Model and System Identification 00 This manual applies to the folloming passenger cas, starting mode! year 197 USA Model Year Systom Type Mode Engine From To Chassis Heating Ventilation and 230 115.954 1977 1978 123.023 ‘Air Conditioning System | 2400. 616.912 197 1983 123.123 {Air Conditioning System i! 300 D 617912 1977 1980 123.130) Automatic Clmate Control 300. CD errg9i2 1978 1980 123.150 300 TO 617.912 1979 1980 123.190 280E 110.984 1977 1980 123.033, 280 CE 110984 1978 1980 23.053 A Conditionng System ill 300.0 ei7912 1981 1981 123.130 Automatic Chmate Control 3000 Turbo 617952 1982 1985 123133 300 CD 617919 1981 1981 123.150 300 CD Turbo 617.952 1982 1985 123.153 300 TD Turbo 617.952 1982 1985 123.193 280 E 110.984 1981 1982 123.033 280 CE 110984 1981 1982 123.053 00-010/100 Model and System Identification Control panel versions The following control panel illustrations and descriptions should help to determine the type of air conditioning system installed in your particular model Heating/Ventilation and Air Conditioning System | Introduced with Model Year (M.Y.) 1977 Models 230 (M.Y, 1977-1978) and 240 D (M.Y. 19771983) are equipped with a manually ‘operated air conditioning and heating system. This system is covered in Section 1 Control panel changed since M.Y, 1981 ‘Air Conditioning System 11 Automatic Climate Control Used From M.Y, 1977—1980 In M.Y. 1977, the Automatic Climate Control (System 1) was introduced in models 300 D/CD/TD and 280 E/CE, The ACC II can be easily recogniced bby the vertical row of pushbuttons on the console. ‘This System is covered in Section 2. Air Conditioning System (11 ‘Automatic Climate Control Used From M.Y. 1981 Since M.Y, 1981, models 300 D/CD/TD (Turbo) and 280 E/CE (M.Y, 1981-1982) are equipped with the ‘Automatic Climate Control (System 111), which can be identified by the horizontal row of pushbuttons ‘on the console, This system is covered in Section 3. 00-010/2Vehicle identification number locations 00 ‘The illustrations depict model 123 sedans. On model 300 TD and coupe, the identification numbers can be found in similar locations. \When ordering spare parts, please state chassis and engine numbers Gasoline Models 1 Certification Tag 6 Information Tag Wert door pita California version 2 Neenstieation Tap Vacuum line routing Tete window post) foremision control system 3 Chass No. 1. Emission Conirol Tap, 3 Engine No, 8 Emission Contol Tag 5 Body No. and Paintwork No. Catalyst Information Diesel Models Certification Tag 6 nformation Tog ete door pillar 200.0 TURBO DIESEL, 2. Idensifeation Tag 300 Co TURBO DIESEL, {fete wincow post) California version 3. Chassis No. ‘Vacuum line routing 3 Engine No. {or emusign contat system 5 Body No.and Paintwork No. 7 Ernsion Control Tap 8 Emission Control Tog Catalyst Information 00-015/183-100 Removal and installation of heater box Note Starting August 1980 a modified heating/venting system is installed. It is externally recognized by the two control levers for controlling the air in up. ward or downward direction. Pay attention to revised scope during removal and installation, 2nd version Removal 1. Remove floor mats in driver's leg area, 2. Remove center console and both covers under instrument panel (68~200 and 68-150) 3 Push driver's seats completely back 4 Drain approx. 2 litres of cooling water e34-100/1 Fa5 Disconnect heater hoses. 6 Remove glove box (68-140) 7. Pull both plugs from switch for glove box lights. 8 Unscrew serews on aie ducts left and right for rear ‘compartment's heater 9. Remove air ducts on transmission tunnel, On heater box 2nd version, unscrew holding straps and disconnect. 83410012 F 410 Pull off connecting hoses toward lateral ring nozzles left and right on heater box. 11 Pull off connecting hose between heater box and the two center fresh air nozzles. 12. Disconnect connecting lever toward fresh air flap (arrow) 13. Remove support on transmission tunnel 14. Unscrew serew on instrument panel 34-0019 Fa18 Remove plug and open cable clamps on heater box. 16 Loosen all electrical connections on heater box. 17 Disconnect bowden wires between control unit fon heater box and water valve, 18 Disconnect bowden wire between blower switch ‘and main air tap, 19 Unserew aut on righthand upper angle bracket. 20 Remove plug connection from ignition starter switch 82410014 Fa21 Unscrew nut on lefthand upper angle bracket (do not remove instrument cluster for this purpose) 22 Unscrew both screws on lower angle bracket 23. Close fresh air flap 24 Lower heater box and place on transmission tunnel so that heater box slides out of defroster, nozzle. 25 Pull heater box toward the rear so that the heater pipes are separated from front wall 26 Lift heater box above front passenger leg room. Hold heater pipes in upward direction so that no cooling water will flow out 834-1005 4Installation Note: During assembly jobs, do not place small parts fn instrument panel, since these parts might drop through defroster nozzles into heating system, (On heater boxes 2nd version, check air flaps to leg room prior to installation and adjust for uniform closing, if required, 27 Lubricate rubber seal at defroster nozzles with soap water or the like 28 Place heater box from side of front passenger behind instrument panel on transmission tunnel, 29 Tilt heater box in direction of front wall, while introducing heater pipes through front wall and into defroster nozzles. 30 Attach heater box to front wall by means of lefthand upper angle bracket. 31. Attach plug connection to ignition starter switch, 834-10016 F232 Attach heater box to front wall by means of righthand upper angle bracket. 33. Install lower angle bracket in such a manner that ‘the following dimensions are attained: 2 = 165mm b= 217mm Attention! Jobs item 34 to 36 are required only for heater box ‘of 2nd version 34 Attach holding straps. 35. Screw-down holding straps under slight tension, 3410017 Fa36 Mount cover on air flap levers. 37. Connect bowden wires between control unit on. heater box and water valve or main air flap. Sette 38 Check whether the main air flap opens and closes correctly. For this purpose, plug center knob to control Unit and turn to the rigth and left up to stop. Note: The blower housing should rest tee of tension ‘against opening in water box. 39. Mount plug to heater box 40 Install electric cable on heater box, 834-1008 Fa41. Install support on transmission tunnel, 42 Install support on instrument panel 43. Attach connecting lever for fresh air nozzles. 44. Check whether connecting lever is perfectly engaged. ea4—10019 Fa45. Mount connecting hose between heater box and the two center fresh air nozzles. 46 Attach connecting hoses to lateral ring nozzle left and right on heater box. 47, Mount air ducts for heating rear compartment left and right in driver's leg room. 48. Install glove box. 49. Mount heater hoses. 50 For further installation proceed vice versa, ea4—r00/10 Fa83-110 Removal and installation of heat exchanger Removal 1. Remove heater box (83-100), 2. Remove both clamps on cover 3 Unscrew serews left and right. vea-a54 4. Remove both clamps on front end of cover. 9-156 ea4—110715 Remove cover from heater box. 6 Knock elamp at the left of blower box downward 7. Knock clamp at right of blower box downward, 8 Remove both clamps at bottom from blower box. e24-110729 Remove both rubber seals trom water pipes. 10 Disconnect blower box from heater box. 11 Lift heat exchanger in upward direction out of heater box. 12 Remove seals from water pipes 83411073 sa9-1269Installation 12. For installation proceed viee versa, making sure that the rubber seal between the blower and heater box is mounted in the recess provided. 3.4110483-112 Removal and installation, adjustment of bowden wires on water valve for heater Note “The lefthand heater switch on control unit is connected 10 the righthand rotary slide valve on water valve by means of a bowden wire, Vice versa, the righthand heater switch is connected to lefthand rotary slide valve Removal 1. Remove locking ring (arrow) on bowden wire. 2 Disconnect bowden wire from water valve. 3. Remove righthand cover under instrument panel (68-150), 4. Remove center console (68-200). 5. Separate bowden wire on control unit, 6 Pull bowden wire out of front wall Installation 7. For installation proceed vice versa. Note: Prior to attaching bowden wire to water valve, adjust wire, saan2Adjustment 8 Close heater switch on control unit. 9 Close rotary slide valve on water valve by pushing rotary slide valve toward the rear 10 Adjust bowden wire at square head until wire coll ccan be connected to rotary slide valve. The wire is. extended by turning square head to the right. 11 Complete function test 934-112283-112 Removal and installation, adjustment of bowden wires on water valve for heater Note ‘The lefthand heater switch on control unit is connected to the righthand rotary slide valve on water valve by ‘means of a bowden wire, Vice versa, the righthand heater switch is connected to lefthand rotary slide valve Removal 1. Remove locking ring (arrow) on bowden wire. 2 Disconnect bowden wire from water valve 3. Remove righthand cover under instrument panel (68-150), 4. Remove center console (68-200) 5. Separate bowden wire on control unit, 6 Pull bowden wire out of front wall Installation 7. For installation proceed vice versa Note: Prior to attaching bowden wire to water valve, adjust wire ea4—121Adjustment 8 Close heater switch on control unit. 9. Close rotary slide valve on water valve by pushing rotary slide valve toward the rear. 10 Adjust bowden wire at square head until wire coil ‘can be connected to rotary slide valve, The wire is extended by turning square head to the right. 11 Complete function test. 8341127283-115 Removal and installation of water valve for heater Removal 1. Drain approx. 2 litres of cooling water. 2 Loosen all hose clips on water valve. 3. Pull off heater hoses and disconnect both wires. 4 Turn out screw and remove water valve from front wall Installation 5 For installation proceed vice versa. 4-1883-120 Removal and installation of heater blower Removal 1. Remove cover from under instrument panel at the right (68-150), 2 Pull off plug from blower motor. 3. Remove screw from contact plate, 4 Lift contact plate and pull off both connecting wires for sores resistance. 5 Remove screws from blower motor flange. 3.4120116 Lift blower motor out of blower housing Installation 7. For installation proceed vice versa, 3.41201283-140 Removal and installation of ornamental grille on air inlet Note ‘The ornamental grille is attached at the front with only four expanding clamps (arrows). Remove windshield wiper arms from windshield wiper shaft at driver's side \ w-n908 Removal 1 Push bolt on expanding clamps completely down, 2 Liftexpanding clamps on one side and take out of ‘ornamental gil 4140/13 Pull out omamental grill in forward direction. Installation 4 For installation proceed vice versa 8341407283-150 Removal and installation of ring nozzles right or left on instrument panel Removal 1. Remove respective cover under instrument panel (68-150). 2 Pull connecting hose from ring nozzle 3. Turn ring nozzle lower half slightly while holding ring nozzle upper half in position. 4 Pull ring nozzle upper half out of instrument panel Installation 5. Insert ring nozzle upper half into instrument panel 6 Push ring nozzle lower haif from rear of instrument ‘panel against upper half, making sure that all the four links will engage in recess provided. 7. Attach connecting hose. 1B Mount cover. 2.41501183-520 Removal and installation of electromagnetic clutch A. York refrigerant compressor Data, test values Designation Models Models 4/8 cylinders 6 cylinders Electromagnetic cutout clutch 12 V Pitts 6.0 inch Pitts 6.7 inch Power input Cold 3.5 amps. Warm 2.8 amps. Tightening torques Nm (kp) ‘Screws (52) coll to refrigerant compressor 4 (1.4) Serew (51) pulley to crankshaft 20-27 (2.0-2.7) Special tool Pulling screw for pulley 100 589 00 35 08 Conventional tools Double open-end wrench 3/8" x 7/16", 1/2 x 9/16" Note For pulling pulley from crankshaft of refrigerant com: pressor (with V-belt mounted) energize electromag: netic clutch (clutch will attract). With refrigerant com> pressor removed, carefully hold pulley with water pump pliers while supporting pliers against fastening sorews of coil Prior to removing clutch, check power input on clutch. Replace clutch if power input exceeds 6.0 amps. 35-526/1 F2Removal 1 Actuate electromagnetic clutch while switching cn ignition, cooling blower and temperature switch 2. Unscrew screw (51) 3. Pull pulley of electromagnetic clutch (2) from Crankshaft of refrigerant compressor (1) with pulling screw (53) 4. Switch off ignition. 5. Disconnect electric line on cable connector. 6 Remove V-belt for refrigerant compressor from electromagnetic clutch by loosening hex. screw (1) fr necked-down screw (1) and swivelling pulley ten: sioning roller in downward direction, oF slacken V-belt by means of tensioning serew (2). Beit-tensioning roller engines 115, 615. 616, 617 Belt-rensioning roller engine 110 836-526/2Belt tensioning rller engine 123 7 Remove belt-tensioning roller of electromagnetic. Clutch (2) while paying attention to spring washer (64) 8 Unscrew 4 screws (52) and remove coil Note If the same clutch is installed again, check friction surfaces of clutch for damage. If score marks are showing up on friction surfaces or burned spots caused by overheating, completely replace clutch. Installation 9. Turn crankshaft of compressor s0 that keyway is facing upwards. 10. Screw coil with inch screws (521, which are painted with “Loctite heavy 270 green’ prior to assembly, to refrigerant compressor in such a manner that the outlet of the electri line is on top. 1 Insect spring washer (54) into crankshaft, 936-5263 Fa12 Mount pulley and slightly tighten with inch sorew (51) and washer in place. 13. Connect electric line of supplementary harness ‘and of electromagnetic clutch to cable connector. Mount ground line between cable connector and refrigerant compressor. 14. Check V-belt and pulley tensioning roller. Mount V-belt and tension with pulley tensioning roller. Note: Lowstretch V-belts are correctly tensioned, if they respond elastically to sturdy thumb pressure. New low'streteh V-belts are subject toa slight elonga: tion which occurs on this type of V-belt already after 2 few minutes of operation, It is therefore of decisive importance for life of V-belts that they are once again tensioned following that short running-in period {Maintenance Manual item 756 and 757) 15 Actuate electromagnetic clutch while switching ‘on ignition, blower and air-conditioning system. Then tighten screw (51). 16 Check electromagnetic clutch for funetion. 3.68264B. Delco refrigerant compressor Data, test values Designation ‘engines 615, 616, 617.912, 617.952 Electromagnotic cutout clutch 12V Delco 4.9 inch aes a3 Thtening torques nm (hom Screws (8) bel pulleyeluteh na) ‘Screw M 10 x 30 pipeline to refrigerant compressor 5023 (543) Nut (1 on dive shat as Screws (6 and 6) M 12 refrigerant compressor on carrier 60+ 10 (6+ Howe line (14) from evaporator to pipeline 78" 29-37 (29-37 Hose line (1) from pipaine to condenser 7/8” 29-37 7 Special tool Holding device for refrigerant compressor . o 116 589 14.31 00 Holding wrench for clutch Ca 116 589.04 40 00, Disessembting 100 or clutch pate ete 1000 589 07 95 00 ee | Gy 0 88049 4200 Guide piece 116 68905 63 00 Double-claw removing tool (000 589 88 33 00 Knocking-out mandrel 115 589 02.35 02 Presingof pate for refrigerant compressor ae 109 589 00 25 00 s36-526)5 FaConventional tools Socket 14 mm, 3/8” square e.g. made by Hazet, 5630 Remscheid e.. made by Hazet, 5630 Remscheid Feeler gauge (set) ‘order No. 2147 e.g. made by Hazet, 5630 Remscheid Langbeck pliers 72 A internal lock) Se aetiaaet eg. made by Hazet, 5630 Remscheid order No. 1846 6-2 Pliers for retaining ring J 2 (external lock) Self-made tool Disassembling tool for O-ring Note Removal and installation of spring plate, of clutch with belt pulley and magnet coil, as well as shaft sealing may only be performed with the refrigerant compressor removed ‘The clutch with support, the belt pulley and the ‘magnet coil are forming one assembly. In the event that one part of this assembly must be replaced, the complete assembly shall be removed (refer to 83-526, section b) a) Removal and Removel 1 Evacuate air-conditioning system (83-516) 2 Remove refrigerant compressor (83-622) 3 Attach holding device to refrigerant compressor and clamp into vise. Serew-ott pipeline (7) from refrigerant compressor (1). For this purpose remove screw (8 and 21). Then close opening by means of pressing-off plate 836-526/6 F24 Loosen refrigerant compressor from holding device and retighten with the drive shaft in upward position, 5 Prevent spring plate (2) from rotating by means of holding wrench, screw off nut from shaft using socket 14 mm, 6 Screw disassembling tool into hub holding too! by means of wrench and tighten central screw. 7 Take out key in shaft 2.6-526/7Installation 8 Clean friction area of spring plate and of clutch. Insert wedge (4) into groove of hub in such a ‘manner that itis projecting by about § mm. 10 Put spring plate on shaft in such a manner that wedge and groove are in alignment. 11 Place spacer on spring plate. Insert assembling tool through spacer and screw assembling tool to shaft end 12. Secure hex. head of tool and screw.in the central screw until there is @ play of approx. 0.5~1 mm be: ‘ween the friction areas of the spring plate and the clutch 13. Take out assembling tool and spacer. 14. Screw in place new screw on shaft (smaller diam: eter of nut directed toward shoulder of shafth and tighten. Check play once again. 15 Install refrigerant compressor (83-52) [Nut on drive shaft Spring plate chuten| Locking ring Support foreluteh Belt pulley Serew with tock Locking ring ring Siping 13 Shaft sealing 14 Drive shat 20 Housing cover 53.6-526/8 F2 12 13 nu'b) Remove and install clutch together with belt pulley, magnet coil and bearing Removal 16 Remove spring plate (83-526, section a, item 1107) 17. Take out lock (5). Mark position of magnet coil terminals 18 Insert guide piece over shaft on headpiece of refrigerant compressor. 19. Pull off assembly by means of puller 20. Bend away locks on hex. screws and take off the 6 screws (8) together with locks. 7 21 Take off belt pulley from clutch and remove ‘magnet coil from belt pulley. Q y if y 9 3 9836-52619 £2Note: If bearing (6) of clutch body (3) must be replaced, perform jobs as per item 22 through 24 Removal of bearing 22 Place clutch (3) on wooden supports and press ‘out bearing (6). For removal of the bearing, the notches need not be removed. Installation of bearing 23. Align new bearing (6) exactly in relation t0 bore of hub and press.in 24. Punch-mark the bearing at 3 points at 120° distant from each other. Do not punch too deep since otherwise the outer race of bearing may be deformed. Do not use again old notches. ~6 83.6-526/10 F2Installation 25. Insert magnet coil (9) into belt pulley (7). 26 Slip clutch (3) into belt pulley (7) and provi: sionally serew-in by means of new locks and screws (8). Provide threads of screws with Loctite. 27. Put down complete assembly on housing cover front. Before pressing assembly completely down, ‘make sure that the magnet coil terminals are in the correct position in relation to refrigerant compressor and that the three projections on the back of the ‘magnet coil are in correspondence with the recesses in the housing cover, 28 Insert locking ring (5) for the assembly, 29 Clean friction areas of spring plate and clutch. 36-526/11 F230. Rotate belt pulley together with clutch in order to determine whether the belt pulley isin alignment. Slightly readjust, if required, 31 Tighten serews (8) of pulley/cluteh. Secure screw heads in a similar manner as the screws were secured prior to removal refrigerant compressor (83-522) 83.6-526)12 F283-500 General description and operation of air-conditioning system 1 Temperature vacuum switeh 10 Operating lever for cooting ir distribution 2 Blower siren Leverett = Air for windshiela an leer! ventilation 3 Later venta. (cling air ust) Lsvercener= Air tor windshield and ates 4 Cooting ar outer canter entiation: a wal a for Srv’ & Gaoting a outlet from detroser nozs' on winds Sravrear compartment legroom with knob 8 Cooling ai outlet inieg room fwith temperature vocuum ettempareure vacuum such (1) pulled Saitenpuiea) Lever right = Airtor tert ventilation as wel ae Tor 7. Gperaing lever eooting ar outlet center ‘river's and rear compartment leg ‘90m Reser switch ethand venice secon wuts knob of temperature wun seh Heater such rghinond vale scan poled 1. The air-conditioning system supplies cooled and dehumidified air for cooling the interior of the ve- hicle. The system operates with outside air and recit culated air cooling. 2 For normal cooling the blower switch (2) is set to stage I, Il or Il. On vehicles to 07/80 the temperature vacuum switch (1) is turned to the right and adjusted depending on desired refrigerant output in range be tween 0 and mark on blue graduated scale, upon which 100 % fresh air will blow through evaporator. Version up to 07/80 e26-500/1 Fa3. For maximum cooling, temperature vacuum switch (1) is set in range between mark and end of blue seale, 30 that approx. 80% of recirculated air and approx, 20% of outside air are quided through eva porator. Heater switches (8 and 9) should be at posi tion 0. 4. On vehicles starting 08/80 the temperature dial (1) is turned out of end position “0”. Stepless increase of refrigerant output continues up to position “Max”. 5. Upon engagement of selector dial in “Max” posi- tion, the system switches from fresh air cooling to recirculating air cooling 80 % recirculating air, 20% fresh air. Version starting 08/80 6 The air-conditioning system operates only with the engine running, High engine speed provides high speed of refrigerant compressor and thereby increased cooling output. A 3-stage blower (2) to increase and control air volume is located below temperature va cum switch (1). 7. The evaporator housing with blower is clipped to heater box instead of standard heater blower. On vehicles with air-conditioning, the heater box has two additional flaps for driver's and rear compartment leg room. 8 With recirculating air flap (3) closed ~ tempera ture vacuum switch up to position 3/4 cooling capa city = approx. 200° cutting-in angle ~ fresh air will ‘be drawn in through upper portion of evaporator housing by blower (5). 9 With recirculating air flap opened (starting at 3/4 cooling capacity) approx. 80% of air inside ve- hicle is drawn out of leg room and approx. 20% out side air (fresh air) through a leak of recirculating air flap, 22.6-500/2 Fa10. The blower forces the air through the evaporator (4) to heater box. With the center nozzles opened operating lever 7 is turned to the left) the air will flow directly out of central nozzle (4), A slight share Of the air is uided through the heat exchangers to the lateral ventilation outlet (3), the defroster nozzles (5) and the rear compartment and leg room openings 6) 11 With the center nozzles closed (operating lever 7 ‘to the right) the air is guided through the heat ex. changers to the defroster nozzles, to the lateral venti lation outlet and the rear compartment and leg room. ‘openings. The cooled and dehumidified air can be warmed up again by turning the heater switches (8 and 9) to the right. If the temperature vacuum switch is turned to the right (starting from approx. 30° cut-in angle) the rear passenger compartment and legroom openings are closed by the additional flaps in heater, box, starting from 03/79 on lefthand steering vehicles 11/79 on righthand steering vehicles also for defroster nozzles. If cooled air is also desired in legroom, pull button of temperature switch (up to 07/80). Starting (08/80 the flaps for defroster and legroom openings are manually operated. Rapid cooling 12. For fast cooling of a vehicle interior which has ‘been exposed to extensive solar radiation for some time, open the adjustable air outlet openings (3 and 4) 13. Set temperature vacuum switch or selector dial (1) to full cooling capacity (turn knob completely to the right into position "MAX" and set blower switch (2) to position 3). Open vehicle windows only until all the hot air is gone. Upon cooling down of vehicle interior, set temperature switch or selector dial (1) in ‘such a manner that the desired temperature is attained, in addition, following sufticient cooling, all the air out: let openings may be opened. However, to obtain an air disteibution free of draft, it is commended to let all the cooling air escape through defroster nozzle behind windshield glass following sufficient cooling down. With this adjustment, the outside of the wind: shield glass will become foggy in moist and cool weather, In such a case, increase the air temperature (or close the cooling air outlet toward windshield gla. 83.6-500/3 FaImportant between seasons 14 Between seasons in periods of high humidity (fogging of window glass from inside) the air-condi tioning system may be engaged in addition to vehicle heater, As a result, depending on position of tempera ture vacuum switch or selector dial (1), the moisture will be drawn out of fresh air or recirculating air at ‘evaporator. This cooled down air can be heated again to a pleasing temperature by the respective position of the heater switches (8 and 9) Note: The air-conditioning system should be switched ‘on at least once a month for a short period. 15 This is particularly important during the cold season, when the air-conditioner is not required. Operation is necessary to lubricate the seal on rotating crankshaft of refrigerant compressor, 89.6-S00/4 Fa83-502 Refrigerant circuit Divgrammotic view of an air-conditioning system The refrigerant compressor (1) driven by the engine will suck up the heated, gaseous refrigerant R12 for delivery to condenser (2). The head wind will flow through condenser located in front of radiator and will cool the ref: ‘gerant vapor which has been additionally heated and put under high pressure, until itis fluid. The fluid refrigerant will then flow to the receiver dehyatrator (3). The filter-drier, installed in receiver dehydrator will extract any remaining water from fluid refrigerant to prevent any icing-up of expansion valve (4). A sight glass at top of receiver dehydrator permits checking quantity of refrigerant in system at any time. With the system switched on, the refrigerant should circulate free of bubbles. From the receiver dehydrator the refrigerant flows to the expansion valve (4). The expansion valve on evaporator and a metering device in expansion valve will change the high pres sure of the fluid refrigerant into a low pressure fluid in evaporator (5), upon which the fluid will become vapor. ‘The required vaporizing heat is taken from the air flowing through evaporator: The air will be cooled, ‘The vaporized refrigerant is drawn up by the refrigerant compressor and is again compressed to complete the cycle. 23.6-50211Layout of refrigerant cireuit | Retrigerant compressor with electromagnetic clutch Tamperature switch lauxiliary fan) 2 Condenser 47 Pressure sites 3 Receiver dehydrator with ier drier and sight glass Fuse 4 Expansion valve 9 Temperature regulator (up to 07/60), 5 Evaporator ‘Temperature dal (starting 08/80) Low pressure — gaseous Low pressure = tia 1 mm High pressure — gaseous me High pressure tie 99.6-502/2 Fa83-504 Safety measures The air conditioning system is filled with safety refri- gerant R 12. This refrigerant is colorless and odorless, At normal temperature itis non-toxic, non-inflammable ‘and not explosive at any mixing ratio with air. When ‘working on air conditioning systems, the following safety measures should nevertheless be observed: a) Avoid touching fluid refrigerant. Treat afflicted skin areas similar to frostbite. Wear goggles to protect eyes. See doctor immediately if refrigerant enters eve. b) Drain system when repairing air conditioner. Do ‘not drain gaseous refrigerant in closed rooms; since «refrigerant is heavier than air inspection pits, if in use, increase risk of suffocation, 1, Refrigerant bottle contents approx. 7.5 ka 2 Oneway Frigen Baby bottle, contents approx. 4309 ‘ch Never clean components of system with hot steam, Unse only hydrogen, R12 and R 11 for cleaning. 4) Never perform any welding jobs on components of closed system or nearby, No matter whether the system is filled with refrigerant or not, heat will lead to a very high overpressure which in turn may damage the system or even result in an explosion. R 12, which is absolutely non-toxie at normal ‘temperatures, will decompose into hydrochloric acid and hydrofluoric acid when touched by @ flame. Among others, the decomposition products also contain chlorine and phosgene. Since these products are detrimental to health, pertinent care is essential If a part of the air conditioning system is damaged (or leaking, e.g. by a vehicle accident, leave system switched off since otherwise the refrigerant com: pressor may suffer damage due to the absence of ‘cooling and lubrication, 83.1-508/1 8 ST i _ — —83-606 Repair instructions for air conditioning system Atention! Carefully observe safety rules (83-504). 1. Repairs are permitted with air conditioning system drained only, 2 Even though the system has been drained, a slight residual pressure may be present when loosening some ‘connection or other. In such a case, reduce pressure slowly prior to loosening connection completely. 3. When handling refrigerant circuit, immediately close all openings airtight with closing plugs. 4. During assembly, make particularly sure that all connections and sealing rings are in perfect condition It will be of advantage to use new sealing rings for repairs. To avoid damage, moisten sealing surfaces ‘and seals always with special cold-flowing oil. 5 When tightening connections, always apply counterhold with a wrench and tighten to specified torque. If this is not done, the connections will be subject to early leaks. Prior to filling system with refrigerant, check oil volume in compressor first and then evacuate entire system (83-512, 514 and 516). 6 Stor I spare parts dry and in enclosed condition. 7. Blow out refrigerant hoses, pipe lines, condensers land evaporators prior to installation with nitrogen or refrigerant R 12, 8 During assembly, remove closing plugs from ‘components only shortly prior to installation. This is particularly important for filter drier (receiver dehy drator). An unclosed receiver dehydrator with filter 16 6 19 2 2 Harness trom Connecting bushings Main fusebox. terminal 30 supplementary tose C. 16 amps (with supplementary heater 25 amps) Main fuse box. terminal 15 fuse no. 12, Bama E:pole coupling terminal 1 (relay fan [13] mina 87) E:pole coupling terminal 5 Welay fan [13] terminal 8) Ground Temperature switeh 52 °C Hud reserve) ground Temperature regulator (8) Ground 6:pole coupling terminal 2 Tealay rerigerant compressor terminal 873) Intermediate plug terminal & (starter terminal 80), Rotary light switch terminal K Ground 2.08 coupling temperature regulator (8) 2-pole coupling temperature regulator (8) Pressure switeh (7) Ground 836-5051 Fa S:pole coupling terminal 3 {relay far [13] terminal 30) Gepole coupling terminal 4 {relay far [13] rerminat 86) 2.pole coupling supplementary fan Temperature switch 52 °C Ireceiver dehydrator) Temperature switch Iracever dehydrator 2-pole coupling supplementary fan G-pole coupling terminal 3 telay Lai Conditioning systers [9] termi 30) {pole coupling terminal (relay ar conditioning systern [9] termina 85) Pressure switch (7) 6:pole coupling terminal 4 (relay air conditioning system [9] terminal 86) 2-pole coupling temperature regulator (8) 2.pole coupling temperature regulator (8) Light socket Light soeker Fetrigerant compressor (10) cable connector Refrigerant compressor (10) ground Color code reaibiock blackires browniyalion blackired blueiwhite rayiviolen bluehwnite Cross 15 10 15 078 18. 15 0.75 078 075 078 7s 10 19‘Supplementary harness or air-conditioning system and supplementary fan, 3rd version with Delco refrigerant compressor starting 08/80 model 123.1 standard version and @ starting model year 1981 alae wate? Color code of supplementary harness Line Electric tine Color code Cross Fuse C terminal 30 Flay supplementary fan terminal 30 reaiblock 18 Fuse 12 terminal 15 Flay supplementary fan terminal 86 backirea 10 Relay supplementary fan terminal 87 Supplementary fan yellow 18. Relay supplementary fan terminal 85 Temperature switch 52°C browniyaiion 0.78 Ground Temperature switch 52°C brown 18. Temperature siteh 52°C ‘Supplementary fan brown 15 Relay eupplamentary fan terminal 86 Roy cerigerant compressor term, 30 backires 10 9 Temperature cal terminal 2 Relay cerigarant compressor ter. 86 blackireaigreen 0.75 10 Ground Rea rerigerant compressor term. 85 brown 075 12 Relay otrigerant compressor term. 85 Prassure switch retigerant comprestor blueiwnite 1.0 13 Resistor group Temperature col terminal 3 Dluefbiock 075 14 Temperature dial terminal Ground brown 078 15 Rotary light switch terminal K Socket, bulb sraylourple 075 16 Switchover valve fresh airveciveulating aie Temperature dial terminal 1 diuelyeliow 0.75 17 Switchover valve fresh aierectculting sir Ground brown 078 19 Temperature dat terminal 4 Socket bulb own 075 21 Pressure switeh reteigorant compressor Retrigerant comprestor blueinnie 10 22 Ground Retrigerant compressor brown 10 836-5082 FaC. Pneumatic function of air-conditioning system Diagram vacuum contol ai-conditioning system 123 (1s version} efthand steering up to 02/79, righthand stering up to 10/78 1 Evaporator housing with blower 2 Heater box 3 Temperature switen 4 Vacuum rotary swith for recirculating ae Hap 5 Vacuum pull switch for legroom fap 8 7 a Tetake manifold or on diesel engines vacuum tine from vacuum pump to brake unit Robber howe Check valve 3 Distbutor 10. Rubber grommet in front wal 11 Reservar 12. Vseuum element for ractculating air lap 15. Drivers or rear compartment legroom fk CCutting-in angle and function of temper Cutting arate 0-200 Air conditioner off — legroom taps open S00 Switenover point af eg room Tlape 30-459 Legroom taps closed ae fi condiuoneron minimum cooling eapocity 45-2479 Gutside av open — reciteulatng sir closes 2470 Switchover point recreulating sir outege 1836-50820 Fa 16 Vacuum tine color code gray ight blue 17 Vacuum ine olor code mediuen green yellow 18 Vacuum line color code medium grees ight Blue 19 Vacuum ine color Code medium green orange 20 Vacuum lin eolor code mediim green white A Fresh air 0 Recirculating air Va toevaporator 13 Recirouating air tap (12) in position “recirulating ar” 15 Recirculating alr fap (13) in position “fresh air” © Legroom Hap (15) in position “closed” ‘ Legroom taps (15 in position “open! ‘Bir outet legroom or rear compartment legroom ure vacuum switch CCutting.in angle 247-3169 Recirculating ar open — outside ar closed (fut outsige a share) 3189 End ~ max. cooling capacity» end stop 45” 3150 Legroom flaps ean be open by pulling 0-316° ——Fotervatary cangeDiagram vacuum control air-conditioning system 123 [2nd version, lefthand steering) lefthand stering starting 03/79, righthand steering storting 11/79 up to 08/80 1 Evaporator housing with blower 2 Heater box 3 Temperature smiteh Vacuum rotary switeh fo recirculating sr tap 20 5 Vacuum pull smiten for legroom flap 8 Intake manifold or on deel engine vacuum line feom vacuum pump to brake unit 7. Rubber hore Check valve 3 Distabytor 10, Rubber grommet infront wal 11 Reservowe 12. Vacuum element fo recireulating ar tap 14) Vacuum element fr legroom top 15. Driers or rear compartment legroom tap 18 Vacuum ine color code red aray 17 Vacuum line calor code graen-yeliow 18. Vacuum ine color code green tight blue 20 Vacuum line color code green-white 21 Distributor 22 Vacuum line color coge reen-white 23 Vacuum element for defroster nozzle flaps 24 Deteoster nozsle taps ‘A. Outside ar (roth ail 0. Recruiting ar Va Yo evaporator 2 Recirculating air fap (13! in position “recirculating ae 1B Recirculating af fap (13) in postion “outside a" © Legroom flaps (181 in postion “closed” Legroom flaps 18) in position “open {Air outlet leg room or res compartment leg oom CCuttingin angle and function of temperature vacuum switch Cattingin onale 0-30" Air conditioner off eg room taps open «__Suitehover point of leg oom lage 30;45° Leg room flaps closed 45° [Ait conditioner 08 = minimum cooling capacity 45-247" Outside ait open — recirculating sir closed 247°" Switchover point recirculating ar — outside aie 826-soa21 Fa Cuttingin anale 247-318" Recirculating air open — outside ar closed q {wath outside ar share) 315°, End max. cooling capacity = end stop 45-315 Legroom flaps can be opened By pulling on knob o-31s* Total rotary rangeDiagram vacuum contrat air-conditioning system 123 (3rd version) starting 08/80 Evaporatar housing with blower Take manifod or an desl engines vacuum line from vacuum pump to brake unit B Check wae 8 Distsbutor 10 Rubber grommet in front wall 11 Reservowr (not on mode! 123.1) 12. Vacuum element for recirculating ai tap 13 Recirculating a tap (postion fresh ain 4 Vacuum element tor fe room tap 836. 508/22 Fa 1s 16 ” 18 2» 2 ‘a ou Ve Driver's or rear compartment leg room fap ‘Vocuum line color cade gray ight blue (not on model waa. Vacuum tine color code medium green yellow Sartchovervave fresh air recirculating 3 (postion fresh \Vscuurn nore calor code black ites lon model 123.1 only) ng ar Fecireulatng ai lap (13) in position “recirculating air” Reeieulating ir lap (13) tn position “Tres ai1. The required vacuum for controlling the air flaps is taken from vacuum line (22) on vehicles with diesel engine and from intake pipe (6) on vehicles with gas- line engines. ‘Vacuum connection an vehicles won cies! engine ‘Vacuum conntetion on vehicier watthgovoline engine To intake pipe or vacuum line (22) Check valve Distsbutor foranch) ‘Vacuum tine to reservoir vacuum switch 2. Vacuum reservoir (71) guarantees operation fof vacuum system for air conditioning system with engine stopped as well as at insufficient vacuum volume in given speed ranges (not on vehicles with diesel engines starting march 1973) aa6-s08i23 Fa3. By switching-on temperature vacuum switch (starting at approx. 30° cutting-in angle) the vacuum pull switch which is set to passage (knob of tempera: ture vacuum switch pushed) is operated via the va ‘cum rotary switch (4) so that the vacuum element (14) is activated and the leg room flaps are closed. 4 Assoon as knob of temperature vacuum switch is pulled, the vacuum pull switch (5) will interrupt the vacuum connection and will vent the vacuum element (14), 28 well as vacuum element (23) starting from 2nd version. The leg room flaps and the defroster nozzle flaps are opened by spring force. 5. The air-conditioning system operates in range up 10 3/4 refrigerant capacity {knob to mark on blue scale of approx. 247° cutting:in angle! with outside air. The rear chamber of the double-acting vacuum element (12) or the single-acting vacuum element (12) is activated by means of vacuum ratary switch (4) ‘st version 12. double seting vacuum 836-508/24 Fa _—6 Starting at 3/4 cooling capacity, the vacuum rotary switch will activate the front chamber of vacuum ele: ‘ment (12) (1st version) or, in the case of the 2nd version, this will be done by spring force, flap (13), will open so that approx, 80 % vehicle inside air and approx. 20 % outside air will be drawnin through a leak of recirculating air flap. 2nd version 7. Since 08/80 the vacuum element for fresh air recirculating air flap is controlled by an electro: ‘magnetic switchover valve (18). If the temperature dial is engaged at “Max.", the switchover valve is supplied with plus and will vent the vacuum-element (12), The recieculating air flap is set to recirculating air under spring force. 2rd version 8356-50825 Fa83-510 Function test and quick test of air-conditioning system Data Angle of rotation temperature switch up to 07/80 Angle of rotation temperature dial (starting 08/80) Conventional tools 1 Suction pressure gauge {bar vacuum (atu) to fr assembly tester 10 bar gauge pressure (atu) (0 ~ 40 bar gauge pressure (atu) 1 High pressure gauge 5 Thermometer 20°C to + 70°C 1 Hygrometer Note ‘Two test methods ate available for checking air-condi: tioning system: A. Quick test For air-conditioning systems, free of complaints. Test ‘after minor repairs, extended period of inoperation or the like B. Function test In the event of complaints or for trouble diagnosis. A. Quick test Test method for ambient temperatures of + 20°C 10 + 40° C, Check values can be read after approx. 5 minutes Test conditions 1. Vehicle should not be exposed to sunshine before and during the test 2. Switeh-on air-conditioning system and watch through sight glass (1) in receiver dehydrator whether the refrigerant flows free of bubbles shortly after switching on electromagnetic clutch ea6-510"1 Fa3. Heater switch (8 and 9) in position 0. 4 Set blower switch 2) to stage 3, full blower speed, 5 Up to 07/80 set temperature vacuum switch (1) to full cooling capacity 6 Slide lever (10) to the right. up t0 07/80) 7. Starting 08/80 engage temperature dial (1) at “Max. & Set lovers (10 and 11) to inside stop. starting August 1980 9 Slide lever (7) to the left (cooling air outlet conter opened) 10. Open air nozzles (3) 11. Insert one thermometer into center nozzle (4) 12. Attach one thermometer for ambient tempera ture (room temperature) approx. 2m away from driver's side 13. Open window and close vehicle doors. Run engine at approx. 2000/min. 14. After approx. 5 minutes read air outlet tempera ture at center nozzle and outside temperature on both ‘thermometers and compare with values on table. Note: The cold air outlet temperature should not be less than + 1°. Details on adjustment of temperature vacuum switch (93-542), A= air outlet temperature, Ta = ambient temperature (°C) sa6-si012 FaB, Function test, Note: Observe safety rules when working on air-con- ditioning system (83-504). For checkups in workshop in the event of complaints about insufficient cooling capacity or for trouble diagnosis of air-conditioning systems, proceed accord: ing to the following test method which is suitable for room temperatures {ambient temperatures) from + 20° to + 40°C. All check data can be read after 10 minutes of constant operation, ‘Test conditions 18 Vehicle should not be exposed to sunshine before and during the test. 16 Check tension of V-belt for compressor drive. 17 Switeh-on air-conditioner and watch reservoir on sight glas (1) to check whether the refrigerant flows {ree of bubbles soon after switching on electromagne: tic clutch, Add refrigerant if required, Ifthe refr {gerant loss amounts to more than 200 g, check system for leaks (83-512) 18 Heater switches (8 and 9) in position O. 19 Set blower switch (2) to stage (3) (full blower speed) 20 Set temperature vacuum switch (1} to full cooling capacity, 21. Slide lever (10) to the right. p10 07/80 93.6-S10/9 Fa22. Starting 08/80 engage temperature dial (1) at ouae 23. Set levers {10 and 11) to inside stop. 24 Slide lever (7) to the left (cooling air outlet cen ter opened) 25 Open side vents left and right. Starting 08/80 26 Insert one thermometer each into center nozzles (4) and into side ventilating nozzles (3) 27 Attach one thermometer for ambient tempera: ture (room temperature) approx. 2 m from driver's side 28 Place one hygrometer into tray of center console. 29. Unscrew closing caps (1). Then connect hose lines of suction pressure or high-pressure gauge (4 and 5} to service valves. Make sure that the connection nipple of hose lines has @ pressure pin in center. 20 Check angle of rotation of temperature regulator by turning knob of temperature vacuum switch (1) to the right up to stop, ‘The marking on kaob of temperature vacuum switch should arrive at end of blue key. Ifthe angle of ro- tation of the temperature vacuum switch is smaller, replace temperature switch, 31 Open window and close vehicle doors 32. On vehicles with engines M 102 pull 1-pole coup: ler from temperature switch 100 °C (20) and connect {0 ground, so that the electromagnetic fan will run ‘along during entire test procedur 33. Run engine at approx. 2000/min. 34 After approx. 10 minutes of operation, read values on thermometers and pressure gauges, as well son hygrometer. ‘Note: Specified values are max. values and may not tue exceeded. s36-510/8 Fa35. Check suction and high pressure in dependence » xo os S of ambient temperature (room temperature) by means of table. Check air outlet temperature (mean value of the four cold air outlet temperatures) also according to values on table. (The difference between the coldest and the warmest outlet temperature should not ex ceed 3 °C) 8 ERSERERE 36 Check cutout temperature of temperature regula tor, for this purpose insert @ thermometer into center nozzle (4). Set blower switch (2) to stage 1 and tem perature vacuum switch (1) to full cooling capacity Cr on vehicles starting 08/80 engage temperature dial at Max’, Run engine at approx. 2000/min, ‘After 3rd cutout of electromagnetic clutch the air outlet temperature should amount to approx. + 3°C, but should not be less than plus 1 °C. All models (except with engine 102) 1) Relative humicity of the ar Ta Outside temperature (c). A Air outiet temperature (°C) © Pressure in front af compressor (bar) Pressure allowing compressor (bar! © Coolant remperature Ce) ease EEKeS bar 37 Adjust temperature vacuum switch (83-642) 38. The supplementary fan in front of condenser for coolant temperature (100°C) and refrigerant tempera ture (62 °C, on 4 and S-cylinder vehicles 62 °C) is ‘switched on at higher outside temperatures ERS osuuee Engine 102 1) Relative humidity of the ar | 0 Ta Outside tamperature "C) A’ Airoutlet temperature (C) Presture'n front of compressor bar) © Pressure following compressor (bar! D Coolant temperature (°C) 826-5105 Fa39 When refrigerant loss is high or pressure in re ceiver dehydrator drops below 2 + 0.2 bar, the voltage supply to refrigerant compressor is interrupted by pressure switch (18), When the pressure increases to 0.6 bar above cutout, pressure, the citcuit is closed again, 40 Remove hose lines from service valves and close service valves again with closing caps. 41 On vehicles with engine 102, plug 1-pole coupler to temperature switch 100 °C (20) 536-5106 Fa83-512 Leak test and evacuat Special tools. Remover and installer for valve insert ar (000 589 24 61 00, Conventional tools Wrench 1/2 x 9/16" Assembly tester with 3 filling hoses and vacuum pump fr evacuating and filling equipment for air-conditioning systems . g, made by Christof Fischer, Reichenhaller Strate 65-59 -7000 Stuttgart 50 Leak tester (Rilo-senior-leak detector) Leak test Ia checkup shows that the air-conditioning system hholds not enough refrigerant, the cause for the loss ‘must be found. The leak test can be made with the system both filled or empty. Leak test with system filled With the system filled, leaks can be found with a leak tester (1) For this purpose, switch on air-conditioning system to full capacity and run engine at approx. 2000/min. Stop engine after approx. 2 minutes. With mouth (2) of leak tester, slowly check circuit and hold for some time close to spots where a leak is suspected, 2g, at connecting points, pipe connections, grease cup of compressor, on valves, on cooling air outlet etc. If refrigerant R 12 emerges at one of these spots, the leak is indicated optically or acoustically by the leak tester. 836-512/1Leak tests with system drained When the system is completely drained, a vacuum ‘pump (1.1) is used to evacuate the entire system, that is, the max. possible vacuum is generated. ‘Checking vacuum with a vacuum gauge permits finding out whether the system has no large leaks. Check oil evel in compressor first (83-520) If there is a leak, the pressure gauge reading will in crease, that is, the vacuum is reduced, For accurate determination of the leaking point, fill system with approx. 100 9 refrigerant R12 and perform leak test with a leak tester. Evacuation 1 Unscrew closing caps (1) of line connections on both service valves. 2 Connect hose lines (5, 8, 9 and 10}. Make sure that the offset end of the hoses (5, 8 and 9) with the pressure pin for actuating the Schrader valve on con. rection (C) of assembly tester or on connection of both service valves is connected {hoses without pres sure pin cannot be used here). 3. Completely open valves (A and 8) on assembly tester (2), Close valves on filling eylinder (12) or refrigerant bottle (16). 4 Operate vacuum pump (11) and evacuate system for at least 15 minutes. 5 Close valve (A and B) upon attaining the required vacuum {0.9 ~ 1.0 bar) e36-512/26 Disconnect connecting hose (8) or close valve (21), ‘and stop vacuum pump (11). Open valves (A and B) after approx. 10 minutes. 7. If the vacuum pressure in relation to previously read value is down by more than 0.16, the system has not been evacuated long enough or is leaking. Evacuate system once again. If the vacuum drops with regard to the previously read value, fill approx. 100 ¢ refrigerant (gaseous) into system. Check entire system 24 for leaks with leak tester and seal leaks, Then evacuate system again. aaa 8 Close valves (A and B), Fill system with refrigerant R12 (83-514) 10 Connect service unit (items 1 and 2). 11 Connect valves (A and B) to assembly tester (2) ‘and valves to filling cylinder (12). 12. Open valve (19 and 21) and operate vacuum pump (11). se-sten ‘Assembly tester and ling elinder with al connections 'A. Valve on suction pressure gauge 3. Suction pressure gauge «Hose line 13. Upper valve @ Val on high pressure snuge High pressure gape 9 18 Lower valve © Schrader val on assembly tester 5 Hose line 10 Hose ine 15 Pressure gauge ¥ Retrigerant comoressor & Service valve [suction end) 11. Vacuumpump 16 Relrigerantnottle with R12 2 Assembly tester 5 Service valve (pressuretend) 12 Filingcyiinder 1? Valwon refrigerant botle 836-512/3 Fa13. Continue evacuating vacuum meter until pointer ‘of vacuum meter stops. The max. possible vacuum has now been attained. 14. Align drag pointer of vacuum meter with pointer. 15. Evacuate air-conditioning system (according to items 3 to 5). The max, possible vacuum is attained, When the pointer of the vacuum meter arrives at value of preset drag pointer. 16 Close vaive (21) and switch off vacuum pump, 17 If the vacuum meter shows a steady pressure increase, the air-conditioning system has a leak. Evacuation with vacuum meter (Torr meter) Note: A vacuum meter (18) is located on the eva cuating and filling device (service unit) between as- sembly tester (2) and vacuum pump (11) ‘The max. attainable vacuum can be measured by means of the vacuum meter. A leak in air-condition ing system is more clearly shown by a drop in vacuum. ‘The passage to vacuum meter is closed by valve (19) ‘The passage from assembly tester (2) to vacuum pump (11) 0 to vaive (21) will remain open. Upon evacuation, valve (19) should always remain closed, Ifthe vacuum meter is loaded at more than 1.2 bar, it will become defective and can no longer be used. 18 Fill air-conditioning system with approx. 100.4 refrigerant, then check entire system for leaks with @ leak tester and seal leak. 19. Evacuate air-conditioning system once again. 20 Close valves (A and B as well as 19 and 21). 21. Fill system with refrigerant R12 (83-514) a36-512/4 Fa See Sees83-514 Refilling or replenishing air-conditioning system Filling capacity ka Refrigerant R12 12 Refrigerant bottle R 12, capacity approx. 7.5 kg One-way bottle Frigen-Baby R 12, capacity approx. 430 g Conventional tools Assembly tester with 3 filling hoses and vacuum pump fr evacuating and filling unit (service unit) for air conditioning system Line connection-reduetion piece 7/16" 1/4" for refri- 0.9. made by Christoff Fischer, Augsburger Strae 289 ‘gerant bottle or tapping valve for Frigen-baby-bottle D700 Stuttgart 60 Filling aid type CH 200 and angle piece 90° with rapid screw connection 7/16" Wrench 1/2" x 9/16" Note ‘The jobs for refilling and filling up of air-conditioning system are in principle alike, When refilling, evacuate system first (83-512). Note: Filling requires a supply bottle (1) with refi gerant, which is commercially available just like e.. a supply bottle with oxygen or acetylene gas. In addi- tion there are small cans (2) [Frigen-babies] ),con- taining approx. 1/2 Liter R 12, If hard to obtain, contact one of the specialist companies manufactur ing or operating refrigerating units. 36-5141)Since the refrigerant in the supply bottle is under pressure and liquid and will flow in the shape of gas when filling the air-conditioning system without filling cylinder or when refilling, itis recommended (at least when the supply bottle is already partially empty) to place the supply bottle in a water bath of ‘max. 40° C, If the system is completely empty, the refrigerant can also be filled in liquid shape via pres: sure side upon evacuation. Filling up can be done only in the shape of gas with the system switched on, When filling the system from a refrigerant bottle of 10 or 20 kg capacity, a scale with 100 g graduation for the bottle or a filling cylinder will be required. Attention! If filling up in the shape of gas, the supply bottle should always be set up with the lock in upward direction, A. Filling system from supply bottle Filling in refrigerant in the shape of gas 1 Remove closing caps (1) from service valves. 2 Screw line connection reduction piece (26) on supply bottle (16). Connect filling hose (5) to reduc: tion piece (26) and blow through for a short moment with refrigerant to remove remains of dirt and mois ture, if any, then connect filling hose (5) to connec: tion (6) (suction side) of service valve (offset end with pressure pin of hose line) 936-51423. Run engine at approx. 1000/min and set tempera ture selector knob to highest cooling capacity and blower switch to full blower speed. In rooms with temperatures above 22 °C blow out condenser with an additional blower. Blowing out of condenser will always speed up filling 4 Slowly open valve on supply bottle. When filling Up air-conditioning system, continue until refrigerant lows free of bubbles past sight glass of receiver de- hydrator. 5. When refilling fill in approx. 100~200 g refr sgerant. Then stop engine. 6 Check complete air-conditioning system with leak tester and seal leaks, if required. Fill system with full ‘quantity of refrigerant only when there are no more leaks. 7 Completely fill airconditioning system (item 1 to 3). 8 Close valve on supply bottle and stop engine. Dis: connect filling hose (5) 9 Screw closing caps (1) to service valves. 10. Check air-conditioning system for function (83-510) 836-518/983-516 Draining of air-conditioning system Conventional tools Wrench 1/2 x 9/16" Assembly tester with 3 filling hoses and vacuum pump oF evacuating and filling unit for air-conditioning systems Note In the event of repairs on air-conditioning system, drain entire system, Attention! Pay attention to safety measures (83-504). Draining the system 1. Unscrew closing caps (1) of both service valves, 2 Connect assembly tester, evacuating and filling unit or two filling hoses to service valves. Make sure that the pressure pin in offset end of filling hoses ‘opens the Schrader valve elements in service valves, 3 Slowly drain refrigerant either into a glass bottle fF into the open air. It quickly drained, the refrigerant will carry the oll from system and refrigerant com: pressor along Attention! Do not drain refrigerant into assembly pits to avoid risk of suffocation, 4. The system is completely drained as soon as the pressure gauge indicates 0 bar or only a slight over pressure, or when no more refrigerant comes out of connected filling hoses. 5 Unscrew hose lines and close service valves with closing caps. The required repairs can then be made, ea6-516"1 2.9. made by Christof Fischer, Reichenhaller Str. 55-59 -7000 Stuttgart 6083-518 Cleaning of air condi Tightening torques Thread connection 5/8" ~ 18 UNF 15-18 (1.5-1.8) 3/4" ~ 16 UNF 14-28 (1.4-2.8) Conventional equipment 7/8" —14 UNF 29-37 (2.9-3.7) 1 Cleaning unit R11 eg. made by Christof Fischer ‘Augsburger StraBe 289 7000 Stuttgart-60 Order no.: 835-3900 DB ‘Scope of delivery: (mounted on cleaning unit) 2 PVC hoses, 1.6 m, 12 mm inside width with bbead connection on both sides and coupling nut 3/4" UNF, 1 connection 45° offset 1 PVC hose for nitrogen 1.5 m, 5 mm inside width, with quickly closing 7/16” UNF/hose grommet for reduction valve 2 Reduction nipples 3/4” x 7/8 601-2129 2 Reduction nipples 3/4" x 3/4” 601-2103 2 Reduction nipples 3/4" x 5/8 601-2123 2 Reduction nipples 3/4" x 1" 628-2400 2 Seals 628-2401 2. Reduction nipples 6/8 x 3/4" 628-2402 1. Screw connection 3/4” x 5/8" 601-2165 1. Screw connection 3/4” x 7/8" 601-2166 1. Wrench for container lock 1. Can of filling material for filter drier (KC dry pearls can: 1 kg) 731-9000 1. 154kg container, filled with R11 ‘808-3902 1 Nitrogen bottle Conventional tool 1/2 x 9/16", 5/8 x 3/4", 7/8 x 15/16", 1 x 11/8" ea.1—518/1Note Dirt oF moisture (water) in air conditioning system ‘may result in failure of system and considerable follow-up damage. Failures in air conditioning system, particularly if refrigerant compressor is defective, e.g. by a blocking effect, will result in considerable conta: rmination of system by burnt refrigerant oil or abrasives. Since there is a possibility that abrasives of refrigerant compressor may arrive in lines of air conditioning system, replace pipe line with hoses on refrigerant compressor in such a case. If contamination of the air conditioning system is ‘suspected or if parts of the air conditioning system have been stored in the open air for extended periods, clean entire sir conditioning system according to extent of contamination. If there is little contamination or moisture, blow out air conditioning system with nitrogen. If the contamination is more pronounced, flush air conditioning system with 11 If cleaning of air conditioning system is required, always replace receiver dehydrator Cleaning with nitrogen 1. Drain air conditioning system (83-516). 2 Remove receiver dehydrator (83-520) 3. Unserew hose lines on refrigerant compressor, 83.1-518/2 F 24 Connect tapping hose on reduction valve (9) of nitrogen bottle (11) 5 Blow out air conditioning system in two stages for approx. 2 minutes by means of tapping hose. 8a) from hose line receiver dehydrator ~ evaporator to hose line evaporator — compressor. bb from hose line refrigerant compressor condenser. 6 Install new receiver dehydrator. Then check oil {evel in refrigerant compressor (83520). 7. Check sealing rings and connections on refrigerant compressor and moisten with cold-flowing ol 8 Mount hose lines on refrigerant compressor or pipe line, 9 Evacuat for leaks, air conditionng system, fill up and check Cleaning with R 11 cleaning unit Note: The boiling temperature of the R 11 cleaner is at + 23.80 C. For this reason, store R11 in cool place and keep container well closed, R11 in cleaning unit may evaporate through pressure relief valve (7) if its temperature is above 24° C, It is therefore recommended to return the contents of the cleaning unit to supply tank after flushing 83.1-51813 F2‘The R 11 cleaner can be used several times. As soon as the cleaner looks rather cloudy (showing up when flowing through PVC hoses (6), renew together with KC dry pearls in filter drier (2) Attention! Do not breath R11 gas in high concentration. Vent closed rooms after flushing 10. Drain air conditioning system (63-516). 11 Disconnect all parts installed in refrigerant circuit such as expansion valve, receiver dehydrator and lines fn refrigerant compressor. 12 Connect hose line from compressor to condenser ‘with feed and return line and line connectors (10) {the hose line and the condenser are flushed first) e2.1-sta/413. Set three-way valve (5) to passage, cleaning unit, (1) — PVC connecting hose (6) 14 Open shutoff valve (3) and engage flushing unit by inserting mains plug, 15 Disconnect cleaning unit and set three-way valve (4) to passage, pressure hose of nitrogen bottle ~ PVC connecting hose. 16 Close shutoff valve (3) and set pressure on pressure gauge (9) to approx, 3 bar. Open shutoff valve on pressure gauge. 17. The flushing compound which is still in connect: ed circuit is forced back into container of flushing Unit (well visible through PVC hose) 18 Close vaive on pressure gauge (9) 19. Disconnect flushing unit. 20 Also flush evaporator and hose line from eva orator to compressor or pipe line as well as pressure hose from receiver dehydrator to E-valve (item 12 10 19). 21. Install new receiver dehydrator and new expan- sion valve. Then check oil level in refrigerant com- pressor (83-520) 22. Check gasket and threads on all components and ‘moisten with cold-flowing oll. Connect hose lines to ‘efrigerant compressor. 23. Evacuate air conditioning system, fill up again land check for leaks and function. 83.1-518/5 F 283-520 Checking oil level in refrigerant compressor A. Vehicles with York refrigerant compressor Oil capacity Oil type cold-flowing oll (for approved cold-flowing ols refer to Specifications for Service Products, page no. 361) min. normal max. Oil quantity in ee 180 240 300 Refrigerant compressor Dipstick depth (mm) 2 25 28 Tightening torque Oil check plug tkpm) (0.6-0.8) Conventional tools Openvend wrench 1/2 x 9/16" ag, made by Christof Fischer, Augsburger Str, 289 Assembly tester with 3 filling hoses or evacuating and 1-700 Stuttgart 60 filling deviee for air-conditioning system Oil dipstick for refrigerant compressor notches each at specified spacings flat length: 210 mm material: brass wire dia. 3 mm ‘A= horizontal instalation 5 = vertical installation. Note Check oil charge of refrigerant compressor prior to each refill of refrigerant or when refrigerant or oil has been lost Since a certain quantity of oil is picked up by the refrigerant and will get into the system, a loss of refrigerant may also include a loss of oil 836-5201 Fail level in compressor should never be below a mini ‘mum level of 180 ec or a maximum of 300 ce. Too much oil is detrimental for operation of system and will also result in reduced eticiency of air-condi tioning system, When the refrigerant compressor is replaced, the oil ‘volume of new compressor should not exceed the normal oil level. All compressors were filled with approx. 0.3 liter of cold-flowing oil by the manufacturer. Under normal conditions, oil must either be changed or added. Never fill in machine or engine oil The oil dipstick for measuring the oil level in refi ‘gerant compressor must be self-made, Attention If only a small quantity of refrigerant (up to approx. 200 g per year) need be added, no oil evel checkup is required, Checking the oil level 1. Drain air-conditioning system (83-518) 2. Slowly turn out oil check serew (b) and slowly evacuate any pressure still prevailing in crankcase. 3. Turn crankshaft of refrigerant compressor so that the splining on crankshaft stub is in upward direction, If the position of the splining cannot be recognized, (refrigerant compressor with built-in electromagnetic clutch), rotate crankshaft by feel until the oil dipstick can be pushed through to lowest part of crankcase, 4 Clean oil dipstick and measure oil level 5. Renew O-ring on oil check screw and moisten with cold-flowing oil. 6 Mount oil check serew. 7. If a subsequent leak test indicates a leak at screw, the leak cannot be repaired by tightening screw still further. Cause of leak may be either dirt under O-ring, a damaged O-ring or damaged seats on serew or com: pressor housing 826-5202 F4B. Vehicles with Delco refrigerant compressor Oil capacity Oil type cold-tlowing oil (for approved cold-flowing oils refer to Specifications for service products, page No. 362) il filling capacity new in refrigerant compressor Oil capacity when working on system Jobs Renew refrigerant compressor (system not flushed with R 11) oil quantity drained from old compressor above 40 cc. *) Renew refrigerant compressor (system not flushed with R 11), oil quantity drained from old compressor below 40 cc, ') Renew refrigerant compressor (system flushed with @ 11 first). ") Recondition refrigerant compressor {drained oit quantity above 40 cc) ") Recondition refrigerant compressor (drained oi quantity below 40 cc) ') ‘Add refrigerant to system (up to 200 g) ‘Add refrigerant to system (more than 200 g) ‘or, in the event of leaks, fill up completely with fresh oil Renew condenser Renew evaporator Renew receiver dehydrator Quantity of cold-flowing oll to be filled in rain cold-flowing oil from removed compressor and ‘measure quantity. Also drain cold-flowing oil on new compressor and store in closed condition. Fill same quantity as in removed compressor into new compressor (fresh oil see above, but fill in 90 cc cold-flowing oil Do not fill-in cold-flowing oil Fill drained quantity of oil and additionally 30 ce (1 02) into compressor. 90 ce Do not fill in cold-flowing oil 20 ce 50 ce ce 40 ce ) Renew receiver dehydrator, but do not add any coldlowing ol into receiver dahydrator 826-5209 FaTightening torques Nov (kom) Screws M 12 refrigerant compressor to support 60+10 (6+1) Screw pipeline to refrigerant compressor 6023 (520.3) Hose line from evaporator to pipeline 7/6 29-37 (29-3.7) Hose line from pipeline to condenser 7/8” 29-37 (2.9-3.7) Special tools Holding device for refrigeration compressor 116 589 14:31 00 Pressing off pate for refrigerant compressor a 109 589 00 25 00 Conventional tools Socket 14 mm, 3/8 square Assembly testing device with 3 filling hoses or evacuating e.g. made by Christof Fischer, and filing device for air-conditioning system ‘Augsburger Str. 289, 7000 Stuttgart 60 Oil pump order no. 823.2250 Note If the system has been flushed with 8 11, itis not necessary to drain cold-flowing oil from new refrige: rant compressor (no compressor oil need be filled in) Be sure to install a new receiver dehydrator. In the event of a refrigerant loss of up to 200 g over an extended period, no topping-up of cold-flowing oil is necessary. If more than 200 9 of refrigerant are topped up, the air-conditioning system should be ‘checked for leaks. The specified quantity of cold:-flowing oil can be forced into filled air conditioning system by means Of an oil pump. If fresh oil must be filled in, add ‘approx. 30 cc cold-flowing oil into system prior to evacuation ‘The 4-cylinder refrigerant compressor has a change of approx. 170 cc (6 02) of cold-flowing oll. Since this refrigerant compressor has not been provided with an oil sump, a certain quantity of oil will circulate during regular operation in the air-conditioning system to- ‘gether with the R 12 compound. If one component Of the system must be replaced, fill a certain quantity of oil directly into the new component, 835-520/4 Fa‘Adding cold-flowing oil with oil pump, with refrigerant installed and air conditioning system filled Note: Connect oil pump (22) to refrigerant circuit first, then determine accurate volume of oil pump by sucking.in and forcing-out cold-flowing oil several times. 1, Put cole!lowing oil into a measuring cup and draw- in with oil pump (22) 2. Remove closing cap from service valve (b) on hose line (14), 3 Connect oil hose (23) of oil pump (22) to service valve (b) and force oil quantity into system. 4 Disconnect oil hose (23) and screw closing cap to service valve, Filling oil into refrigerant compressor 5. Remove refrigerant compressor together with pipe: line (83-522) 6 Screwoff pipeline (7) from refrigerant compressor (1) and collect cold-flowing oil flowing off. 7 Let oil flow out from refrigerant compressor, while holding refrigerant compressor with shaft end in upward direction, and let oil flow out for approx. 10 minutes through pressure or suction port. By rotating clutch shaft several times, flowing out of oil will be acceler ated, 8 Let cold-flowing oil flow out from new refrigerant compressor, as described under item 3. 9 Determine quantity of oil flown out from original refrigerant compressor and pipeline. 36-5201 Fa10 Add the same quantity of fresh oil into new refrigerant compressor through suction port if drain: ed oil quantity of more than 40 ce has run out of removed refrigerant compressor and the system has ‘not been flushed with R 11, If the drained quantity Of oil is less than 40 ce, add 90 cc into new refrigerant compressor 11 If the refrigerant compressor is reconditioned, let cold-flowing oil run out of refrigerant compressor 1s described under item 3. If the drained quantity Of oll is more than 40 ce, add the drained quantity and an additional 30 ec of oil into regriferant com pressor. If the drained quantity of oil is less than, 40 cc, add 90 cc of cold-flowing oil into refrigerant compressor, 12. Screw-on again pipeline (7), while checking O-ring for correct seat, and provide with cold-flowing oil 13. Install refrigerant compressor together with pipe line (83-522), 1836-52016 Fa83-522 Removal and installation of refrigerant compressor A. Engine 110 (with York refrigerant compressor) Oil capacity Oil type cold-flowing ol (approved cold-Flowing oils refer to Specifications for Service Products page no. 361) Oil level at min, normal max. il quantity in cc 180 240 300 Refrigerant compressor Dipstick depth (mm) 22 25 Tightening torques Nm (kpm) Suction or pressure hose on refrigerant compressor 40-45 (4.0-4.5) ‘Screw (7) carrier to cylinder head 30-5 (3.0-05) Inch screw (4) fastening plate to compressor 30 (3.0 ‘Screw (9) fastening plate to carrier 45 (45) ‘Screw (31) holder tensioning roller to cylinder head 30-5 (30-05) Necked-down screw (28) belt-tensioning roller 45 (45) Inch screw (51) coupling to refrigerant compressor 25 (25) Oil check serew 68 (06-08) Special too! Pulling-off screw for pulley rede 100 589.00 35 00 Conventional tools Double open end wrench 1/2" x 9/16”, 6/8" x 3/4", 7/8" x 16/16", 1" x 11/8" Socket 1/2" Self-made tool A Oil dipstick for refrigerant compressor ad = 7 3 notches each in specifies spacings eer iat onan 210 mm mine material brass wie dia. 3mm Cr [A= horizontal installation B= vertical instalation eoe-s2a1 FaNote All threaded bores and screws on refrigerant com pressor are in inches. Remove refrigerant compressor together with fasten: ing plate (3). Check oil charge of refrigerant compressor each time prior to adding fresh refrigerant (83-520) f the refrigerator must be renewed or reconditioned, insert a strainer into suction connection. For details refer to 83-524. Removal 1 Cover righthand front fender. 2. Switchon ignition, air-conditioning system and blower (electromagnetic clutch will pull. 3. Unscrew serew (51) 4. Remove pulley of electromagnetic clutch (2) from crankshaft of refrigerant compressor (1) with puller screw (53) 5 Switchoff ignition, 6 Disconnect battery. 7. Drain air-conditioning system (83-516) ea6-s2212 Fa8 Loosen necked-down screw (28) for tensioning 23017 2 roller (27) 9 Slacken V-belt (34) with adjusting serew (25) and remove V-belt, 10. Disconnect electric line on cable connector (17). 11 Unscrew struts (14 and 19} on compressor, ‘eylinder head and engine carrier. 12. Loosen 3 screws (8 and 9) as well as nut (12) and remove refrigerant compressor with fastening plate @ 13 Loosen screws (4) and remove fastening plate (3) from refrigerant compressor. 14 Remove pulley of electromagnetic clutch (21, pay attention to spring plate (54). 18. Unscrew 4 screws (52) and remove coll of electro: ‘magnetic clutch (2) from refrigerant compressor. 36-5221 FaInstallation 16 Check carrier (6) for cracks and screws (7) for tight seat. Attention! New refrigerant compressors are filled with nitrogen. Remove closing caps (C) on connections only, when the gas has been evacuated via oll check serew (b).. For this purpose, unserew oil check screw for a few threads until gas is heard to escape. 17 Screw fastening plate (3) to refrigerant com- pressor with inch screws (4) and washers (5) 18 Screw electromagnetic clutch to refrigerant com: pressor. 19: Slip spacing ring (11) on stud (10. 20 Screw refrigerant compressor with fastening plate (3) to carrier (6) by means of screws (9) 21. Screw fastening plate (3) with crew (8) and a washer (22) to cylinder head, as well as with nut (12), on he and washer (13) on stud (10) leas ROE vlee 22. Mount strut (14) with holder for cable connector (17) to refrigerant compressor as well as the cylinder head. 23. Mount strut (19) 24 Mount V-belt, tension with adjusting serew (25) and tighten necked-down screw (28) 25 Connect electric line of electromagnetic clutch and supplementary harness to cable connector. 26 Check oil level in refrigerant compressor (83— 520) aa6-s224 Fa27 Connect hose or pipe line to refrigerant com- pressor while checking sealing rings and moistening threads with cold flowing oil Note: Connections on refrigerant compressor are marked with “S" (suction ~ suction end) or “D” (Disch. pressure end). Wrongly installed hose tines will result in failure of refrigerant compressor (fluid shock} 28 Evacuate air-conditioning system and fill up again (83-514), 29. Switeh-on ignition, air-conditioning system and blower and tighten screw (51), 30 Check air-conditioning system for funetion (@3-510), 226-522/5,B. Engines 115, 615, 616, 617 (with York refrigerant compressor) Oil capacity il type cold-Flowing oil (approved cold-Flowing oils refer to Specifications for Service Products page no. 361) Oil level at Oil quantity ince normal max 240 300 Refrigerant compressor 8 28 ‘Tightening torques Nm (kom) Suction or pressure hose on refrigerant compressor 40-45 (4.0-4.5) Inch screw (7, 12) carrier to refrigerant compressor 30 (3h Screw M 12 x 1.5 (13) carrier to eylinder head 45-5 (45-05) Screw M 10 x 40 (14) carrier to cylinder head 30-5 (3.0-0.5) ‘Screw M8 x 55 (17) carrier to water pump 30 3) Nut M 10 (22) carrier to intake pipe (gasoline engines) 50 6) Screw M 10 x 25 (18) carrier to intake pipe (diesel engines) 50 5) Necked-down screw (21) belttensioning roller 45, 4.5) Inch screw (51) coupling to refrigerant compressor ry (25) Oil check serew 6-9 (06-08) Special tool 100 589 00 35 00, Pulling serew for pulley Conventional tools Double open end wrench 1/2” x 9/16! Socket 1/2 5/8” x 3/4", 7/8" x 15/16" x1 1/8" Selt-made tool il dipstick for refrigerant compressor A notches each in specified ss] spacings ces flat length: 210 mm oe material: brass wire dia. 3 mm ‘A= horizontal instalation @ = Gernca inctallation 4836-52216 FaNote The refrigerant compressor can be removed only together with refrigerant compressor carter. All threaded bores and screws on refrigerant com pressor are in inches Check oil charge of refrigerant compressor each time prior to adding fresh refrigerant (83-620) Attention! If refrigerant compressor must be renewed or reconditioned, insert a strainer into suction connee- tion. For details refer to 83-524. Removal 1 Cover righthand front fender. 2. Remove air filter. On diesel vehicles, loosen vacuum line an vacuum pump. 3. Switeh-on ignition, air-conditioning system and blower (electromagnetic clutch will pull). 4 Unscrew screw (51) 5 Remove pulley of electromagnetic clutch (2) from crankshaft of refrigerant compressor (1) by means of palling serew (53), 6 Switchoft ignition. 7. Disconnect ground line of battery. 8 Drain air-conditioning system (83-516). 226-82217 Fa9 Loosen screw (26), swivel belt-tensioning roller (23) in downward direction and remove V-belt (26), 10 Unscrew screw (24) and unscrew refrigerant lines, (18 and 19) from refrigerant compressor. Close connections with blind plug Mose! 123.0201022 Model 123.120/123/126 11. Disconnect electric lines from cable connector (70). Unscrew screw (71) and remove holder with cable connector, Mode! 123,130 836-522812. Remove radiator (not applicable on mode! 123,130). 13 Remove fan or viscofan coupling. 14 Remove V-belt for alternator and take pulley from water pump. 18 Unscrew screw (13, 14 and 17) 16 Unscrew 2 nuts (16) as well as nut (22) oF serew (8). Engine 115, (Cartier on exhaust manifold 17 Remove refrigerant compressor with carrier while paying attention to spacing sleeve (24). Engine 615, 616, 617 Carrier an exhaust manifois 236-822918 Remove pulley of electromagnetic clutch (2), pay attention to spring washer (54), 19 Unscrew 4 screws (52) and remove coil of electro ‘magnetic cluteh (2) 20. Unscrew 4 inch screws (7) and 2 inch screws (12) {and remove refrigerant compressor from carrier (3) Installation Attention! New refrigerant compressors are filled with nitrogen. Remove closing caps (C) on connections only, when the gas has been evacuated via oil check serew (bh. For this purpose, unscrew oil check screw for a few threads until gas is heard to escape, 21 Mount electromagnetic clutch on refrigerant compressor. 22. Screw refrigerant compressor (with parts item 4 10 12) to carrier (3) Refrigerant compressor Electromagnetic clutch Carrier Washer (3.8 mm thik! Fibber aise (8.5 mm thick) Sleeve (17 mm longl Inch screw 3/8" 16 (25 mm long) Washer (2.5 mm erick) Fibber dise (13,5 mm thick) Sleeve (22 mm long! Wather Inch serew 3/8” 16 150.8 mm long) 2 3 3 5 8 + 8 8 83,6-522/10 3 = 5 Se 7D, Engines 615, 616, 617.912, 617.952 (with Delco refrigerant compressor] Oi capacity Oil type cold-tlowing oil (for approved cold-tlowing oils refer to Specifications for service products, page No. 362) it filling capacity new in refrigerant compressor 170.ce Tightening torques Nm tkpm) Screws M 12 refrigerant compressor to support 60+10 (6 +1) Screw pipeline to reftigrant compressor 50:3 (5203) Hose line from evaporator to pipeline 7/8” 2-37 (29-37) Hoe line from pipeline to condenser 7/8 29-37 (29-37) Special tos Holding device for retrigerant compressor oo . 116 589 14 31 00 Pressing off plate for reftigrant compressor 93, 109 589 00 25 00 Conventional tools Double open-end wrench 1/2" x 9/16”, /8" x 3/4”, 7/8" x 15/16", 1° 1 1/8" Socket 14 mm, 3/8" square Assembly testing device with 3 filing hoses or evacuation e.g. made by Christof Fischer, and filling device for air-conditioning system ‘Augsburger Str. 289, 7000 Stuttgart Attention! If the refrigerating compressor must be renewed, e.. ‘owing to blocking, always renew pipe line with hoses (on refrigerant compressor, since small parts abrasives) of refrigerant compressor may enter pipe Tine and may then not be completely removed up to 100 % when flushing with R11 Removal 1. Cover front fender 2 Pull plug from clutch and drain air conditioning system, Ba6-s22/18 Fa3. Loosen nut (3) on clamping screw (4) 4. Loosen screws (5 and 6), swivel refrigerant com: pressor (1) inwards and take-off V-belt (2) Retrigerant compressor 6 Screw M 12 140, Nut 7 Pipeline Clomoing screw 8 Screw tt 10x 30, Screw a2 «170 1 Retegerant compressor 2 Vitel 5 Scrowoff hose lines (14 and 15) from pipeline (7) and close connections with plugs. 14 Howe Ine from evaporator to pipeline 7 Pipeline 15 Howe line from pipeline to condenser 36-5219 Fa6 Completely screw-out screws and nuts (5 and 6) and remove refrigerant compressor (1) with pipeline (7). 7. If the refrigerant compressor is replaced, refer to section “Check oil level in refrigerant compressor” (83-520), 8 When working on the electromagnetic clutch or the shaft sealing, screw off pipeline (7) and close connec: tions on refrigerant compressor with pressing-on plate. Installation 9 Check O-rings on refrigerant compressor and screw: ‘on pipeline (7), 26 922/20 Fa10 Provisionally screw refrigerant compressor to carrier by means of screws and nuts (5 and 6), tensioning screw (4), spacer sleeve (9), and spacing washers (10, 11 and 12) 11. Serew nut (3) on tensioning serew (4) 12 Put V-belt (2) in place and tension by means of ut (3) Refrigerant compressor 9. Spacer sleeve 3 Nut 10 Spacing washer 5 mm 4 Tensioning sre 12 Spacing washer 9 mm 5 Screw 13 Spring washer © Screw 13. Tighten screws and nuts (5 and 6) 14 Remove closing caps on pipeline and hose line Provide O-rings with cold-flowing oll and screw hose lines to pipeline and tighten, 15 Evacuate air-conditioning system and replenish (83-514). Note: If os filled into refrigerant compressor, the compressor is treated like a new refrigerant compressor, that is, when operating engine for the first time, run for at least 4 minutes at idle only (S 83/26 dated 26.07.1979) 16 Check air-conditioning system for function and leaks {83-510 and 512) 836-5222 Fa83-524 Reconditioning of refrigerant compressor B. Delco refrigerant compressor Data Designation © Delo (Frigidaire) Radia 4-oyinder : cin - 7000 Required input at max. compresior speed KW (HP) approx 6.385) Volume of cylinders . 164 co . il filling capacity Oil type cold-flowing oil (for approved cold-Flowing oils refer to Specifications for service products page No. 362) (1 fiting capacity now in etrigerant compressor W706 Tightening torques Nm thom) screws (8) belt pulleyieluteh tan Screw M 10 x 30 pipeline to rerigerant compressor sora 623) Nut 1 on rive shat — Serews (5 an 6) M 12 rerigerantcomprenor to carrier eo+10 6+ Hose line (14) from evaporator 0 pipalin 7/8" ican 29-37 (29-37) Hose line (15) from pipeline to condenser 3/4” 24-28 (2.4-2.8) 226-5249 FaSpecial tools Holding device for rerigerant compressor Pe nee 116 889 14.31 00 Holding wrench for cluteh 116 589 04 40 00 Disassembling tool with spacer for spring plate (000 589 07 35 00 sembing tot wih space for spring pate (Ga? 00 599 49 «3 0 Guide piece 116 589 05 63 00 Double-claw removing too! 000 589 88 33 00 Knocking-out mandrel 115 689 02.35 02 Disassembling and assembling tool for slip ring iol 000 589 21 61 00 Disassembling and assembling too! for shaft sealing (000 589 65 63 00 Pressing-off plate for refrigerant compressor ge 109 589 00 25 00 Conventional tool Socket 14 mm, 3/8” square eg: made by Haze, 630 Remscheia eg. made by Hazet, 5630 Remscheid order No, 2147 e.g. made by Hazet, 5630 Remscheid order No, 1846 a-1 Feeler gauge (set) Langbeck pliers 72 A (Internal tock} 9. made by Hazet, 5630 Remnscheid Pliers for retaining ring J 2 (external lock) ea istics Double open-end wrench 1/2” x 9/16", 5/8" x 3/4", 7/8” ‘Self-made too! Disassembling taol for O-ring e36-s24/10 Faa) Replacing shaft sealing of refrigerant compressor Removal 1 Evacuate air-conditioning system (83-516) 2. Remove refrigerant compressor (83-522) 3. Remove spring plate (83-626) 4. Remove retaining ring (10) for shaft sealing 5. Remove slip ring (12) by means of disassembling and assembling tool 6 Remove shaft sealing (13) by means of disassem: bling and assembling tool. For this purpose press on tool, then turn too! to the right in order to grip projection on shaft sealing by means of the lacking tongues on the tool. Completely remove shaft sealing from shaft by pulling in straight-forward direction 826-5201 Fa7. Take out O-ring (11) from inside of bore in housing ‘cover. For this purpose, a wire bent in the shape of 2 hook may be used 1 Muton drive shalt 9 Magnet coi! 2 Spring piste 10 Locking ing 3 Cluten 11 Grng 5 Locking «ing 12 Slipring 6 Support for clutch 13. Sh T Bettpulley is & Screw with lock ——20.-Housing cover Installation 8 Check whether parts of the old shaft sealing have been left in the bore of the housing cover. Prior to inserting new sealing, clean bore. 9 Immerse new sealing parts into clean, cold-flowing oil, Place O-ring (11) into groove of housing cover. 10 Insert shaft seating (13) into too! and slip on shaft. Then turn tool to the right up to the point when the shaft sealing engages in the shaft, Turn tool to the left only then, for disengaging it from the shaft sealing projection and removing it. 11 Insert slip ring (12) by means of too! into bore Up to contact with shaft sealing. Make sure that O-ring (111 is not pushed out of groove. Attentior ‘The sealing surface of slip ring 12) must be protected ‘against any damage, e.g. scratches, 12. Insert locking ring (10) with its flat face directed downwards up to the point when it rests on slip ring. ‘Then press with locking pliers or a screw driver on locking ring so that it springs into groove, 13. Install spring plate (83-526) sa6-s24/12 F3 8 3 2 13— ah —s 1“ 1 : NSS, hata 20 —| 2b) Checking refrigerant compressor for external leaks Note: When working on the shaft sealing, itis recom: mended to drain all cold-flowing oil from refrigerant ‘compressor. Determine the quantity of cold-flowing oil flown off and fil-in same quantity of new cold. flowing oil into refrigerant compressor. For details refer to “Check oil level in refrigerant compressor” (83-520) 14. Check condition of sealing rings (2) installed in refrigerant compressor and renew, if required, and provide with cold-flowing ol Felrigerant compressor Seating ring Exhaust connection 15. Serew pressing-on plate (3) by means of the exist: ing hex. screw to refrigerant compressor 16 Connect hose line (4) from service unit to in ternal connection of pressing-on plate. 17 Let refrigerant vapour stream into refrigerant compressor. A bottle oF filling cylinder pressure of lover 4 bar gauge pressure is required 18 Rotate in direction of rotation compressor shaft In instalation position of refrigerant compressor several times by hand, 19 Test refrigerant compressor for leaks by means of leak testing device. 20 Close valve on service unit, that is, on filling cylinder again and remove hose line at pressing off plate 21 Remove pressing-off plate again, however only immediately before connecting pipeline 22 For details on oil filling capacity of refrigerant ‘compressor refer to "Oil level in refrigerant compres sor’ (83-6201, 23 Install refrigerant compressor (refer to section "Removal and installation of refrigerant compressor” 83-522). ag6-52413 FS83-520 Removal and installation of electromagnetic clutch A. York refrigerant compressor Designation Models Models 415 cylinders 6 cylinders Electromagnetic cutout clutch 12 V Pitts 6.0 inch Pitts 6.7 inch Power input Cold 3.5 amps. Warm 2.8 amps. Tightening torques Nm (kpm) ‘Screws (52) coil to refrigerant compressor 14 (a) Screw (51) pulley to crankshaft 20-27 (2.0-2.7) Special tool Pulling serew for pulley 100 589 00 35 08 Conventional tools Double open-end wrench 3/8” x 7/16", 1/2" x 9/16” Note For pulling pulley from crankshaft of refrigerant com: pressor (with V-belt mounted) energize electromag. netic clutch (clutch will attract), With refrigerant com: pressor removed, carefully hold pulley with water pump pliers while supporting pliers against fastening screws of col Prior to removing clutch, check power input on clutch, Replace clutch if power input exceeds 6.0 amps. 836-5261 F2Removal 1. Actuate electromagnetic clutch while switching Con ignition, cooling blower and temperature switch, 2 Unserew serew (51). 3. Pull pulley of electromagnetic clutch (2) from crankshaft of refrigerant compressor (1) with pulling screw (531 4 Switeh off ignition. 5 Disconnect electric line on cable connector. 6 Remove V-belt for refrigerant compressor from electromagnetic clutch by loosening hex. screw (1) fr necked-down screw (1) and swivelling pulley ten sioning roller in downward direction, or slacken V-belt by means of tensioning serew (2). Berecensioning roller engines 115, 615, 616,617 Bele-tensining roller angine 110 ea6-52612Bels-tensioning raler engine 123 7 Remove belt-tensioning roller of electromagnetic. clutch (2) while paying attention to spring washer (64), 8. Unscrew 4 screws 152) and remove coil Note If the same clutch is installed again, check friction surfaces of clutch for damage, If score marks are showing up on friction surfaces or burned spots caused by overheating, completely replace clutch. Installation 9 Turn crankshaft of compressor so that keyway is facing upwards. 10 Screw coil with inch screws (52), which are painted with “Loctite heavy 270 green prior to assembly, to refrigerant compressor in such a manner ‘that the Outlet of the electric line is on top. 11 Insert spring washer (54) into crankshaft, 1936-52619 F 412 Mount pulley and slightly tighten with inch screw (51) and washer in place. 13 Connect electric line of supplementary harness and of electromagnetic clutch to cable connector. Mount ground line between cable connector and refrigerant compressor. 14. Check V-belt and pulley tensioning roller. Mount V-belt and tension with pulley tensioning roller. Note: Lowstretch V-belts are correctly tensioned, if they respond elastically to sturdy thumb pressure, New lowsstretch V-belts are subject to a slight elonga- tion which occurs on this type of V-belt already after a few minutes of operation, It is therefore of decisive importance for life of V-belts that they are once again tensioned following that short running-in period (Maintenance Manual item 756 and 757) 15. Actuate electromagnetic clutch while switching (on ignition, blower and air-conditioning system, Then tighten screw (51). 16 Check electromagnetic clutch for function. a16-526/4B. Delco refrigerant compressor Data, test values Designation engines 618, 616, 617.912, 617.952 Electromagnetic cutout clutch 12 V Deleo 4.9 inch Powe input in amps. 185 Y on Thtning ore tim komt Screws (8) belt pulleylutch a an Screw M 10 20 pipeline to etrigrantcompresior sora (623) Natt onive a : a Serews (6 and 6) M 12 refrigerant comprestoroncarrir e010 +) Hose line (14) from evaporator 0 pipeline 78 29-37 (29-37 Hose line (151 from pipeline to condenser 7° 287 (29-87) Special tools Holding device for refrigerant compressor 116 889 14.31 00 Holding wrench for clutch 116 589 04 40.00 Disassembling tool for clutch plate (000 589 07 35 00 ‘Assembling tool with spacer for spring plate (000 589 49 43 00 Guide piece 116 589 05 63.00 Double-claw removing tool (000 589 88 33 00 Knocking-out mandrel 115 589 02.35 02 Pressing-off plate for refrigerant compressor a 109 589 00 25 00, 836-5265 FaConventional tools Socket 14 mm, 3/8” square Feeler gauge (set) Langbeck pliers 72 A (internal lock} Pliers for retaining ring J 2 (external lock) Self-made tool Disassembling tool for O-ring Removal and installation of spring plate, of clutch with belt pulley and magnet coil, as well as shaft sealing may only be performed with the refrigerant compressor removed. ‘The clutch with support, the belt pulley and the ‘magnet coil are forming one assembly. In the event that one part of this assembly must be replaced, the complete assembly shall be removed (cefer to 83-526, section b) a) Removal and installation of spring plate Remove! 1. Evacuate air-conditioning system (83-516) 2. Remove refrigerant compressor (83-622) 3. Attach holding device to refrigerant compressor and clamp into vise. Serew-off pipeline (7) from refrigerant compressor (1). For this purpose remove screw (B and 21). Then close opening by means of pressingoff plate 836-5266 F2 eg. made by Hazet, 5630 Remscheid e.g. made by Hazet, 5630 Remscheid order No. 2147 €.g. made by Hazet, 5630 Remscheid ‘order No. 1846 a-1 eg, made by Hazet, 5630 Remscheid order No. 1846 24. Loosen refrigerant compressor from holding device ‘and retighten with the drive shaft in upward position, 5 Prevent spring plate (2) from rotating by means of holding wrench, screw off nut from shaft using socket 14 mm 6 Screw disassembling tool into hub holding too! bby means of wrench and tighten central screw. 7 Take out key in shaft 83.6-526/7Installation 8 Clean friction area of spring plate and of clutch 9. Insert wedge (4) into groove of hub in such @ manner that it is projecting by about 5 mm. 10 Put spring plate on shaft in such a manner that wedge and groove are in alignment. 11 Place spacer on spring plate. Insert assembling tool thraugh spacer and screw assembling tool to shaft end. 12. Secure hex. head of tool and screw: the central screw until there is a play of approx. 0.5~1 mm be: tween the friction areas of the spring plate and the clutch 13. Take out assembling tool and spacer. 14 Screw in place new screw on shaft (smaller diam. eter of nut directed toward shoulder of shaft) and tighten, Check play once again. 15. Install refrigerant compressor (83-522), 1 Nut on drive shaft 2 Spring plate 3 Chuten’ 5 Locking ving 6 Support for clutch 9 elt pulley 8 Seren with tock 9 Magoot cot 10 Locking eng 11 Oring 12 Storing 13 Shatt soning 18 Orie snatt 20 Housing cover 836-5268 F2 (RSssp 9'b) Remove and install clutch together with belt pulley, magnet coil and bearing 16 Remove spring plate (83-626, section a, item 1107) 17. Take out tock (5). Mark position of magnet coil terminals, 18 Insert guide piece over shaft on headpiece of refrigerant compressor. 19. Pull off assembly by means of puller 20. Bend away locks on hex. screws and take off the 6 screws (8) together with locks. 21. Take off belt pulley from clutch and remove ‘magnet coil from belt pulley. 836-5269 2 poeNote: If bearing (6) of clutch body (3) must be replaced, perform jobs as per item 22 through 24. Removal of bearing 22 Place clutch (3) on wooden supports and press out bearing (6). For removal of the bearing, the notches need not be removed. Installation of bearing 23 Align new bearing (6) exactly in relation to bore. of hub and press.in 24 Punch-mark the bearing at 3 points at 120° distant from each other. Do not punch too deep since ‘otherwise the outer race of bearing may be deformed, Do not use again old notches. 