Removal and Replacement

AR83.30-P-5540P Remove/Install Evaporator
- with CODE (580) Automatic air conditioning [model 203]
- with CODE (581) Comfort automatic air conditioning [model 203]











DANGER:
- Risk of explosion through welding or soldering work on the connected air conditioning system. Risk of poisoning through inhalation of overheated refrigerant vapor. Risk of injury through skin and eye contact with refrigerant liquid
- Do not perform any welding work on the connected air conditioning system nor in its immediate vicinity. No smoking and naked flame. Wear safety glasses and protective gloves, and work in well-ventilated areas only Repair work to be performed on air conditioning system's circuit only after system has been drained.

CAUTION: Protect circuit and components in air conditioning system from moisture when performing repair work.

DANGER:
- Risk of explosion from electrolytic gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling lead-acid batteries
- No fire, sparks, naked flames or smoking.
- Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

CAUTION: Do not connect quiescent current retention device.

2 Remove evaporator housing
3 Detach coupling from air humidity sensor (B31/2)
- With Code (580a) automatic air conditioning

4 Detach coupling from actuator motor for fresh and recirculation doors (M2/5)
5 Detach coupling from activated charcoal filter flap adjustment motor (A32m2)
- With Code (581b) comfort automatic air conditioning

6 Expose cable
7 Remove clamping springs (4)

NOTE: Five clamping springs.

8 Remove blower housing (5) from evaporator housing
9 Unscrew bolts (13)
10 Remove damping springs (6)

NOTE: Ten clamping springs.

11 Unscrew bolts (1)
12 Fold evaporator (7) with cover (8) forwards
13 Remove clamping springs (6a)

NOTE: Slightly detach right blending air flap actuator motor (M217) with mechanism.

14 Remove cover (8)
15 Remove seal (11)

CAUTION: Check seal for signs of damage, replace if necessary.

16 Unscrew bolts (9)

CAUTION: Installation: tighten screws on alternate sides to avoid any tilting.

- Screw of expansion valve: 10 N.m

17 Detach expansion valve (10)

CAUTION: Seal openings using suitable plugs.

- See "Special Tools" given below.

CAUTION: Installation: Replace O-rings.

- Wet threads and O-ring using compressor oil.

18 Remove evaporator (7) from evaporator housing
19 Clean pan of air-distributor housing (12)
20 Install in the reverse order
21 Function check of air conditioning system
22 Read diagnostic trouble code memory and erase
23 Perform basic programming.

Special Tools

Set of Plugs, P/N# 129 589 00 91 00: