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Remove/Install Expansion Valve - AR83.30-P-5520GQ

Model 166, 292 

MODIFICATION NOTES

05.10.2016 Safety note added AS83.00-Z-0006-01A  
13.09.2016 Compressor oil specification changed BB00.40-P-0362-01A  
12.09.2016 General note added AH83.30-P-0003-02A  
12.09.2016 General note added AH83.30-N-0003-01A  
12.09.2016 General note added AH83.30-P-0005-01A  
12.09.2016 Safety note added AS83.00-Z-0001-01A  
12.09.2016 Safety note added AS83.00-Z-0007-01A  

Shown on Model 166 

Fig 1: Expansion Valve Components Location - Model 166
G14238199DANGERWARNINGREMOVINGNOTESSPECIAL TOOLNOTESSPECIAL TOOLINSTALLINGSPECIAL TOOLREFER TO CAPACITIES & SPECIFICATIONSIMPORTANTREFER TO CAPACITIES & SPECIFICATIONSIMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLREFER TO CAPACITIES & SPECIFICATIONSIMPORTANTTORQUE SPECIFICATIONINSPECTCourtesy of MERCEDES-BENZ USA
DANGER 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 rep Air 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 
WARNING 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 rep Air 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 
Protect Air conditioning circuit and components from moisture when carrying out rep Air work   AH83.30-N-0005-01A
  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
REMOVING Remove     
1 Drain Air conditioning system   AR83.30-P-1760CW 
2 Remove windshield wiper system   AR82.30-P-6400GZ
3 Remove connecting strut at left If necessary.  
4 Remove panel (2)    
5 UnScrew nuts of low-pressure line (5) and high-pressure line (4) from expansion valve (1)    
6 Pull low-pressure line (5) and high-pressure line (4) out from expansion valve (1) and seal with a stop plug NOTES The openings of the refrigerant lines must be closed off.
Otherwise, penetrating dirt and moisture will damage the Air conditioning system.		  
    SPECIAL TOOL Record plug Fig 2
7 Remove Screws (3)    
8 Lift seal (6) (arrow) and remove expansion valve (1)    
9 Seal openings on Air conditioner housing using suitable stop plugs NOTES The openings on the Air conditioner housing must be sealed.
Otherwise, penetrating dirt and moisture will damage the Air conditioning system.		  
    SPECIAL TOOL Record plug Fig 2
INSTALLING Install     
10 Remove stop plug from Air conditioner housing SPECIAL TOOL Record plug Fig 2
11 Insert sealing rings of expansion valve (1) and moisten with compressor oil    
REFER TO CAPACITIES & SPECIFICATIONS Compressor oils (specification 362.1) IMPORTANT Sealing rings must be replaced. BB00.40-P-0362-01A
12 Lift seal (6) (arrow) and insert expansion valve (1)    
13 Moisten Screws/bolts (3) for expansion valve (1) with compressor oil and apply in alternating fashion    
REFER TO CAPACITIES & SPECIFICATIONS Compressor oils (specification 362.1)   BB00.40-P-0362-01A
    IMPORTANT This serves to prevent the expansion valve (1) from tilting.  
14 Tighten Screws/bolts (3) for expansion valve (1) TORQUE SPECIFICATION Bolt, expansion valve to retaining plate *BA83.30-P-1006-01J 
15 Remove stop plugs from low-pressure line (5) and high-pressure line (4) SPECIAL TOOL Record plug Fig 2
16 Insert sealing rings on low-pressure line (5) and high-pressure line (4) and moisten with compressor oil    
REFER TO CAPACITIES & SPECIFICATIONS Compressor oils (specification 362.1) IMPORTANT Sealing rings must be replaced. BB00.40-P-0362-01A
17 Insert low-pressure line (5) and high-pressure line (4) in expansion valve (1)    
18 Tighten nuts of low-pressure line (5) and high-pressure line (4) at expansion valve (1) TORQUE SPECIFICATION Nut, low- and high-pressure lines to expansion valve *BA83.30-P-1004-01J 
19 Install paneling (2)    
20 Install left connecting strut If removed.  
21 Install windshield wiper system   AR82.30-P-6400GZ
INSPECT Check     
22 Evacuate Air conditioning system, refill it, and then check the system to make sure that it functions correctly and does not leak   AR83.30-P-1760CW 
AIR CONDITIONING

Number Designation Model 166 Model 292
BA83.30-P-1004-01J Nut, low- and high-pressure lines to expansion valve Nm 8 8
AIR CONDITIONING

Number Designation Model 166 Model 292
BA83.30-P-1006-01J Bolt, expansion valve to retaining plate Nm 5 5
Fig 2: Identifying Set Of Sealing Plugs (129 589 00 91 00)
G14238200Courtesy of MERCEDES-BENZ USA
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