special tool

Fig 2: Identifying Special Tools (201 589 13 21 00 00 42 80)

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Removing and installing heat exchanger

Undo pipe clamps (arrows).
Unscrew screws (21).
Pull heat exchanger (22) up and remove.

Fig 3: Locating Heat Exchanger And Screw
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Remove charcoal canister (if fitted). To do this, remove cover (27, 5 screws), evacuate pneumatic gasket with tester and pull charcoal canister up and out.

Fig 4: Identifying Cover And Screw
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Fig 5: Identifying Evacuation Connection
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If a charcoal canister is not installed, there is a damping mat in its place. Remove damping mat.

Fig 6: Removing Damping Mat
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Remove defroster outlet nozzles (6 clips and 2 screws on right-hand outlet, 8 clips on left-hand outlet), then unscrew 2 screws (26) on each.

Fig 7: Identifying Defroster Outlet Nozzles And Screws
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Fig 8: Identifying Defroster Outlet Nozzles And Screws
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Unscrew 2 screws (26) under vacuum elements for defroster outlets (37 and 38).

Fig 9: Identifying Vacuum Elements For Defroster Outlets And Screws
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Unscrew 4 screws (26) in front of vacuum element for recirculated air flap (49).

Fig 10: Identifying Vacuum Element For Recirculated Air Flap And Screw
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Remove damping mat, 22 screws (25).
Remove housing for blower (3 screws).

Fig 11: Identifying Damping Mat, Blower And Screw
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove housing for bypass flap (7 clips and 2 screws [28]).

Fig 12: Identifying Housing For Bypass Flap
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Pull threaded plate (24) up and remove, and unscrew screw (26).

Fig 13: Identifying Threaded Plate And Screw
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Unclip actuating linkage for recirculated air element (arrow).

Fig 14: Locating Air Element
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Unscrew retaining frame with studs (7 screws and 2 nuts), carefully pull off sealing strips around the joint.
Disconnect top section of air conditioner unit from bottom section; undo 25 clips.
Remove top section of air conditioner unit from bottom section.
Remove evaporator from bottom section of air conditioner unit and clean evaporator housing.
Install in the reverse sequence ensuring that the sealing strips on the evaporator and on the air conditioner unit are correctly seated.
When renewing the evaporator, fill it with 40 cm³ compressor oil.

After completing the work: Erase fault memory in the control unit (Diagnosis manual - air conditioning). Parts which have come into contact with compressor oil for R12 or R134a may only be installed in systems operating with the same refrigerant.