Remove/Install Air Conditioner Housing - AR83.30-P-5200GQ

MODEL 166, 292 

Shown on model 166 

Shown on model 166 

Shown on model 166 

	Risk of poisoning  caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury  to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated. Model 166, 292 except code 2U8 (Alternative refrigerant)	AS83.00-Z-0006-01A
	Risk of fire  due to ignition of R1234yf refrigerant on hot components. Risk of poisoning  caused by inhaling overheated refrigerant vapors. Risk of injury  to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion  due to formation of ignitable refrigerant/air mixtures	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated. Model 166, 292 with code 2U8 (Alternative refrigerant)	AS83.00-Z-0007-01A
	Risk of injury  to skin and eyes suffering scalding from contact with hot coolantspray. 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 containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-P-0005-01A
	Procedure for a damaged or leaky air conditioning system		AH83.30-N-0004-01A
	Notes on coolant		AH20.00-N-2080-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on handling refrigerant R1234yf	Model 166, 292 with code 2U8 (Alternative refrigerant)	AH83.30-P-0003-02A
	Notes on handling refrigerant R134a	Model 166, 292 except code 2U8 (Alternative refrigerant)	AH83.30-N-0003-01A
	Remove/install
1	Drain coolant at radiator	Model 166 with engine 157, 276, 278, 642, 651 Model 292 with engine 157, 276.8, 278, 642	AR20.00-P-1142GQ
2	Drain air conditioning system		AR83.30-P-1760CW
3	Remove windshield wiper system		AR82.30-P-6400GZ
4	Remove cover (2)
5	Detach refrigerant lines (5) from expansion valve (4)	Always replace seals on refrigerant lines (5).	AR83.30-P-5520GQ
6	Detach coolant hoses (7) to connection fitting of air conditioner housing (1)
7	Remove top part of dashboard		AR68.10-P-1020GQ
8	Remove front right floor covering		AR68.20-P-2070GQ
9	Remove cover below right front floor covering
10	Open line routing (3)
11	Remove electrical lines (10) from line routing (3)
12	Release and disconnect electrical connectors (12)
13	Release and disconnect electrical connector (11) from front SAM control unit
14	Release and disconnect electrical connector of electrical line (13) from SRS control unit
15	Detach all ground lines from the ground point (14) at the frame floor assembly
16	Remove air duct segment (15)
17	Remove cover (6) from air conditioner housing (1)
18	Detach drain hoses (8) from the frame floor assembly
19	Remove jacket tube		AR46.10-P-0400GQ
20	Remove screws/bolts from instrument panel carrier	Screw/bolt, instrument panel crossmember to firewall	*BA68.10-P-1001-01B
		Screw/bolt, instrument panel crossmember to A-pillar	*BA68.10-P-1002-01B
		Screw/bolt, instrument panel crossmember to transmission tunnel	*BA68.10-P-1003-01B
21	Remove air conditioner housing (1) and instrument panel carrier	Helper required. Ensure correct routing of the electrical lines (10) and electrical connectors (11, 12). Ensure correct seating of the instrument panel carrier and air duct segment of the air conditioner housing (1) on the firewall.
22	Install in the reverse order
	Check
23	Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks	Model 166, 292	AR83.30-P-1760CW