83.6-526/10 F2Installation 5 26 Slip clutch (3) into belt pulley (7) and provi sionally screwsin by means of new locks and screws (8). Provide threads of screws with Loctite. 27 Put down complete assembly on housing cover front, Before pressing assembly completely down, ‘make sure that the magnet coll terminals are in the ‘correct position in relation to refrigerant compressor and that the three projections on the back of the ‘magnet coil are in correspondence with the recesses in the housing cover. 28 Insert locking ring (5) for the assembly. 29 Clean friction areas of spring plate and clutch. 3.6-526/11 F230. Rotate belt pulley together with clutch in order to determine whether the belt pulley isin alignment. Slightly readjust, if required 31 Tighten screws (8) of pulley/clutch. Secure screw heads in a similar manner as the screws were secured prior to removal 32 Install refrigerant compressor (83-522). ea6-526/12 F283-528 — Removal and installation of condenser Data ‘Surface area/depth Version Tightening torques 21.7 dm? /32 mm, 2ow Hose line (18) to condenser Hose line (19) to condenser Conventional tools Inch-type wrench If the condenser is not immediately installed again, flush condenser with refrigerant R 11, or blow out with refrigerant R 12 oF nitrogen. Then close connec: tons with plugs. Removal 1. Drain air-conditioning system (83-516). 2 Drain coolant and remove radiator. {st condenser version 3. Remove air-low grille under bumper at front right (88-410), 4 Unscrew screw (20) and remove pipe line (18) from condenser. 936-5261 Nm (kpm) 15-18 (15-18) 24-28 (24-28)5 Loosen screw (11) and unserew pipe line (19). 2nd condenser version 6 Disconnect hose lines (18 and 19) from condenser 8) 7. Close hose and pipe connections with plugs 8 Unscrew screws (8) and remove condenser Installation Note: In the event of damage on condenser the rule is that dirt and moisture have entered the air-condi tioning system. If such aconclusion is appropriate, ‘blow out air-conditioning system with nitrogen and replace receiver dehydrator (83-518 and 530) 836-52829 Place condenser from inside on side member and serew to side member and to radiator supporting frame by means of screws (9). 10 Connect pipe line (18 and 19) to condenser (8) while checking O-rings and moistening rings with cold-flowing oil stat version cre Dice lie (16) tole ee with screw (20). 12. Install radiator and fill in coolant. 13. Evacuate air-conditioning system and fill up ‘again, check for leaks and function (83-510 to 514}, 14 Ast version. Install air flow grille under bumper front right, 83.6-526/3,83-530 Removal and installation of receiver dehydrator Date Version Steel housing with sight glass Fuse Coolant should blow off at 117° + 3°.C “Temperature switch in receiver dehydrator Cutting.in point: 52° + 3° C (Diesel models 4/5 cylinders) Cutting.in point: 62° + 3° C (Gasoline models 4/6 cylinders) Temp. tolerance: 7 ~ 12°C Pressure switch in receiver dehydrator Cutting-out pressure: 2 + 0.2 bar gauge Cutting-in pressure: max. 0.6 bar above ‘utting-out pressure Tightening torques Nm (kom) Hose lines to receiver dehydrator 18-18 (15-18) Im the event of trouble on air-conditioning system as, the result of contamination or icing-up, as well as on air-conditioning systems without refrigerant, a new receiver dehydrator should generally be installed. ‘According to contamination, the air-conditioning system must be blown out with refrigerant R12 oF nitrogen or flushed with refrigerant R 11 prior to installation of new receiver dehydrator. Removal Drain air-conditioning system (83-516). at version ext fags Fa2 Pull electric plug from temperature switeh (14) and from pressure switch (13) and unscrew both 3. Unscrew hose lines (16 and 18) from receiver de hydrator (17). Close connections blind. 4 Unscrew two screws (12) and remove receiver dehydrator (17) Installation. 5. Attach new receiver dehydrator with screws (12). 6 Mount temperature switch (14) and pressure switch (13] on receiver dehydrator (17). On pressure switeh Ist version (cone seal), moisten threads and cone with cold-flowing oil. Pressure switch (2nd version) with O-ring (13) check and renew, if re ‘quired (83-532). 2a version 7 Mount electric plug on temperature switch (14) as well as on pressure switch (13). 8 Evacuate air-conditioning system and refill, (83-514). 9 Check air-conditioning system for funetion (83-510). 5 To expansion valve © Fuse 83.6-530/2 1834-770683-532 receiver dehydrator ‘Temperature switch in receiver dehydrator Pressure switeh in receiver dehydrator Tightening torques Temperature switch Pressure switch Note Drain refrigerant of ait-conditioning system to remove pressure switch (13), ‘The temperature switch (14) can be renewed with air-conditioning system filled. Inspection or removal and installation of temperature switch (14) 1 Pull off electric plug and unscrew temperature ‘switeh (14) from receiver dehydrator. 2. Switehon ignition and connect the two electric flat plugs with each other (short). If supplementary fan in front of condenser is not switching on, the fault is outside temperature switch (83-608) aae-so21 Fa Inspection or removal and installation of pressure switch or temperature switch in Cuttingn point: $2° + 3°C (Diesel models 4/5 evlinders) Cuttingin point: 62° +3 °C or 52°C starting 11/81 (Gasoline models 4/6 cylinders) 12°C Temp. tolerance: 7° Cutting-out pressure: 2 + 0.2 bar gauge pressure Cuttingsin pressure: max. 0.6 bar above cutting: out pressure Nm tkpm) 814 (080.4) 2:4 — (2+04)3. Insert electric plug on temperature switch and immerse temperature switeh in water in accordance with cutting-in temperature (55° C or 65°C). If ‘temperature switch is defective, the supplementary fan in front of condenser will not switch on. 4 Let water bath cool down (max. by 12° C) Supplementary fan should switch off, ‘8. Switch off ignition and screw temperature switch into receiver dehydrator. Inspection or removal and installation of pressure ‘switch (13) ‘Checking cutting.in pressure (air-conditioning system filled with refrigerant), 6 Run engine and switeh-on air-conditioning system. [switch-on blower and temperature switch). 7. If the electromagnetic clutch of refrigerant com: pressor does not attract, check both flat plugs on. pressure switch for voltage (do not pull plug from pressure switch) 8 If both plugs of pressure switch are energized, the fault is on coll of electromagnetic clutch or on elec tric line between pressure switch and clutch coil (83-508), 9 Ifonly one flat plug of pressure switch is energized, there is either not enough refrigerant in air-condition: ing system or the pressure switch is defective. 10. To check level of refrigerant, pull off both electric plugs on pressure switch and connect to each other (short). Run air conditioning system for approx. 23 minutes, then check shortly after switching.on electromagnetic clutch whether refrigerant flows free of bubbles past sight glass of receiver dehydrator. 11 If there is enough refrigerant, the fault is with pressure switch. 12. Switch off ignition, aa.6-sa22 FaChecking cutting-out pressure 13 Connect pressure gauge (service unit or shop tool) to service valve (pressure end), 14. Pull both electric plugs from pressure switeh and connect ohmmeter to pressure switch. 15 Drain refrigerant, at approx. 2 ¢ 0.2 bar gauge pressure the cutout of the pressure switch must be indicated by ohmmeter (ohmmeter at infinite} Removing pressure switch 16 Drain air-conditioning system (83-516) 17 Pull off electric lines and unscrew pressure switch (13) from receiver dehydrator (17). 18 Close connection on receiver dehydrator with plug. Pressure siteh with cone sea) Installation Note: For sate sealing of pressure switch 1st version (cone seatl, a copper ring (13) 7/16”, part no (000 835 05 98, can be used. 19 Moisten O-ring or sealing cone and threads with cold-flowing oil 20 Screw pressure switch (13) into receiver dehyde: tor (17) and plug-on electric lines. 21 Evacuate air-conditioning system, refill and check for function (83-510 and 514), Pressure snitch with O-ring Seal ea.6-sa2ia FA83-534 Removal and installation of expansion valve Data Version Thermostatic valve with outer pressure compensation Tightening torques Pressure hose to expansion valve 6/8 Suction hose to expansion valve 7/8" Evaporator pipe lines 3/4" Evaporator pipe line 7/8" Note {f heavy contamination is shown up in expansion valve, replace receiver dehydrator and expansion valve (83-530), Injection valve (agrom) 3 To ewsporstor From evaporator 9 Tocompresior 13. Injection vate 18 On 15 Oring fitting for howe line from injection wale to etigerant 16. Oring Hitting for hose line from Feenver dehydrator to injection Injection valve (section! sa6-5341 Fa Nm tkpm) 15-18 (1.5-1.8) 29-37 (29-3.7) 24-28 (24-28) 29-37 (2.9-3.7)Removal 1. Drain aie-conditioning system (83-516) 2. Remove cover at right under instrument pane! (68-150), 3. Open insulating housing (18) by halt 4. Unscrew hose and pipe lines on injection valve (13), 5. Remove injection valve and close connections with plug Installation 6 Moisten threads with cold-lowing oil and check O-rings (14) 7. Screw injection valve (13) to evaporator pipes. 8 Connect refrigerant line (15 and 16) to injection valve 9 Evacuate airconditioning system, refill and check for function and leaks (83-510, 512 and 514). 10 Attach housing (18) carefully to injection valve, 11 Install cover under instrument panel 36-524/283-536 Removal and installation of evaporator housing Tightening torques Nm ¢kpm> Suction hose expansion valve 7/8" 29-37 (29-3.7) Pressure hose to expansion valve 5/8! 15-18 (1.5-1.8) Note When removing evaporator, always replace condensate drain hose (section 15 {item 22)) between evaporator housing and tunnel. Up to november 1977 install a condensate drain hose, part no. 123 832 28 94 and. starting december 1977, part no. 123 832 41 94 Remove evaporator housing together with heater box M the evaporator is renewed, refer to note (83-538) 1 Drain air-conditioning system (83-816) 2. Drain approx. 2 liters of coolant 2 Remove driver's seats (91~100) 4 Remove center console (68-200) 5 Remove instrument panel (68~100) 6 Disconnect heater hoses 7 Remove air ducts for rear compartment heater ga6-5a611 FaB Remove air ducts on transmission tunnel 9 Pull off plug {b) and open cable bands on heater box. Loosen all electrical connections on heater box. 10. Separate bowsien wires between operating unit ‘on heater box and water valve, 11 Force bowden wire (3) from lever of main air tap and loosen clamp (t) 83.6-526/212 Remove support on iransmission tunnel 13. Unscrew refrigerant line (15 and 16) feom injec: tion valve, Then clase with plug. 14 Pull vacuum line (26-medium green/yellow) and electric plug from temperature vacuum switch. 18 Loosen condensate drain hose (22) from connec: tion of evaporator housing, 536-5363 Fasag dares 16 Unscrew nut (1) and angular fastening bracket (a. 17. Unscrew nut on righthand upper angular holding bracket. 18 Unscrew nut on lefthand upper angular holding bracket. 19 Remove evaporator housing with heater box while holding heater pipes in upward direction so that no coolant will come out 8536-99614Installation 23. Flange evaporator housing to heater box. 24 On vehicles up to 07/80, insert capillary (8) of temperature regulator up to yellow mark into guide tube of evaporator or starting 08/80 insert tempers ture sensor in-between ribs of evaporator and mount rubber grommet in evaporator housing 25 Plug vacuum lines (19 and 20) to vacuum element Mine 19 green/orange, line 20 green/light blue}. 26 Screw evaporator housing with heater box to front wall while guiding heater tubes through arom: ‘mets in front wall 27 Screw evaporator housing at top 10 front wall 28 Install lower angular holding bracket in such a manner, that the following dimensions are maintained: a= 165mm: b= 217 mm 29. Mount condensate drain hoses (22 and 34). 30 Install support at transmission tunnel 31 Connect refrigerant lines (1 and 16) to injection valve, while checking O-ring and moistening threads with cold-tlowing oi 32. Plug vacuum line (26) to temperature switch 33. Install bowden wires, electric tines and plugs and 34° Install air ducts for rear compartment heater. 35 Connect heater hoses and add coolant. 36. Install instrument panel and center console. 37 Install driver's seats 38 Evacuate air-conditioning system, refill and check for function (83-510 to 514) ma6-s16'6 FA20 Pull vacuum lines (19 and 20) from vacuum ele iment (9) 21. On vehicles up to 07/80 pull capillary (8) of temperature switch out of guide tube in evaporator housing, 22. Remove evaporator housing from heater box, by removing nuts (2) and clamps (b) 836-5365 Fa 199-127683-538 Removal and installation of evaporator Note Two evaporator makes are optionally installed, but they are not interchangeable in relation to each other. When renewing evaporator, order evaporator in accordance with respective make, Then evaporator make is identi- fied as follows: Air-conditioning system Evaporator housing made by Behr Starting 08/80 with sticker (arrow), before 08/80 without sticker ‘Automatic climate contro! Evaporator housing made by Behr: With sticker, lever for main air flap white (arrows). Air-conditioning system Evaporator housing made by Siemensithermal Part number on lever for main air flap (arrow). sa6-saa"1 Fa‘Automatic climate control Evaporator housing made by Siemens/thermal Lever for main air flap black (arrow) Removal 1 Pull capillary of temperature switch out of guide tube in evaporator housing or pull temperature sensor out of evaporator. 2. Remove clamps (6) between evaporator housing bottom and center section, 3. Remove four-point coupling (5) from holder and loosen electric lines from evaporator housing, 4. Remove preresistors (8) from holder in evaporator housing upper half (1) 5 Take off evaporator housing lower half (3) and remove evaporator. 6 Clean evaporator housing, paying attention to perfect passage of condensate drain connection. ea6-sa8/2 Fa7. Insert new evaporator (7) into evaporator housing, while paying attention to evaporator ribs. 8 Reinstall evaporator housing lower half (3) and electric lines (5) with pre-resistors (8 or 10), 9. Close passage for evaporator pipes on evaporator housing center section (2) with sealing tape. 10. Flange evaporator housing to heater box and ‘mount expansion valve (83-534 and 536). ith aie conditioning system with automate climate control up to 780 836 538/3 F 483-540 Removal and instal Data Power input 210 W Blower speed Vein Ast detent 1300 2nd detent 2300 ‘3rd detent 3000 Air volume at 12 V(r? min} 70 1. Remove covers at right under instrument panel (68-150), 2. Unscrew screw (22] and remove contact plate (25), Then pull off flat plug and remove serews (23) with clips on Ist version, 3. Expose electric tine on 2nd version, 4 Unscrew screws (21) and blower (20) in down- ‘ward direction while turning blower slightly 2nd version 83.6-540/1Installation 5. Introduce biower into evaporator housing, 6 Turn blower in evaporator housing into correct installation position and attach with washers and screws (21) 7. Plug electric lines to contact plate, screw-on con: tact plate and mount supply line 8 Check blower for function 83.6-540/283-542 Removal and installation, adjustment or checkup of temperature vacuum switch or temperature dial and temperature sensor for air-conditioning system ‘A. Temperature vacuum switch up to 07/80 Data Cutting.in temperature °C. + 4541 completely cold +16 +2 minimum cold Cutting-out temperature °C ret Difference between cutting-in and cutting-out ae temperature in rotary range Angle of rotation © Note During the function test (83-510) of air-condition: ing system the air outlet temperature may not be less than 1 °C. A prerequisite is that the capillary of temperature switch is slipped into guide tube up to mark, that the fluid level of the system is in order and that the required pressures at suction and pressure end of compressor have been attained. If the measured temperature is outside the specified values (83-510), the temperature switch must be readjusted. Adjustment 1. Pull off knob (1) and unscrew hex. nut (2). sa6-sazi1 Fa2. Remove cover (3) by loosening screws at left and right (if in place. 3. Remove lock (7), unscrew screws (4) and remove holder (5), 4 Remove temperature vacuum switch (6) from ing in center console only to the extent that the closing cover (11) can be removed. Important! Pay attention to capillary (8) 2nd version 5. Adjust temperature switch by turning adjusting serew (12) ("“colder" to the left). One full turn corresponds to approx. 2° C. 6 Put back closing cover (11). 7. Additional installation item 18 to 19. aa6-sa212 Fa8 Refer to item 1103. 9. Remove glove box and pull capillary (8) out of evaporator 10. Pull two flat plugs from temperature switch and loosen double coupling 11 Pull vacuum lines (9 to 11) from vacuum switeh (6) (pay attention to color code) Installation 12. Plugon double coupling and two flat plugs on temperature switch, 13. Plugon vacuum lines (9 to 11) on vacuum switeh according to color code. 14 Install capillary (8) to evaporator and slide into guide tube up to mark, 15. Attach holder (5) to temperature vacuum switch (6) with lock (7) 16. Screwson holder (5) with screws (4). 17 Install cover (3) and screw temperature vacuum switch with aut (2) to cover. 18 Check bulb in temperature switch for correct seat and push-on button (1), 19 Check air-conditioning system for function, B36-542/3 FaB. Temperature dial and temperature sensor starting 08/80 4) Removal, installation and checkup of temperature dial for air-conditioning system 0: completely cold minimum cold Cut-in temperature °C Difference between cutting-in and cutting out temperature °C in turning range Angle of rotation ° 180 Note During function test (83-510) of air-conditioning system the outlet temperature should not drop below 1°C. A prerequisite is that the temperature sensor is correctly seated between evaporator plates and corresponds with the Ohm values named in section b, ‘that the fluid level of the system is in order and that the required pressures at suction and pressure end of compressor are attained. If the measured temperature Js outside of the specified values (83-510), replace temperature dial Removal 1 Remove cover (3) 2 Unclip temperature dial from holder (refer to arrow) and remove in forward direction. 3 Pull 2- and 4-pole coupler from temperature dial and socket for lights. 36-5424 FaInstallation 4 Place 2: and 4-pole coupler on temperature dial, as well as socket for lights, and clip into holder. 5 Install cover eciaesa ae = Q 2 Selector dial Nominal value oat aaa | Oengaed vp os set rar ered w1a eOrer ‘The potentiometer and the electronic system in selector dial cannot be tested with ohmmeter. 'b] Remove and install, test temperature sensor for air ‘conditioning system Test values Sensor temperature Resistance °c 30K2* 1K 18°C KD ATK 25°C 17KD# TKD 36°C 13kD 21k 40°C TKDE TKR 26-5425 FaRemoval 1. Remove cover at the right (on righthand steering vehicle at the left) under instrument panel 2 Pull 2.pole coupler from temperature dial (1) while removing temperature dial for this purpose (refer to section al 3 Pull temperature sensor (17) out of evaporator housing Installation 4. Check temperature sensor. If required, insert new temperature sensor (17) carefully in-between evaporator plates. Make sure that the temperature sensor (171 is correctly seated, that is, sensor should engage between evaporator pipes. Then mount rubber grommet into pening in evaporator housing a mae 5 Plug 2-pole coupler on temperature dial (1) and install temperature dial refer to section a). 6 Install cover under instrument panel 7 Check air-conditioning system for function (83-510), Ba6-s426 Fa83-544 — Removal and installation of vacuum elements Data Permissible leaks in vacuum elements 20 mbar/min at 300 mbar vacuum 1) Vacuum elements for leg room flap Removal 1. Remove cover at right under instrument panel. 2 Pull vacuum line (2) from vacuum element (1). 3. Remove clip (3) from connecting rod (4). 4 Carefully remove housing upper half (5) from ‘housing lower half (8) and take out spring (7) and sleeve (8), 5. If housing upper half (5) or sleeve (8) are damaged, remove parts from new vacuum element and install. 6 If housing lower half (6) is damaged, remove fuses @ Installation 7. When installing a new vacuum element, always se new fuses (9) with rubber washers. 8 Check vacuum element for function and leaks, e26-540/1'b) Vacuum element for recirculating air flap Removal 1. Remove glove box. 2 Pull vacuum lines (7) from vacuum element (1), paying attention to color code. 2nd version 3. Separate connecting rod (3) from elip (4), arrow. 4 Serew-out screws (2) and lift off locks (2) by means of a screwdriver and remove vacuum element. Installation 5 For installation proceed vice versa. 6 Check vacuum element for correct function and leaks 83.6-544/2 F2©) Vacuum element for defroster nozzle flap Removal 1. Remove cover left under instrument panel 2 Pull vacuum line from vacuum element (23), 3. Remove clamp (63) and remove locks (64) by means of a screwdriver. Installation 4. Fasten vacuum element (23) on holder of air conditioner housing with locks (64) and rubber disks. 5 Mount vacuum line and actuating rod by means of clamp (63). Check vacuum element (23) and defroster nozzle flaps for function and leaks. 6 Install cover left under instrument panel 836-544/9 Fa83-545 Checking vacuum elements and temperature vacuum switch for leaks Data Permissible leaks in system (without vacuum reservoir) {6 mbar/min at 400 mbar vacuum Permissible leaks in components 20 mbar/min at 300 mbar vacuum Plug-on length of connections 1242 Vacuum tine Color code Line from distributor to red-gray or vacuum reservoir (16) gray-light blue Suction line to vacuum switeh (17) ‘green-yellow Controt line “cooling fresh air” (18) Control line “cooling recirculating air” (19) Control tine “leg room flap” (20) fefroster nozzle flap" (2nd version) Control line Special tool Tester for vacuum systems Note For normal cooling the temperature switch is turned clockwise, The air-conditioner operates in range be- ‘ween 0 and mark on blue scale (approx. 3/4 cooling capacity) with fresh air (outside air) For maximum cooling (temperature vacuum switch ‘between mark and end of blue scale) the air-condi: tioner operates with recirculating aa6-sasi1 Fa greenvlight blue orange green-white green white 116 589 25 21 00Checking vacuum system of air-conditioner without 1. Pull suction line green-yellow (17) out of distributor (9) and connect tester. 2 In position “cooling fresh air” evacuate system and read pressure increase on pressure gauge of tester, Check likewise in position “cooling recirculating ai Depending in which condition (“cooling fresh air” or “cooling recirculating air") the pressure increases, continue checkup according to section “leaks while cooling fresh air or cooling recirculating air”. Ifa leak ‘occurs in position according to section “cooling fresh air and recirculating air continue checkup according to section “leaks while cooling fresh air and cooling recirculating air" Attention! Prior to exchanging vacuum elements, check hose lines and their connections in circuit found leaking. Leaks while cooling fresh air or cooling recirculating air 1st and 2nd version 3. Remove cover under instrument panel right, as well as right and left starting with 2nd version. 4 Pull off connection with line green-light blue (18) fr green-orange (19) of circuit found leaking 5 Connect tester and evacuate. 6 If readout on pressure gauge changes while testing, replace vacuum element (12h. 7. If readout on pressure gauge remains constant, the Teak is at vacuum element (14) for leg room flap or (on 2nd version at vacuum element (23) for defroster nozzle flap. tighthand steering starting 11/79 ta 08/80 sa6-545/2 Fa8 In such @ case, pull connection with line green: white (20) fram vacuum element (14) or on 2nd version from vacuum element (23) 9 Connect tester in each case to vacuum element (14) and (23) and evacuate. 10 a vacuum element is leaking, readout on pressure gauge will change. 11 Renew leaking vacuum element. Leaks while cooling fresh air and cooling recirculating air (1st and 2nd version) 12. If both circuits are leaking, leak may be in check valve 13, Pull check valve (8) out of distributor (9) and connect tester with connecting hose (refer to arrow), ‘evacuate and read pressure gause. 14 If readout on pressure gauge is not changing, check valve is leaktight. f both circuits are still leaking, the fault is with temperature vacuum switch, 15. Insuch a case, remove temperature vacuum switeh, ‘Note: The temperature vacuum switch comprises the ‘temperature switch as well as a vacuum rotary switch (4) for recirculating air flap and a vacuum pull switch (5) for leg and rear compartment flap, as well as from 2nd version for defroster nozzle flap, 16 Pull control line green light blue (18) and green ‘orange (19) from connections (17) 17. Pull connecting bridge (1121 from vacuum pull switch (5) 18 Close connecting bridge (112) and connections (171 with blind plugs (84) 19 Pull suction line from vacuum rotary switeh, connect tester [refer to arrow! and evacuate, en6-S45i9 Fa20. Turn vacuum rotary switch (104) from position “cooling fresh air to end stop and read pressure gauge. 21. If readout on pressure gauge changes, replace vacuum rotary switch 22 If readout on pressure gauge remains constant, the vacuum rotary switch is leaktight and the leak is at vacuum pull switch 23 In such a case, pull control line green-white (20) out of connection (17) and close with blind plug (84). 24 Pull of connecting bridge (112) at vacuum pull switch (5) and connect tester with connecting hose (refer to arrow) 25. Evacuate vacuum pull switch with tester. 26 If vacuum pull switch leaks in pulled or pushed. position, readout on pressure gauge will change. 27. Replace vacuum pull switch, In the event of leaks (3rd version) 28 Pull vacuum line medium greer-yellow (17) from switchover valve (18). 29 Connect tester and evacuate. 30 If readout on pressure gauge changes during test, pull vacuum hose (20) from vacuum element (12) and close Sed version 31. Evacuate with tester, if readout on pressure gauge remains constant during test, renew vacuum element 2) a36-sasia FAChecking vacuum reservoir 28 Pull suction line red-gray or gray-light blue (16) from distributor (9). Connect tester with connecting hhose (refer to arrow) to suction line (16) and evacuate. 29 If readout on pressure gauge changes, replace sealing of vacuum reservoir or vacuum reservoir, if required, B16-545/5 F 483-546 — Removal and installation of supplementary fan Data Current input 11.5 amps. Fan speed at 12 V 2300/min Removal 1 Disconnect battery. 2 Pull double coupling (27) on stiffening at front left in engine compartment from clip (10) and loosen plug connection, 3. Expose electric line up to supplementary fan while loosening cable bands. 4 Unscrew screw (4) and clamps (5). 5 Unscrew screw (7) and put strut (6) slightly aside. ‘Then remove supplementary fan 6 Unscrew holder (3) fram supplementary fan, 7 Screw holder (3} to supplementary fan. 8 Install supplementary fan, attach to strut (6) and to cross member, Reattach strut (6). 9. Install harness up to clip (10) and attach, 10 Connect 2:point coupler and fasten with clamp (10) Check supplementary fan for function, for this purpose pull the two flat plugs from temperature switches (14 or 15} and connect to each other {connecting short) 11 Check direction of rotation of supplementary fan, Fan is rotating clackwise; if direction of ratating is wrong, interchange jacks in 2-point plug (27) aa6-546"1 Fa83-600 Operation of automatic climate control A, General Models 123 can be optionally provided with a newly developed automatic climate control system instead ‘of manual air conditioning ‘The automatic climate control system regulates the desired in-car temperature. Heating, cooling and air distribution {top, center, bottom) are automatically controlled ‘Autamatic climate control operates only when the engine is cunning 3 Temperature cial 4 Pushbutton salteh wit Siunetions 5 Blower switen For adaptation to prevailing weather conditions, the various functions can be selected by means of push: buttons. The air inlets in center of instrument panel ‘and the side vents can be opened, closed or swivelled as desired For perfect operation of automatic climate control, the manually operated air inlets in instrument panel should not be closed altogether. Buttons should be pushed only one at a time, 838-600/1B. Control unit, The control unit is located in center console and com: prises a temperature dial (3), a pushbutton switch unit (4) and blower switeh (5) ‘The temperature dial serves for stepless adjustment of in-car temperature between the two end detent posi tions “MIN” = not heating and “MAX” = fully heating ‘Set to “MAX” means full, uncontrolled heating ca pacity; set to “MIN” means full, uncontrolled cooling capacity, each time in Sth blower stage, These func: tions apply only for pushbuttons “band “e", “a for uncontrotied heating only, as well as for blower switch in position “AUTOM” The temperature set with temperature dial is attained 2 quickly as possible and will then remain constant, 6 Temperature sensor for heat exchanger To prevent undesired temperature fluctuations, the temperature, once set, should be corrected in small steps only. Rotation of temperature dial will adjust a potentiometer. Together with in-car sensor (7) and sensor (6) for heat exchanger, the potentiometer provides a nominal value for temperature control. 2 nar temperature sensor ‘The pushbutton switch unit (4) has § functions (a to e), the blower switch (5) has 3[f,g,n);all are includ- ed in control unit The temperature dial (3) and the blower switch can be individually removed from control unit. 3 Temperature i 4 Pushbutton so Siunetions 5 Blower switch e2.8-600/2 et >Function selection “e” (off) Selecting this function will switch off the air supply ‘through main air flap into inside of vehicle (e.g. in the event of unpleasant outside dust or odors). The electronic system continues to operate while driving and the monovalve (11) remains closed. Blower is not operating Function selection “a (cooling system off) EC {ECONOMY ~ refrigerant compressor is off), system operates with fresh air only In heating range, tempered air will flow out of the legroom and side nozzles, with a leak air share from. defroster nozzles, The windshield will be provided with just enough air to remain free of fog during normal weather conditions In venting range, air is routed to air inlets in center of instrument panel and to lateral vents only. The ‘minimum in-ear temperature depends on outside temperature and on solar radiation. At low outside temperatures the air supply and the blower remain in off position until the engine is heated to approx. 35 °C by the coolant. The blower ‘operates in stages 3 to 5 at “AUTOM”, We recommend the above function selection at outside temperatures at which no cooling of fresh air is required (to sate fuel) Function selection “c” (normal adjustment) Function selection “c” corresponds to function selec: tion “A, with a cooling effect. ‘The refrigerant compressor of the air conditioning system is switched on at outside temperatures above +2°C. If the vehicle in-car temperature is higher by approx. 4°C than the preselected temperature on tempera ture dial, the blower will start immediately. At "AUTOM" "AUTOM" the blower operates in stages 2 to 5, 1838-60013In heating range, tempered air will flow out of leg room and side nozzles with a leak air share from defroster nozzle. In cooling range, cooled air will come out of center and side jets only, The mode changes operate auto: ‘matically, overlapping is possible, that is, legroom and center nozzles ean be open simultaneously. Tne compressor is added, at outside temperatures above + 2 °C, the evaporator temperature is held to approx. 0 °C. If the system moves to “cooling”, the fresh air/recirculating air flap is automatically switched to recirculating air. 3 Temperature dat 4 Pusnbutton soiteh unit with 6 functions 5 Blower switch with functions Function selection “b' (top and bottom) ‘The blower starts after approx. 10 sec., also below 35 °C coolant temperature, in position “AUTOM” in stages 3 t0 5, {In heating range, air is routed to windshield, to side vents and to legroom; in cooling range additionally 10 air inlets in center of instrument panel ‘The interior of the vehicle is extensively free of draft — the legroom is cooled more intensively. This, function serves the purpose of removing fog, if any, (on glass during damp, cold weather conditions, ‘The refrigerator compressor is switched on at outside ‘temperatures above + 2 °C, 3 Temperature iat 4 Pushbutton swatch unit with § functions 5 Blower teh with 3 functions 183.8-600/4Function selection “a” (defrosting) With the ignition switched on, the blower will start immediately and operate in 6th blower stage only, Independent of temperature dial adjustment, max. hheated air will be routed to windshield. The recirculating pump is always running along and the refrigerant compressor is switched on at outside ‘temperatures above + 2 °C. If, with the ignition switched on, function selection "a" or “bis pushed followed by switching to “c" or “d, the system re: ‘mains in operation also below 35 °C coolant tempe: ature. Blower switch (5) The blower operates in 6 stages. ‘At function selection “b”, "e"* and “d the air vol: ime can be set as required. Switen Air volume: Blower stage f (top) max. 6 12v) hbottom) min. 1 (aw gcenter) automatic 2 5 (6-10V) During “AUTOM” operation in functions “b, ¢ and "the blower will start in 2nd blower stage after the system has been switched on with a delay of approx. 10 seconds, and remains constant for approx. 10 se: conds (on vehicles up to December 1980 approx. 30 seconds). If required, the blower will switch up to 5th blower stage. 83.8-60015,C. Temperature sensor ‘The in-car temperature sensor (7) is located under a grille at top in instrument panel. The sensor feels the in-car temperature and transmits that temperature to the electronic switch gear (9) to balance the tempera: ture as set Layout of in ear temperature sensor ‘ninstroment panel Timear temperature sensor ‘Am air jet (47) attached to blower housing will draw air from interior of vehicle by way of the in-car temperature sensor, while the blower is running. As a result, the response period of the sensor is shortened and the control accuracy is increased AT Airjet ‘The temperature sensor (6) for heat exchanger is located in housing for heat exchanger and transmits its resistance to the electonic switching unit for temperature control 6 Temperature sensor for heat exchanger Layout of temperature sensor (6) for heat exchanger 22.8-600/6D. Monovalve with check valve, electric recirculating pump and cold engine lock ‘The monovalve (11) controls the flow rate of the coolant in heat exchanger and comprises 3 magnetic valve, which is provided with plus directly from fuse element and is connected to ground in control range by electronic switching unit in a S-second cycle Without ground connection the valve is always open, if ground is connected, the valve is completely closed, ‘Opening and closing times are activated by the electonic switching unit for temperature control and depend on the deviation from actual and desired temperature The installed check valve (arrow) in lower housing section of monovalve makes sure that the heat ex. changer is not filled with hot coolant when the engine is stopped {monovalve “open Monovolve seas The recirculating pump (30) at front right in engine compartment serves to maintain a uniform coolant flow through heat exchanger even at low engine speeds (Fig. During controlled operation, the pump is switched on by the signal “legroom nozzles open” Electric activation is by way of control unit. 0 Layout of recirculating puma front Fightin engine compartment ‘The temperature switch (2) (cold engine lock) prevents the system from starting at a coolant temperature below 33 °C in functions “ec” and “A and thereby guarantees that no undesired, cold air is blown against passengers. 2 Layout of temperature switeh Feald engine ock! engine 110 838-6007E. Electronic switching unit for temperature and blower control with electric wiring diagram. ‘The resistance values of the in-ear temperature sensor, the temperature sensor for heat exchanger and the nominal value potentiometer (temperature dial) are processed in electronic switching unit for temperature control, Switching unit (9) for temperature control regulates according to requirements a) Flow through heat exchanger via monovalve, by change of mode, that is, switching from “cooling” to “heating” and vice versa, during which in accordance with pertinent in-car temperature conditions, tempered air may simultaneously flow out of legroom nozzles as well as out of center nozzles (overlap), position of fresh air ~ recirculating ar flap, 3) control of blower stages via pre-resistance group (1) by means of switching unit for blower control 19) 9 Electronic contrat unit for 19 Electronic swtching unit for Blower contol 2 fs 1 Precesstance group for blower stwheelhoure ight 838-6009Mode! 1230, 123.1 Electric wiring diagram automatic climate contro! T"prevexsanee group 2 Temperature saith (cold engine tock) 3 Temperature dal 4 Paanbutton switch unit 3" Detrosting 'b Top and bottom ‘alo legroom! © Normal agjustment air condstioning an) Ee (ai conditioning at © OF 5 Blower switeh Temperature wensor for heat exchanger 8 Switchover valve for rpm stabilization lxcepr 123.1) 8 Electtome satehing unit for temperature 10 Fuse box 3 Fuse C16 amps. Fos 8. 16 ampe © Fuse 148 amps. 838-600110 11 Monovaive 12 Blower motor 13 Switenover valve for canter nozzle flap 14 Samtenover valve for legroom flaps, 15 Swterower valve for detrorter nozzle Flaps 17 Soutehower valve for main ai lap 18 Suitchowe valve for fresh airseciculating ar fap 19 Electronic switching unit for blower control 20 Temperature switeh 100 °C for additional fan 21 Relay additional fan (code number 6) 22 Temporarure switeh 52 OC for aaaitvona fan 25 deans! fon 26 Electromagnetic coupling refrigerant comaressor 29 Low pressure sw ton rtrigerant comaressor 28 Relay relrgerant compressor leode number 12) D9 ETRaneten 30 Recirculating pumpShoe Model 1232 Electric wring diagram automatic climate contra 1" Prevesstance group 2 Temperature switch \cald engine lock) 4 Temperature ci! 4 Puthinttan switch unit {Top and bottom (alo feroam! © Normal agjustment air cond tioning on) EC Taieconditioning aff © Of 5 Blower switch Temperature sensor for heat exchanger 2 near temperature sermon 8 Switchover valve for ror stabilization Electron sitching unit for temperature 0 Fue box 3 Pum C: 16 amps b Fuses. 16 amps © Fuse 14.8 amps Fuse 10: 16 amps 83.8-600/11 Fei) yp baer ily | wh | 3 8 Hi fy all f 7 \] 11 Monovaive 12 Blower motor 13 Svotchaver valve for center nozzle tap 14 Sentehover vale lagroom flap 15 Sertenover valve defroster nozzle aps 17 Swatchover valve for main at fap 138 Seatehover vale for ferh air oerculating ai lap 15 Election smtching unt for Dower cont 20 Temperare switch 100 °C for additional Fan 21 Relay odaitional fan and magnetic luteh (code number 63) 22 Temperature saitch $2 9C for suxiary fa8 25 Magnetic counter fr an 25 fadastonal tan 26 Electromagnetic coupling-refrigerant compresior 29 Low preature switch retrgerant compressor 28 Relay teligerant compressor feode number 12) 29 ET Rmtch 50 Recireuiting pure5251 565554 595857 39 3855575847 54 ong 5 verso Color code of additional harness ine Eaves ~Gabrcode Giga 1 Fuse @ termina! 15 X Rey celrigerant compressor terminal 30 rediveliow 10 2 Fuse 8 terminal 15 x Switching unit blower terminal 12 —_rediyelow 25 2 Fuse 10 terminal 15, Switching unit temperature blackired 078 5 Fuse B terminal 15 X Pusnbutton swith ltt rediyetion 078 terminal 12 © Fuse 10 terminal 15 Monovaive bickred 078 1) Pushbutton ewiteh right EGR switen blackired 078 terminal 6 12 ETRewiten Relay rlrigerant compressor bilackiredigreen 0.75, terminal 86 13 Grouse Relay refrigerant compressor brown 07 terminal 85 14 Relay retrgerant compressor Pushbutton switeh blue 10 terminal 87 17 Pushbutton ewiteh right Switching unit temperature black/biue 075 terminal 2 control seminal 70 18 Switching unit emperature Ivear temperature sensor biackibive 08 ‘contra! terminal 10 19 Switching unit temperature Pushbutton switch sight block/areen 75 Eoatol terminal 3 terminal 8 20 Switching unit temperature Pushbutton switeh ght black/vetiow 078 ‘control terminal 12 terminal 8 21 Saiteing unit emperature Pusnbutton switch itt blsck/puroie 075 eantal terminal feeminal 22 Ground Blower motor brown 25 23° Blower motor iground) Switching unit blower brown 078 feral 10, 24 Ground ‘Switching unit temperature brown 075 ontal terminal 6 25 Switching unit temperature Invear temperature sensor brown 078 onal terminal 8 26 Temperature sensor haat Pushbutton switeh ltt brown 078 exchanger terminal 2 2) Ground Switchover vole 1 brown 078 23.8-co0112Color code of additional harness (ctd.) Line Ever tine Color code roe wcton rank © some 2 —Seitchowervave | Switchover vive? brown 075 29. Snitchover valve 2 Switchover vive brown 07s 30, Pushbutton sth rahe Siitenover valve terminal 8 vellowbieck 07 rormnat 2 3) Incar temperature sensor Temperature sensor host row 078 croton 32 Conta anit emi! 2 Raayrtigerant compost biue 07s ssimnai 33 Switchover vane 6 Pusnbutton suite eight town 075 terminal 24 Shtenover ni tempore Panton sie it blac nite 07 comer enna tomo 35 Switeing unit temperature Pusnbutton site et Diack olueiyelion 0.78 conve mat. terminal a 38 Switehing unit temperature Poanbutton stn ite Dlackyelowired 0.78 conver ema trina 37 Switching unt tarperture Temperature sans est backorinied 078 conv tecmna' 9 cnchenger 38 Saiteing unit temperature Snitching unit lower Diack gwenintite 0.78 SSnvolterminat termina 38 Switehing unit bower Pusnoutton ater itt block reenwnite 0.75 mma termeal 40 Pushbutton swteh rine Saitenover valve 5 iuegreenyaion 0.75 terminal? 41 Swtehover sale ermina 3 Switchover vai erin 4 bookie 07 49° Pusnbuttonswiteh rane Seitchover vive buries 076 somal 1D 48 Puanbuttonsteh rane Hontna water ave brownie 078 45 Pushbutton sateh cane ‘Suatehing unit bower velow ree or termina wenn 45 Pushbutton ste rahe Switching uni bower yellow back 076 ‘orm 12 emir 47 Pushbutton ste ee Siitching uni bower valloworeen 078 comet terminal 48 Pushbutton steht Swutehover valve 3 blacked 078 terminal 12 49° Pushbutton stn ett Switchover ve 3 bronnibive 075 termina 9 80 Pushbutton suite itt Switchover vie 2 divepupe 07 terminal 51 Pushbutton sith eft Aecrelating pune Duckvedipunle 0.75 terminal 10 52 Ground Rearevtating pum brown 075 53 Pushbutton sith itt Cold erin eck brown/oiack a7 tema S¢——Shitehing unit blower Resistance aroun soe | oreenbiue 07 termina tt termina 55 Switching unit blower Resistance group stne2 areenivtow 07 emt wma 56 Switching unt bower Resistance aroun stioe 3 orcen ick 10 termina tema 57 Switching unt bower Resistance aroun sage 4 arvenini 18 ‘ermal tema 58 Switching unit bower Resistance groun sage 5 arson 1s tsmna temas 58 Snitching unit blower Resistance group sae 6 oveenies 1s tema termina oo eee Bower motor sreeneed 25 83.8-600/13F. Air path and control of air flaps with vacuum function diagram ‘The fresh air inlet openings are located at left and Fight in front of windshield ‘The spent air from inside vehicle is routed through ‘openings in rear pillars at left and right. The main air flap (arrow, position “open'"), as well as the Fresh air recirculating flap (arrow, position "{cesh ait”) are located in evaporator housing (also refer to £00/17) Main aie lap (arrow) The flaps for controlling the air outlets in passenger ‘compartment, such as ait to windshield, center nozzles and to legroom, are located in air conditioning cabinet ‘The air outlets at left and right for lateral venting can bbe opened oF closed manually only. In center, the center nozzle flap is automatically opened or closed. In addition, manual opening and closing is performed by turning the inserts. Center nozee flap (arr! 838-600/18 FaLayout of electric witchover volves 13 Center nozzle lap 17 Main aie tap, 14 Lagroom tap 18 Fresh aievaciculating air lap 15 Defroster norte tap ‘The vacuum elements (38 to 42) for air flaps in air conditioning cabinet are activated with vacuum by ‘means of the electric switchover valves (13 to 18) All switchover valves (13 to 18) are generally set to passage when energized and will activate all vacuum elements directly {38 2 stage vacuum element for Setronter nazte taps 29 Vacuum element for egroom Tops 444 Theotlelontiee! 40 Vacuum element for enter nozzle fap 444 Throttle forties! 45 Check valve 49 S point datributor 50 3 point aistibutor 3.8-eo0/'s.9 Electronic sitehing unit for temperature contol 29 ETRawmieh| 42 Vacuum element for main air lap 12 Blower motor 2 Vacuum element for 22.8-600116owen am Vacuum function diam automatic climate conteal 13°" Sitchover valve for center nase flan 13 Seutehower valve fr legroom flaps 15. Sevtehover valve for defroster novee flaps 17 Seutchower vai for main ai fp 18 Sevtchover valve for fresh airsecirovlating i lap 35 Vacwum connection atintake manifold 38 Check vaive 39 Vacuum reservoir 8 2atage vacuum element for detroster nozele flaps flape “open”? 39. Vacuum element for legroom Has aps “closed”? 40 Vacuum element for center nozzle lap Itap “closed 421 Vacuum element for fresh or retrelotng ai lap close 442, Vacuum element for main ar fap Nap “closed? 4& Throtte (orice! ‘Aga. Throttle (once! starting 05:82 4S) Check valve (arom - rection of pasagel 48 point astributer 49° point otmbutor 50. paint gatrbutor 8 Boniton “Yeah air" Color code of Yecuum ines ge yellow an = green ogy ft ota ho Nght bive or block 2260011783-601 — Manual and optical function test of automatic climate control ‘The manual test permits checking the function (opera: tion) of all components of automatic climate control system ‘Additional tests for finding the cause of the fault are only required in the event of deviations from the functions or air outlets shown here. Fun engine at idle and at operating temperature during entire test. 3 Temperature dal 4 Pushbutton sltching unit 5 Blower swim Open swivel inserts for air outlet center, left and right Remove glove box (68-140) 1. During electric test on 2-pole coupler of mono: valve (with voltmeter, test lamp) be sure to avoid ashort, which may destroy the electronic switch ing unit for temperature control. 