Removal and installation of the air conditioning system evaporator and its casing (Mercedes-Benz G-Class W463)

Caution! Observe all necessary precautions related to servicing the A/C systems (see Section General information and safety precautions)! Removal and installation of the evaporator casing must be done by two people!

Evaporator housing

1. Open the hood.

2. Open the cap, release the pressure in the cooling system, then drain the coolant (see Chapter Routine care and maintenance).

3. Remove the receiver-dryer assembly (see Section Removal and installation the receiver-dryer).

4. Remove the expansion valve mounting nut (1).

5. Remove the pressure lines together with the mounting plate (2) - immediately seal the open ends of the lines to prevent moisture from entering the working tract of the system, prepare replacement sealing rings.

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6. Remove the supply (4) and return (5) heater hoses from their necks - prepare suitable plugs.

7. Move both front seats as far back as they will go.

8. Remove the instrument panel (see Chapter Body).

9. Remove the gas pedal.

10. Remove the carpet from the driver's footwell floor.

11. Remove the left rear air supply hose.

12. Disconnect the connector (6) of the evaporator temperature sensor wiring (B10/6).

13. Remove the ignition control module (see Chapter Fuel and exhaust systems).

14. Disconnect the connectors (7 and 8).

15. Using a suitable tool, remove the drain hoses (9).

16. Remove the evaporator housing support brackets from the A-pillar, floor panel and bulkhead.

17. Remove the evaporator casing (10).

18. Installation is carried out in the reverse order. New sealing rings should be lubricated with compressor oil before installation.

19. Finally, clear the memory of the on-board diagnostics system processor and synchronize the stepper motors of the actuator drive using the STAR DIAGNOSIS reader (contact Mercedes-Benz service station specialists for help).

Evaporator

1. Remove the expansion valve (10) (see Section Removal and installation the expansion valve).

2. Disconnect the electrical wiring from the air humidity sensor (B31/2) and the air circulation mode switching flap drive electric motor (M2/5). Release and move the harnesses aside.

3. Remove the 5 spring clips (4).

4. Remove the heater fan housing (5) from the evaporator housing.

5. Unscrew the bolts (13 and 1) (TORX), remove the 10 fasteners (6) and lower the evaporator (7) assembled with the cover (8), pushing it forward and down.

6. Slightly pull the electric motor (M2/7) of the right mixing flap drive with the actuator to the side and remove the clamps (6a).

7. Remove the cover (8).

8. Remove the evaporator (7) from the casing.

9. Wipe the air distributor housing pan (12).

10. Installation is carried out in the reverse order - use soapy water to lubricate the sealing elements (14 and 15) of the expansion valve and the evaporator casing (do not use any oils or lubricants!). Apply a small amount of grease to the guides (16). Make sure that the sealing elements and guides are seated correctly.

11. Finally, perform synchronization of the drive motors using the STAR DIAGNOSIS reader and clear the memory of the on-board diagnostic system (see Chapter Engine electrical systems).