Remove/install AC housing - AR83.30-P-5200M
Models 215, 220
| Remove/Install | |||
| 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 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. | AS20.00-Z-0001-01A | |
| Wear protective gloves, protective clothing and eye protection. | |||
| 1 | Reduce pressure in cooling system | ||
| 2 | Drain coolant, fill | ||
| Engine 112 in model 220 | AR20.00-P-1142HA | ||
| Engine 113 (except 113.991) in models 215, 220 Engine 137 in model 215, 220 |
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| Engine 113.991 in models 215.374, 220.074/174 | AR20.00-P-1142RVK | ||
| Engine 275.950 in models 215.376, 220.176 | AR20.00-P-1142H | ||
| Engine 613.960 in model 220.026 Engine 628.960 in model 220.028/128 Engine 648.960 in model 220.025/125 |
AR20.00-P-1142HB | ||
| 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. | Never perform welding work on or near a closed air conditioning system. 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. | AS83.00-Z-0001-01A | |
| 3 | Discharge air conditioning system | ||
| Conduct if air conditioning system is damaged or leaking | All models | AH83.30-N-0004-01A | |
| Protect air conditioning circuit and components from moisture when carrying out repair work | All models fitted with air conditioning | AH83.30-N-0005-01A | |
| Notes on handling refrigerant R134a | All models fitted with air conditioning | AH83.30-N-0003-01A | |
| 4 | Remove wiper system (1) | AR82.30-P-6400M | |
| 5 | Remove air plenum chamber and water collector (3) | AR83.10-P-9998M | |
| 6 | Disconnect pressure lines at expansion valve (4) | ||
| 7 | Slacken hose clamp (5) and detach heater water supply hose (6) | ||
| 8 | Slacken hose clamps (7) and remove heater water return hoses (8) | ||
| 9 | Remove instrument panel (9) | ||
| Model 215 | AR68.10-P-1000N | ||
| Model 220 | AR68.10-P-1000M | ||
| 10 | Remove air ducts in rear compartment/ stowage compartment ventilation (11) | ||
| 11 | Remove front left floor covering (12) | AR68.20-P-2050M | |
| 12 | Remove front right floor covering (13) | AR68.20-P-2070M | |
| 13 | Remove rear compartment air ducts on left/ right (14) | ||
| 14 | Remove air ducts for side outlets and left footwell (16) | ||
| 15 | Remove air ducts for side outlets and right footwell (17) | ||
| 16 | Unplug plug of front passenger airbag squib 1 (R12/4) | ||
| 17 | Unplug connector of control unit box blower motor (M2/2x1) | ||
| 18 | Unplug connector of electronic ignition switch (15) | ||
| 19 | Unplug connector of stepper motor electronics (20) | ||
| 20 | Temperature sensor connector Unplug left heat exchanger (19) | ||
| 21 | Temperature sensor connector Unplug right heat exchanger (18) | ||
| 22 | Unplug connector of evaporator temperature sensor (20a) | ||
| 23 | Unscrew bolts from jacket tube (21) | ||
| 24 | Unscrew bolts from left A-pillar (22) | ||
| 25 | Unscrew bolts from firewall (23) | ||
| 26 | Unscrew nut from AC housing (24) | ||
| 27 | Unscrew bolt from left transmission tunnel (25) | ||
| 28 | Unscrew bolts from right A-pillar (26) | ||
| 29 | Unscrew bolt (28), remove cable duct (29) with wiring harness | ||
| 30 | Unscrew nuts from AC housing (27) | ||
| 31 | Disconnect all tie straps from transverse pipe (30) | ||
| 32 | Remove transverse pipe (30) and put on the front seats | ||
| 33 | Remove AC housing | ||
| 34 | Replace fluid reservoir | AR83.30-P-6520M | |
| 35 | Install in the reverse order | ||
| Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns | Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts. |
AS00.00-Z-0005-01A | |
| 36 | Correct coolant level and perform a leak test |