2. At room temperatures > 25 °C the cycling of the heating water valve cannot be readily shown during second and sixth test. For this purpose, the vehicle interior should be cooled down to approx. 22°C (with doors and windows, as well as sliding top) closed 3. Other tests can be made with an adapter for automa tic climate control 126 $89 03 21 00, 22e-601/14, Illustration of special operating condition: Only one button at the time should be pushed, on principle. The operating conditions described be- low are therefore not included in test scope ‘They are mentioned only to assist customers if such a condition has been established by chance. No damage will occur, even if the vehicle is driven for an extended period a) All buttons “a” ~ “e” not pushed: Operating condition similar to “e”, but the lowest automatic blower stage will then be raised to 3rd stage 'b) Button “e” pushed in combi button: System always in switched-off condition. jon with another ‘) Buttons “e” and “a” pushed at the same time: Operating condition similar to "d", but 3rd blower stage will drop to 2nd stage. 4d) Buttons "band “e” pushed at the same time: Operating condition similar to "b", but 3rd blower stage will drop to 2nd stage, ) Buttons “a” and “b” pushed at the same time: Operating condition similar to “a, but legroom flaps will be additionally open. 4) Operation of button “a” (DEF) will always pre- dominate in relation to selector dial and blower. 9) Buttons “b" and “dl pushed at the same time: Function similar to “b", but compressor will be switched off, ‘Significance of arrows in graphic displays of tests 112, Arrows, large Arrows, small Outside air Gray Cooled air Black Heated air White Air outlet (warm! White 83.8-601/2Test: Selector gist Function button Blower n°c “e " "AUTOM © Monovaive closed © Compresior switched off © Main ai ap closes, © Blower not running ‘© Recirculating pump not running ‘The electronic system is ready for operation, Main sir flap clore (arrow), no fresh wap Test 2 Selector dial _—-Funetion button Blower 22°C _— AUTOM" Establish condition “mode change” (overlap) by turning temperature dial slowly in upward or down: ward direction until legroom flaps and center nozzle flap are open (© Monovalve cycting (every 4 to 5 seconds) ‘At temperatures > 25 ° refer to 83-601, item 1 ‘© Compressor switched on at outside temperatures above + 2°C. © Main air flap open (fresh air). © Blower starts after approx. 10 seconds Recirculating pump running Control unit 3 Termperature ail 5 Blowersmiten 3 Function selection buttons 1° Man blower stage (6th stage 9 Automatic blower (2nd staged Minimum blowor stage (Tet tape) a 83.8-601/3Test 3 Selector diat Function button Blower MIN (engaged) ‘© Monovalve closed. © Recirculating valve not running, ‘© Compressor switched on at outside temperatures >2°c. © Fresh air-recirculating air flap in position “ce circulating air” (20 % fresh air, 80 % recirculating air), (© Main air flap open © Blower runs (10 V or Sth stage) Also refer to vacuum function diagram 2 b (83-604). Vacuum elemant 41 for ‘ream ar rctreuating sr fap Inporition “reeireulsting ai Test 4 Selector dial Function button Blower MIN (engaged) “auToM © Monovalve closed. © Recirculating valve not running © Compressor switched off. © Fresh air-ecireulating air flap in position “fresh air" {© Main air flap open (fresh ait) © Blower running (10 V or 5th stage) Also refer to vacuum function diagram 4 a (83-604), Fresh sieeecrculating air lain position "Tees ae" tavrowl 33.8-601/4Test 5: Selector dial Function button Blower MIN (engaged) “e' © Center nozzle flap open, © Monovalve closed (© Fresh air-recirculating air flap in position “recircula- tng air” (20 % fresh air, 80 % recirculating air) (© Main air flap open © Recirculating pump not running © Blower running (4 V or tst staged ‘Also refer to vacuum function diagram 3 b (83-604) Significance of arrows in graphic displays of tests 1-12 Arrows, large Arrows, small Outside air Gray Cooled air Black Heated air White Air outlet (warm) white 40. Vacuum element for center oss ‘lap 44 Throttle lonfice) 45. Check vale 43. point distributor 50 Spointaistibutor Moin ir fap closed (arrow 8 Electronic switching unit for tom perature control, 29 ETR-aniter 42 Vacuum element for main air flap 83.8-601/5Main air flap opened (arrow) Test 6: Selector diat Function button Blower 22°C “AUTOM Set up condition "made change’ (overlap) by slowly turning temperature dial in upward or downward direction until legroom flaps and center nozeles are ‘opened, Wait until blower has switched to 8 V or 2nd stage. 5 V on blower = preparation for next test! ‘© Monovalve cycling (every 4 to 5 seconds). At tem: peratures >25 °C refer to job no. 83-601, item 2 ‘© Compressor switched on at outside temperatures above +2 °C (© Main air flap open (fresh air) © Fresh airrecirculating ar flap in position “fresh air" (arrow) © Recirculating pump running Significance of arrows in graphic displays of tests 1~12. Arrows, large Arrows, small Outside air Gray Cooled air Black Heated air White Air outlet (warm) White 83.8-601/6Test 7: Selector dial Function button Blower 22°C \uTOM" © Blower switches one stage higher (from V to 65 V or from 2nd to 3ed stage). '® Monovalve cycling (every 45 seconds) waecon © Compressor switched off. (© Main air flap opened (fresh air) ‘© Fresh air-recirculating air flap in position “fresh air’ (arrow) © Recirculating pump running, Test 8 Selector dial Function button Blower 22°C © Blower running at max. speed (6th stage) ‘© Monovaive cycling (every 45 seconds) © Compressor switched off © Fresh air-recirculating air flap in position “fresh ‘© Main air flap open (fresh air) Recirculating pump running. Significance of arrows in graphic displays of tests 112. Arrows large, Arrows, small Outside air Cooled air Heated air Air outlet (warm) white 83.8-601/7Test 9: Selector dial Function button MAX (engaged) “AUTOM” © Monovalve opened © Recirculating pump running © Compressor switched on at outside temperatures above +2 °C, © Blower running (10 V or Sth stage) © Center nozzle flap closed (no air from center nozzle) (© Main air flap opened (fresh air) ‘Also refer to vacuum funetion diagram 3 (83-604) Test 10: Selector dial Function button Blower Optional Optional ‘© Blower running at max. speed (6th stage. ‘© Monovalve open. ‘© Recirculating pump running, ‘© Compressor switched on at outside temperatures >2°, (© Fresh airrecirculated air in position “fresh air (arrow) © Main air flap open. Also refer to vacuum function diagram 1 (83-604). a38-6o18Test 11: Selector dial Function button Blower MN © After switching to "b”, cold air should come Immediately out of center and side nozzles Significance of arrows in graphic displays of tests 1~12 ‘Arrows, large Arrows, small Outside air Gray Cooled air Black Heated air White Air outlet (warm) White Test 12: Selector dial Function button Blower 22°C ve" “AUTOM” ¢ Monovalve close. ‘© Recirculating pump not running ‘© Compressor switched off Main air tap closed. © Blower not running ‘Also refer to vacuum function jagram 5 (83-604) 83.8-601/9Test 13: Pull coupling from cold engine lock (2) Selector dial Funetion button Blower “AUTOM” 2 Temperature switch [cole engine lock) engine 102 © Main air flap closed © Blower not running Do not yer plug.on coupling af cold engine lock. 2 Temperature switch Test 14: Selector dial Function button Blower MIN “AUTOM! Feole engine lock) engine 123 (© Main air flap open. ‘© Frosh aie-recirculating air flap in position “recircu lating air” © Blower starts after approx. 10 seconds [5 V to 10V (or 2nd stage to Sth stage) ‘© Plug:in coupling of cold engine lock. For all tests, also refer to electric wiring diagrams. 2 Temperature switch (cold engine lock) dive! engines 828-6010 oon’i q tr -_ Electric wiring ingram automatic elma Model 1320123" Pre cosstance group TTempnrature teh (cold engine lock! Temperature aia) Pushbutton switening unit 3 Detroming| 5 Top and bottom (also legroom) Normal adjustment far conditioning on) EC conditioning of) Ot Blower switeh “Temperature sensor for heat exchanger In-car temperature sensor Switchover valve for rpm stabilization lexcapt 1231) Electronic swtehing unit for temperature Fusebox 3 "Fuse C16 amen. B Fute 8: 16 amp. © Fute 14: 'Bampr ea-coit Blower motor Switchover valve for canter nozzle tap ‘Snitehover valve for legroom flaps Switehower valve for defroster nor2o #laps Shitehover vale for main a flap Suitehowe vale for fresh ateciculating i flap Electronic stoning unt for blower control ‘Temperature switch 100 8C for adsitgnal fan Relay adcitonal Yan (code number 6) “Terporature switch 82°C for adlitional fon ‘adonal fan Etectromamnatic coupling refrigerant compressor Cow preerre switen refrigerant comprestor Fey rerigarane comprescor (code number 12) ETR switch Recirculating pumpElectric wiring diagram automatic climate control Mog! 123.2 1 Prevesistance group 2 Temperature switch (cold engine lock) 3 Temperature ha! 4 Pormburton sw tehing unit 2 Detrostag 15 Top and bottom (also legroom! © Normal adjustment lair 2ondioning on) % EC lar conditioning of) © of 5 Blower switch 6 Temperature sensor for heat exchanger 7 incar temperature sansor {3 Switchower vale for rpm stabilization 4 Electronic switaning unie for temperature contol 10 Fusebox 2 Fuse C16 amps 5 Fite 8: 18ampe © Fure 14: |B amon Fure 10: 16ampe saa-cowi2 Monovaive Blower motor Seatehover valve for cent ‘Sovtchover valve for fg Switchover valve for defroster nozzle laps Swtchover value for main a fl Swatchover valve for fresh ar recirculating ai lap Electronie switching unit for blower contra Temperature switch 100 °C for additional fan Relay addtional fan and magnetie coupling (code number 6) “Temperature switeh 82 2C for additonal an Magnetic coupting for fan ‘Additional ten Electromagnetic coupling rfrigrant compressor Low pressure site religerant compressor Relay rerigrant compressor (code number 12) ETRswiten tape83-602 Preparation for testing, connecting adapter to volt/ohm measuring instrument Preparation for test 1. Remove glove box (68-140), Connecting adapter to volt/ohm measuring instrument 2 Pull 12:point plug from electronic switching unit (9) for temperature control and connect to adapter Yellow test card (issue October 1980) must be used 9. Electronic conteol unit for temperoture control 3 Connect adapter with voit/ohm measuting instru ‘ment to 12-point coupling and switch adapter to test step 1 ea.8-co2183-603 Function test of total system and remedies (with adapter) Note 1. During electric test on 2-point coupling of mono valve {with voltmeter, test lamp), be sure to avoid @ short, since this may destroy the electronic switching unit for temperature control 2. Perform test program in the event of unknown causes of trouble, customer complaints which are not clearly expressed, and following repairs for gua ranteeing all functions. 3. Prior to starting the following test, check all fuses for automatic climate control, auxiliary fan and blower motor. It is additionally recommended to ‘oerform a manual and optional function test of air flaps according to 83-601 9 Electronic control unit {or temperature control 19 Eleetrome swrtehing unit for blower contol Testing voltage supply and connecting lines Vand 6 ‘Switch-on ignition: Position of Nominal value adapter switch 1 uv Nominal value correct | Nominal value wrong ae 1. Test electric lines and fuses for correct connection and interruption. 2. Test battery for state of charge 838-6031)Wiring diagram for test step 1 with adapter 9. Electconi switching nit for temperature contol 10 Fusebox Testing in-car temperature sensor (7) Remove 2:point coupling from in-car tem) ture sensor (7) and connect additional line from ‘adapter to in-car temperature sensor and to multimeter (volt-ohmmeter) Disconnect battery, switch-on ignition. Ambient Nominal value temperature £0.5k22 15°C 15.72 25°C 10.0K2 35°C 65kQ 60°C 2.52 Nominal value correct | Nominal value wrong Ieee eae eee Replace in-car temperature sensor. e3.a-6032Testing connecting lines 6 and 10 Connect 2-point coupling of auxiliary harness from inccar temperature sensor. Connect plug of additional line/adapter to 2-point coupling from harness and bridge 2:point coupling from auxiliary harness, Disconnect battery, switch-on ignition Position of Nominal value adapter switch 2 02 Nominal value correct | Nominal value wrong ae eee eee 1. Check electric lines for correct connec: ton 2, Replace control unit ~~ w~ 2 Coupling trom hamess in-car sensor. Additional hna from adapter © Badge ww w Wiring diagram for test step 2 with adapter 2 In-car temperature sensor 9 Elactrante switching unit for temperature control ww w 3.86029‘Testing temperature sensor (6) for heat exchan- ger and connecting lines 6 and 9 Disconnect additional line/adapter and plug 2 point coupling for in-car temperature sensor (on again. Disconnect battery, switch-on ignition. Position of Ambient tempera: Norinsl adapter ture heat value switeh exchanger £0542 3 15°C 15.7 kD 25°C 100k 35°C 65k2 80°C operating 1.52 temperature Nominal value correct | Nominal value wrong cece eee eee 1. Check electric lines for correct connec: tion, 2. Replace temperature sensor for heat exchanger w wv Wiring diagram for test step 3 with adapter & Temprature sensor for heat exchanger Electronic switching unit for temperature control w w 33.8-603/4 0756Testing temperature dial (3) and connecting lines Sand 6 Disconnect battery, switch-on ignition. Function selection button "e” pushed. Position of Position of Nominat adapter temperature value switch dial £05k 4 MIN (engaged) 1.6 KS 22°C B15 Ka "MAX" (engaged) 1.6K Nominal value correct | Nominal value wrong +. 1. Check electri lines for correct connec: 2. Connect new temperature dial, if test step 7 also shows deviating values. 3, Replace pushbutton switching unit, | ooh et Ee era Ae [eS ie ed o—t dete Wiring diagram fortes step 4 with adapter 3. Temperature ial 4 Pushbutton switching unit Temperature sensor for heat exchanger 8 Detrosting 7. incur tempersture sensor Overall ventilation 9 Elgetronie switching unit fr temperature control © Normal acjustment {ser conditioning 99) EC lar conditioning off ° OF + + 83.8-609/5‘Testing electromagnetic coupling (26) and ‘connecting lines 2 and 6 via switchover valve 8 Disconnect battery, switch-on ignition. Position of Nominal adapter value switch 219 5 4a Nominal value correct | Nominal value wrong dS 1. Check electric lines for correct connec: tion 2. Test switchover valve (8) for ground connection (only if readout is approx. on) 3, Pressure switch refrigerant compressor no passage or refrigerant charge too low (only with readout ©), 4. Replace electromagnetic coupling am Wiring dagram for tet step S with adapter 8 Switchover valve for rpm stabilization 3 Electron smatehing unit for temparature control 26 Electromagnetic coupling refrigerant compressor 27 Pressure switch rerigerant compressor 28 Relay retrigaant compressor t + 83.8-603/6Testing function selection “c" or “e”, as well as, connecting lines 1 and 3 Disconnect battery, switch-on ignition. Position of Function Nominal scaptr—stlection «au switch £302 6 B02 1. Check electric lines for conact connection, 2, Renew pushbutton switch unit ~ ee =p 1 Ae84 of = At) 8 eee Ca a i ee ESS eae ing er eTeh ! aiard Wiring aiagram for et tap 6 with adapter 4 6 5 Pushbutton switeh unit Detrosing ‘Top and bottom 9. Electronic switching unit for emperature contro! 10. Fuse bow Norma position [airconditioning ont EC lr conaitoning of ow + 83.8-609/7 +‘Testing temperature dial (3) and connecting lines Sand 7 Disconnect battery, switch-on ignition. Push function selection button “e’ Position of Position of Nominal adapter temperature value switch dial £15k 7 MIN" (engaged) 2.0 kS2 229 35KQ "MAX" (engaged) — 2.0K Nominal value correct | Nominal value wrong 1. Check electri lines for correct connec: tion 2. Renew temperature dial (potentio: meter). 3. Renew pushbutton switch unit, Fea ieee 3 ce Wiring diagram fortes step 7 with adopter 3 Temperature dal 4 Pushbutton site unit oDetrosiag Top snd bottom Normal agjustment (airconditioning ant EC lair conditioning off) eof + - 83.8-60318 8. Electronic switching unit for temperature controlTesting control line recirculating air and ‘connecting lines 1 and 12 Disconnect battery, switch-on ignition. Push function selection button “c” Nominal value #202 Position of ‘adapter switch Nominal value correct | Nominal value wrong ~~ 1, Check electric lines for correct connec: tion, 2, Pushbutton switch unit defective 3, Switchover valve defective. Wiring diagram fortes step 8 with adapter 44 Pushbutton switeh unit Detrosing TTop snd bottom Normal agjustment Ine conctioning onl EC (air conctioning off on 10 38-6029 9. Electronic switching unit for temperature controlTesting switchover valve (13) for center nozzle flap and connecting lines 1 and 4 Disconnect battery, switch-on igni Push function selection button "e’ Position of Nominal value adapter switch +200 9 45.0 “Nominal value correct | Nominal value wrong 2 1. Check electric lines for correct connec 2. Check switchover valve for center nozzle flap and renew, if required 3. Renew pushbutton switch unit. Wiring diagram for test step 9 with adapter 4 Pushbutton snitch unit 9. Electronic witching unit for temperature contr fo Detrosting 10 Fore box Top and bottom 13. Switchover valve for canter nozzle flap SEC’ tarr conditioning off) > OW + + 83.8-603/10‘Testing function selection “e", connecting lines Gand 11, as well as electronic switching unit for blower control (19) Connect battery, switch-on ignition, Position of Function Nominal adapter selection value switch 403V 10 o6v Nominal value correct | Nominal value wrong Beeeeesemereeee 1, Check electri lines for correct connec: tion, 2. Electronic switching unit for blower control defective. 3. Renew pushbutton switch unit. Wiring diagram fortes step TO with adapter 3 Temperature ial 3 Electronic suitching unit for temperature control 4 Poanburton eaten unit 19 Electronic swstohing unit for blower control Detrosing ‘Top and bottom Normal adjustment lait conchtioning ant EC airconditioning off) of 2.860911Testing mono valve (11), function selection “c”” and connecting lines 1 and 8 Connect battery, switch-on igni Push function selection button “c Position ot —Pasition of Nominal adapter temperature value switch ial 242 " “MIN” (engaged) 2 22°C 159 "MAX" (engaged) © Nominal value correct | Nominal value wrong a ae 1, Cheek electric lines for correct connec: tion 2. Check mono valve, renew if required. 3. Renew pushbutton switch unit. + i a £ i *. + - iamlaaen ea (air condi®.aning on) EC larreonditioning offh © Of 83.8-60311212. Testing blower motor (12) Plug:in coupling of electronic switching unit for temperature control ‘Then pull 2-pole connecting coupling (82) from blower motor and connect 2-pole coupling from adapter, switch on ignition, pull coupling from 33°C switch (2) and bridge with ground. Run engine at idle Position of Blower speed Nominal pushbuttons value in blower 21VU 1A) switch (2a) Pushbutton “h'” Fixed stage 3.5 V (4A) pushed slow Ist stage Pushbutton “g"” 2nd stage 45 VISA) pushed!) 3rd stage 5.5 V(7.5A) 4th stage 65 V (9A) Bth stage BV (138) Pushbutton “Ff” Fixed stage >11V (1BA) pushed fast th stage 9 in wer surroundings interior set temperature dat up to.top in front of “RIN” orn cool surrouncing ot temperature dal before "MAX Nominal value correct | Nominal value wrong ies 1. Check all electric lines for correct connection. 2. Connect new electronic switching unit for tryout, 3. Connect new blower switch for tryout. 4. Renew blower motor. 5. Renew pre-resistance group. se eaa-coaiaww 2 Temperature switch [cold engine Tock) engine 102 2 Temperature switch [cold engine tock) engine 110 ~~ 2 Temperature switch (cold engine 1c) engine 123, ~~ 2 Temperature switch ~~ (cold engine lock! disel engines 83.8-603/14Erecwie wiring diagram automatic climate contol Mosel 23001231 2. Temparature syvtch (cold engine lock! 3 Temperature da! | Posnbutton sniten unit 4 Detrosing bb Topand bottom ils laqroom) € Normal adjustment fair condoning an SEC tare conditioning 18) eof Blower switeh “Temperature sensor for heat exchonger Changeover valve for rom stabilization lexcepe 123"), Electronic switching unit for temperature contol Fane box 2 Fuse 1G amps Fuse 8: 1eampe Fute 14: Bampr e2e-coans 11 Mono valve 12 Blower motor 13 Swotchover valve for canter nozzle tan 18 Switchover valve far legroom taps 15 Switchover valve for defroster nozzle Flaps 17 Switchover valve for main ar flap 18 Switchover valve for eeiteulating ae fap 10 Electron smitching unit for blower contro! 20 Temperature smiten 100 %C for ausiary for 21 Relay auxiliary fon (code number 6) 22 Temperature susten 82 8C for auxiliary fan 28 unitary fan 26 Electromagnetic coupling ~ refrigerant compressor 2) Lowreseure sw teh refegerant compresso” 28 Relay relngerant compressor (cade number 12) 29 ETA smiten 40 Recirculating pumpElectric wiving diagram automatic climate contol Mode! 123.2 Prevreestonce group perature switch (cold engine lock! Temperature oil Pushbutton sunteh unit 1 Top and bottom (also legroom! © Normal adjustment tair conditioning on) BEC tar conditioning 216), cor Blower switch “Tempersture tensor for heat exchanger Inear tersperature sensor Swrtchover salve for rpm sabiization Electron switching unit for temperature contol Fuse box 2 Fuse © 16amps, bFuse 8: teampe Fuse 14 Bamos Fuse 10:16 amps 838-603116 11 Mono valve 12 Blower motor 14 Sertohower waive for center nozze lap 1 Stutchower valve for tegroom Hops 16 Switchower salve for detroster nozzle flaps 19 Seutchower valve for main a lap YB Seitchowe: valve for Pesh sr recirculating ae tap 19 Electronic switching unit for blower control ature switch 100 2C for auxiry fon unilary fan and magnetic coupling number 6 22 Tomparature siteh 62 9C for auxiliary fan 23 Mognetc coupling for fan 25 Auxiliary tan 36 Elactromagnetic coupling ~ refrigerant compressor 23 Low pressure switch rtrgerant compresio" 26 Relay verigeront compressor Icode number 12) 29 ETR omen 50 Recieculsting pumpPlug 2pole coupling of harness to in-car temperature sensor, Connect battery, switchon ignition, run engine at idle. Checking switchover valves for main air-, recirculating air, center nozzle-, defroster nozzle-, and legroom flaps: recirculated a Function Mode Main air Recirculating Center Defroster Legroom selection flap air flap nozzle nozzle flaps flap flaps (fresh air indication in) a Heating mode 100 100 closed open closed ry Heating mode 100 100 closed open open Cooling mode 100 20") open open open © Heating mode 100 100 closed Leak air open Cooling mode 100 20") open closed closed a Heating mode 100 100 closed Leak air open Cooling mode 100 100 open closed closed e of closed 20 closed open closed "1-1 the inscar temperature is 3°C higher than the temperature set on temperature dal, the system operates with Flap position correct, Flap position wrong 83.8-603/17 1. Check electric lines for eorrect connection 2. Check vacuum lines for correct assembly (refer to 83-604). 3. Check respective switchover valve and replace, if required (refer to 83--604) 4. Check respective vacuum element and replace, if required (refer 10 83-604),‘Testing cold engine lock (engine temperature below 33 °C) Switeh-on ignition, push function button “e”, pull electric connecting plug from cold engine lock and bridge (ground) Heater blower should start Heater blower starting | Heater blower not starting . 1. Check electric fines for correct ‘connection, 2. Check blower control {test step 12) 3. Change pushbutton switch unit. 2 Temperature switch (cold engine lock! engine 102 ‘Attach plug to cold engine lock and run engine warm at approx. 2000/min, Push function selection button "c" (Engine temperature > 33 °C) Heater blower should start. Heater blower starting | Heater blower not starting 2. Temperature switch (cold engine lock) engine 110 Renew cold engine lock. 2. Temperature switch {cold engine lock) engine 123 93.8-603/182 Temperature switch (cold engine ck! dese engine Checking mono valve for leaks Set temperature dial to "MIN" engaged, push function selection button “b”. Run engine to operating temperature {function test bench) Heat exchanger should remain cold, that is, no heated air should come out Heated air not Heated air coming coming out out 1. Check whether plus and minus are connected to coupling for mono valve Caution: short circuit risk! 2. Connect electronic switching unit for temperature control (8) for tryout 3. Renew mono valve (11) End of test 83.6-603/19 Cs < 8 Cf Eh =) ina e ce83-604 Vacuum function diagrams Fuetion selection "> Idetrontngh 13° Sentehover valve for conter Nozzle fap 13 Sautehover valve For fegroom laps 15. Shetchower ae for eon nora aps 37° Shtchover valve for main aw tap 12 Soutchover value for eth srreiculatng sr lp 38. Vacuum connection on intake manifold 38 Check valve 37 Vacuum rerervor 38 2 tage vacuum element for deroster nozzle taps iteps “open"I 33, Vacuum element Tor leyroom Ila lap “closed” 40 Vacuum element for center nozzle flap ilep "closed"? 421 Vacuum element for fresh airroireuating ar fap Iposiion “eesh ai") 42° Vacuum element for main avr tap ap “open 24 Throttle fortice 45 Check valve larrow= flow direction) 48 Gone astibuor 49° @point dstrioutor 50. S-point dstribotor Color code of ‘acum ines ge yellow 5 = areen a” -a8y ft rea! vas = white ‘noI= ight blue w= block a2a-c04it‘vacuum function diagram 2 automatic climate contrat Fanetan selection “0 heating 3 15 Swutchover valve 10" legroom tap Swatchover valve for main a fla Soutchover valve for fresh 3 ecrculating ar fap ‘Vacuum conneetan on intake manifold Check valve Vacuum reservoir 2tage vacuum element for defroster nozzle flaps (Slaps “open Varuurs element for lagroom laps Hap. “onen' Vacuum element for conter nozae Hap (lap “closed") tr element for frerh a recirculating a lap iposition “fresh ai") Vacuum element for main ai flop ilap “open? Thratte (orice) Check valve (arrow Spoint astidutor point distributor point gitributor Color cove of ge yellow a Breen ft re’ tee = white hb Hane bive 83.8-604/2 flow direction)\Vacuurn function diagram 22 automatic elimate tol Fanetion selection "Beating 13" Setchover valve for center nozzle lap 14 Switchover valve for legroom flaps Soitchover value for detroster nozzle laps 6 17 Soitehover vale for main ai lap 18 Switchover valve for fresh ar-eeireulating i flap 5 Vacuum connection on intake manifold 38 Check valve 37 Vacuum reservar 38> Stage wecum element lor defromer nozee Has Nap “open” 39 Vacuum element for legroom Ils "lap open? 40 Vacuum element for center nozze lap Nap “open” 45 Vacuum element for fresh arrecreuiating sit Pap (position “eesh air") 42 Vacuum element for main a flap lap "open"? 44 Throttle lorstce! 45 Cheek wala (row 48 Goon dntedutor 49 Sipoint dutributor 50 pone garnbutor Color code of @ -asy Fe cred Hole fghe bie 83.8-604/3 Tees ai)Low wes ‘Vacuum function diagram 2b automatic limate contol Fanetian selection "BIeoaling recirculating ail 13” Sartenover valve for canter nozzle lap TH Shitenover valve for legroam tape 15 Switehover valve for defroster nozzle flaps 17 Sawtehover valve for main st tap 18 Srmtchover valve for ean air-recirculating air flap 35. Vacuum connection on intake manifols 38 Check valve 38 Ztoge vacuum element for defroster nozzle flaps (laps 39 Vacuum element for lopfoom Tlas lap “open 440 Vacuum element for center nozae lap (lap open") 4) Vacuum element for fresh or-recreulating si fap Ipostion “recirculating ait") 42 Vacuum element for main ai lap (lap “open”? 42 Throttle lortice) 45. Check vave (arrow = flow direction! 48 Gpointastrbutor 49S point dstrbutor 50 S.pointsitetbutor Color coe of an -areen fs = white fot Ht bive so black 838-6044‘Vacuum function diagram 3 automatic climate control Funeton selection "e” theating) 13” Sertehover vale for center nocte flap 14 Sontchower vale fr legroom lisps 15 Shtchover valve for tronter morale taps 17 Sontchower valve for main air 18 Swutchower valve for fresh ar-ecreulating ar ap 38 Vacuum connection on intake manifals 36 Check valve 31 Vacuum rerervir 538 2staye weuum element for defroster nozzle taps (laps “closed” fra teak ar share! 3a Vacuum element for legroom taps (taps “open? 40° Vacuum element for center nozzle Ml (lap "closed" 431 Vacuum element for Hesh ir reireulating ar fap [postion “Yresh air") 22 Vacuum element for main i lap lap “open” 44 Throttle (ontice) 45. Check value larraw = flow direction) 48 point aistrdbutor 430 point datributor 80 point dstenator Color cove of f= block 83 8-604/5Furnetion selection “e'leooling ~ resh ai 13" Samtchover valve for center ngezie lap 13 Sevtchover valve for tegroom tlape, 15, Switchover valve for deroster nozele Maps 19. Switchover valve for maine tape 18 Siutehover valve for fresh aie recreulating ai op 35. Vacuum connection an intake manifold 38 Check valve 37 Vacuum rereroir 38 2stoge vacuum element for defroster nozzle Flaps (taps “closed” | 33. Vacwum element for layroom fpr lap “closed” 29. Vacwui element for center nozae tap (fap "open"? 42)_Vacuvm element for fresh arrectraulating sir flap (nottion “fresh air") 22. Vacuum element for main a fap tlsp "agen 4a Thowle forties) 45 Chock valve lrrom ~Hhow direction! 48. Gooine diatributor 49 point dietnbutor 50 Spaint aistabutor Color code of Gn — deen a grav alight bive sw - black e38-c0816‘Vacuum function diagram 3b automatic climate contr! Faction selection "e" man. cooling = recreulating sr) 3 a 3 0 18 8 % y 38 3 ao a2 as a 3 50 Switchover valve fr groom flaps Switchover valve for doroster morale flaps Seutchover valve far main a flap Switchover valve for fresh air recirculating ai fap Vacuum connection on intake manifold Check valve Vacuum reservoir 2 Stage vacuum element for defroster nozzle flaps (laps closed”) y ‘Vacuum element fr legroom flape (ape slo Vacuum element for cenrer nozae "ap flap acusim element for fash ar recirculating se Vacuum element far main ai lap flap “open? ‘Thrattie(ortcs) Cheek valve (arrow « flow aiection! Soint cstributor point astnbutor ‘point distabutor Color code of be = yellow gn =araen ® -arey = ight bive black 838-6047 recirculating aie")Vacuum function diagram 4 automatic climate contol anetion selection "al (heating economy! 13” Satenover valve for center nozzle Hap 14 Switchover valve for legroom laps 1 Saitehover valve for detroster noz2e flaps 17 Switchover valve for main at fap 18 Switchover valve for fresh aerecreutaing ai lap 35, Vacuum sonnection an intake manitols 3G Check valve 37 Vacuum reservoir 382 stage vacuum element for defroster nozzle flaps (laps “closed! eth igak ar share) 29 Vacuum element tor laproom tips "laps open" 40. Vacuum element for center nozzle Ilan (lap "slosea"?) 42) Vacuum element for fresh ait recirelating a fap (postion “rash ai) 43 Vacuum element for maim ai flap (ap "open" ‘44 Throttle lores! 435 Check vale (arow = flow direction) 48 Gpoint dstabuter 49S point chataoutor 50 Spon distabutor Colar code of ge yellow -arey ft fed fbv= ight blue 838-604/8Vacuum function diogram 4a automatic climate control Funetion selection "sealing - economy) 13° Sitehover valve for center noezie Hep 414 Swatchover valve for legroom taps 1S. Swutchover valve for detroster morale Maps 1° Srwschover valve for main atop 18 Sauichover valve for fresmaterecrculating ai lap 38 Vacuum connection an intake manifold 36 Check valve 3) Vacuum reservar [BB 2srage vacuum element for defroster nozzle flaps (laps “closed”) 39 Vecuum element for leyroom flan tiapr “losed") 40 Vacuum slamont for center nozzle Hp (lap "epen” ‘31 Vacuum element for fesh arrecirculating ar fap (postion “ees ai") 42 Vacuum element for main ai flap (lap “open”? 44 Throtte lorfce! 45 Check vale (arrow 48 Grpoint dntedutor 49 point intsbutor 50 point detributor low direction) Color cove of ge =yaliow On = green a = ary ft red (ee = white Fb taht bive fw black 83.8-604'9,Vacuum function diagram § automati climate contol Function selection “e'"folt — ignition on) 13°" Sentchover valve for center Nozze flap 12 Sevtchover valve for lagroom Flaps 15 Switchover valve for dtrasternovale flaps 17 Seutchover valve for main at tap 18. Sautchover valve for fresh airreereuating ae tla 35. Vacuum sonnection on intake mantels 36 Check valve 33 Vacuum rorervor 38 2 sage vacuum element for defroster nozzle taps slap “closed” 39. Vacuum eiomont for legroom flap lap 'losad) 40 Vacuum element for cantar nozze fap ‘open fresh arrectreulating ai fla (position tegh ar") 42. Vacuum element for main avr Hap (lap "stored 48 Throwtle fonfice 45 Check valve (ar7ow = flow aivecvon) 48 Spot dstnbutor 490 Spoint ehrtbutor 50 Syoint detabutor Color cous of Be = yellow a -aioy 1838-6041083-607 Output test Conventional tools 1 suction pressure gat 1 bar gage pressure to anaes or assembly 10 bs gaepresure 1 high pressure gage ae 0-40 bar gage pressure 3 thermometers 20°C + 70°C 1 hygrometer Note On engine M 102, during test for cooling capacity, pull off coupling on 100 °C switch for electromag- netic fan coupling and connect to ground, so that the fan is continuously tuning along. For tests in workshop, in the event of complaints due {0 insufficient cooling or heating capacity and for ‘rouble diagnosis on air conditioning systems, proceed according to the following test method, which is applicable for ambient temperatures from + 20 °C to + 40°C All control values ean be read after 10 minutes of constant operation, The values named are max. values and should not be exceeded, A, Refrigerant capacity Test The vehicle should not be exposed to sunshine before ‘and during test 1 Test tension of V-belt for compressor drive Layout 100 °C ~ snitch tor M102 20 Temperature switch 100 °C tor Btectromagnetie fan coupling 838-60712. Push function selection button “e" and run engine at idle. On sight glass in receiver dehydrator, check whether the coolant flows through free of bubbles shortly after switching on electromagnetic clutch, If refrigerant charge is insufficient, fil up system. If refrigerant loss exceeds 200 g, check system for leaks. 3 Open elements for center nozzles, as well as left hand and righthand side vents 3 Open elements for center nozzles, as well as left hand and righthand side vents 4 Attach a thermometer for outside air temperature (ambient temperature) approx. 2 m from driver's side 5 Place a hygrometer into storage tray of center console, 6 Connect suction and pressure gage to service valves, 7 Plug one thermometer each into center nozzle and lefthand side vent 8 Open window, close vehicle doors and engine hood. 9. Temperature dial engaged in “MIN” position, Push blower switch (f) 6th stage 10 Run engine at approx. 2000/min. Temperature di 43 Pusnbutton switch unit ‘Blower switch 838-607211 Read data on thermometers and pressure gages, 2 well as on hygrometer, after an operating period of approx. 10 minutes and compare with values on table Note: Specified data are max. data and should not be exceeded, 34-6073 Engine 102 1) Relative humiay Ta Outside tomperature °C} A Airoutlet temperature °C) 5 Brossure betorecompresir (bar). C.Prassure ater compressor (bar B Coolant temperature 20) or Al engines except engine 102 1 Retative mum To Ouse temperature °C) 2 ir outie temperature °C) B Pressure betore compresior bar Pressure after compressor Ibo! Coolant temperature fC}12 Check cutout temperature of ETR switch (29) by plugging 1 thermometer into center nozzle. Push ‘blower switch (h) 1st stage and pushbutton (c) im control unit and run engine at approx. 2000/min. ‘After 3rd cutout of electromagnetic clutch, the ‘outlet temperature should amount to approx. + 4 °C, but should not be less than + 3 °C. Note: If cooling capacity is insufficient or outlet temperatures are below + 3 °C, check capillary of ETR switch (29) for correct assembly (slit into guide tube up to red mark) or replace ETR switch B. Heating capacity Test 1 Start vehicle engine 2 Push function selection button “a”. Blower ‘operates in 6th blower stage 3 Plug thermometer into defroster nozele at the left. 4. Keep engine running at approx. 2000/min after attaining operating temperature. 5 Read thermometer after approx. § minutes, ‘Thermometer should indicate approx. 55 to 60 °C. Note: If heating capacity is insufficient, check engine thermostat or mono valve and replace, if required. 83.8-607/4 rs) ie83-614 Preparations for vacuum test Data Permissible leaks per vacuum circuit 30 mbar/min. (without vacuum reservoir! at 400 mbar vacuum ‘50 mbar in 10 min, Permissible leaks in check valves pee 20 mbar/min, etmissble leaks in remaining componen' cena See 2 300 mbar vacuum Plug-on length of connections 10 —12 mm Special tools Tester for vacuum systems 116 589 25 21 00 Distributor 115 805 03 22, Self-made tool 1 blind plug Welding wire 4 mm dia. 40 mm tong Note ‘The vacuum system is. subdivided into 7 test circuits {fa given trouble prevails (e.g. center nozzle not ‘opening) the respective circuit can be tested first If 3 leak or functional trouble is suspected in entire vacuum unit, proceed according to 83-615 and perform each time the first test step (total test) of the individual vacuum circuits until the faulty vacuum cireuit is found. Then continue testing the respective circuit until the actual fault is found, aga-eran1. Run engine warm to approx. + 60 °C. Cold engine lock (2) is switched off. Then shut off engine again. 2 Temperature switch (cold engine lock) engine 102 2 Temperature smiteh (cold engine tock) engine 110 2 Push function selection button “a! 2 Temperature smiteh [cold engine lock! engine 123 2 Temperature switch [cold engine lock) diesel engines 38-614283-615 Testing check valve and vacuum reservoir ‘These tests are omitted for diesel madels a} Testing check valve 1 Pull vacuum line color code green yellow from check valve (8) and close this connection with a blind plug 2. Pull vacuum line color red-grey from check valve (8) and connect vacuum line from tester (refer to arrow) to check valve, evacuate and read pressure gage readout 3. If gage shows a pressure increase, replace check valve (8). bb) Testing vacuum reservoir 4. Pull vacuum line color code redigrey from connection, 5 Connect vacuum line from tester to redvarey line and evacuate. 6 If readout on pressure gage changes, replace ‘gasket of vacuum reservoir (92) and also replace vacuum reservoir (32), if required aa8- 61511\Yeeuum function diagram automatic climate contro! Function selection "a Idetrostng! 15 0 18 8 8 a Ey 40 a Svutehaver valve for center nozzle flap Switchover valve for legroom Has Switchover valve for defroster nozzle aps Swrtenover valve for main ai fap Sartchover valve for fern arr-racroulating ir fap Vacuum connection an intake manifold Check valve 2stage vacuum element for defroster nozzle flaps Maps “open”? Vacuum eiemont for legroom flaps aps “closed”? Vacuum element for center nozale ap (flap "closed" Vacuum element far fresh arreetreiating a” fap (postion “fresh air") Vacuum element for man air flap (lap “open Throttle (ortice) Cheek wave arrow = flow direction) Bipoint distributor ‘point distbutor point shetburor Color code of 1838-6151283-620 Testing vacuum circuit I, I! and III A, Testing vacuum circuit | Ignition is not switched on. 1 Pull vacuum line yellow-green from check valve ) 2 Connect vacuum line from tester to vacuum line green-yellow, evacuate and read pressure gage readout, 3 If gage shows a pressure increase, test switchover valves individually (83-629), B. Testing vacuum circuit I! with vacuum element (38) for defroster nozzle flaps stage 1 1 Remove lefthand cover under instrument pane! (68-150) 2. Remove optional switch 3 Remove cover for optional switch, 4 Pull red-white vacuum line from switchover valve (15) and connect tester 5 Evacuate vacuum circuit I, while paying attention 10 operation of defroster nozzle flaps. If gage shows pressure increase, replace vacuum element (38) or vacuum line 38-6201C. Testing vacuum circuit III, with vacuum element (38) for defroster nozzle flaps stage 2 1 Remove glove box (68140) 2 Pull red/light blue vacuum line from distributor (49) and connect tester. 3. Evacuate vacuum circuit II] If pressure on pressure ‘gage increases, replace vacuurn element (38) or vacuum line 40 Vacuum element for center norale fap 44 Throwle forte! 45 Chock valve 49° Spoint ehetntbusor 50. point astrbutor 38 2tage vacuum element for Gatroster nozzle taps 39 Vacuum element for leg room flape 44 Throttelontice) 4 Install lefthand cover under instrument panel (68-150), 5. Install cover for optional switch. 6 Install optional switch 7 Install glove box. 83.8-620/213 Switchover valve for center nozzle flap 13 Shatehover valve for legroom flaps 15. Shitehover valve for det-onter nozzle flaps 37. Swtenover valve for main air Hap 18 Sputchower valve for fresn aireeceulating i flap 35. Vacuum connection on sake mani 36 Check vave 37 Vacuum reservoir 438 DStage vacuum slament for defroster nozzle laps (laps “closet 39 Vacuum clement for legroom fps taps "elased"? 449, Vacwim slament for center nozre fap flap "elosed”) 41 Vacuum element for fresh airtecirutating ar lap (positon “recirculating air") 422° Vacuum element for main a fap Tap “closed” 44 Tirotte fontice 45 Cheek vale (arrow = flow direction) 48 Gpamtastnbutor 49° point aistabutor 50 Spoint datnbutor 4 =areen moore ‘= te ov Hight bive fw black 83.8-620/9,83-622 Testing vacuum circuit IV, V and VI A Testing vacuum circuit IV with vacuum element (40) for center nozzle and check valve (45) 1. Remove optional switch 2. Remove cover for optional switch, 3 Pull rediblack vacuum line from switchover valve (13) for center nozzle flap and connect to vacuum tester (test circuit 1V) and evacuate 4 If pressure on measuring instrument increases, test vacuum element (40) individually, remove glove box for this purpose (68-140) 5. Install cover for optional switch 6 Install optional switch 7. Install glove box (68~140) 8 Check automatic climate contro! for function 38-6221B. Testing vacuum circuit V with vacuum element (39) for legroom flaps 1. Pull red/yellow vacuum line from switchover valve (14) and connect tester 2 Evacuate vacuum circuit V, while paying attention to operation of legroom flaps. In the event of a pressure increase on pressure gage, check vacuum fine for leaks or replace vacuum element (39) (83-665) C. Testing vacuum circuit VI with vacuum element (41) for recirculating air flap 1 Pull green vacuum line from switchover valve (18) and connect tester. 2 Evacuate vacuum circuit VI. In the event of a pres sure increase on pressure gage, check vacuum line for leaks or replace vacuum element (41) (83-665), 3 Install cover at the left under instrument panel (68~150), 4 Install cover for optional switch 5 Install optionat switch 6 Install glove box. (68-140). 83.8-622/2 ou y aie LI ee dere13 Switchover valve for canter nazae tap 14 Sovtchower valve for lagroom tape 15 Suvtchover valve for detrorter nozzle flaps 47 Saitchover value for fresh avergereulating ar tap. 18 Swtchowes valve for teen aieracieeulating ar 3p 35 Vacuum connection on intake manifold 536 Check valve 37 Vacuum reservoir |B8 2 stage vacuum element for detroster nozzle flaps laps “open”? 39 Vacwum element for legroom flaps Maps. “open 420 Vacuum eloment for center nozzle isp tap "open" 4 Vacuum element for fresh irecitelating i flop Iposition “Yresh aie") 482 Vacour element for main ai flap lap “closed”? 44 Throttle lontice) 445 Check valve (arrow = flow erection! 438 Spomtaistrbutor 49 S point datributor 50 S point distbutor Color code of ge yellow an = Green o> Sray fee = white We Nghtbive fw black 238-622383-624 Testing vacuum circuit VII 1. Remove glove box (68140). 2. Remove optional switch 3. Remove cover for optional switch 4 Pull red vacuum line from switchover valve (17), and connect tester. 5 Evacuate vacuum circuit VII while paying attention to function of main air flap. In the event Of a pressure increase on pressure gage, replace vacuum clement (42) (83-665) 6 Install cover for optional switch 7 Install optional switch. 8 Install glove box. 838-6241se om 13 Switehover valve for center nozae fan 14 Saitenover valve fr legroom Tape 18 Sevtehover valve for Gefrorter nozzle taps 17 Santehower vale for main ai ap 18 Sotchover valve fr fresh air-ecreulating ae tap 235 Vacuum connection on intake manifold 36 Check valve 37 Vacuum reservoir [38 2atage vacuum element for defrost 39 Vacuum element for legroom flap (lap “closed” 420 Vacuum element for conter nozze flap (lap “closed” 42) Vacuum element for fresh airteeeulating air Hap tpotition “reciculatng air”) 42 Vacuum element for main air lap (lap "open"? 44 Throttle (orice! 45 Check valve (rrow = flow direction! 488 G-pomt distributor 49 4-poimt aistibutor 50 Spoint datribator nozzle laps lage “open”? an = areen or = ory fae = ite oi ght btae fw back 38-624283-625 Removal and installation of mono valve Removal 1. Drain coolant. 2 Disconnect battery. 3. Loosen hose clamps on both heating water hoses and pull off hoses. 4 Pull electric coupling (2 pole) from mono valve a 5 Unscrew both fastening screws and lift mono valve from holder 11 Mone valve Installation 6 Prior to installation of mono valve, check ‘grommets between mono valve and holder for damage and renew, if required. 7. Serew mano valve (11) with both screws to holder 8 Attach 2,point coupling to mono valve (11). 9 Plug hoses on mono valve (11) and fasten by ‘means of hose straps, 10 Connect battery 11. Fillin coolant and check cooling system for leaks. 12. Check automatic climate control for function. aa8-625/183-628 Testing switchover valves Data Permissible leaks for individual 20 mbar parts of vacuum system at 300 mbar vacuum Special too! Tester for vacuum systems 116 589 25 21 00 Blind plug 000 987 11 45 Preparation for test 1. Remove optional switch as NN Ace aera 2. Remove cover for optional switch, 3 Pull S:point distributor and vacuum line from switchover valve (13, 14, 15, 17, 18), 4 Pull electric couplings (2:pole) from switchover valves. 62.8-628/1Testing 5 Connect tester to connection A of switchover valve and evacuate. ‘Vacuum should remain at permissible values, If tester ‘shows a pressure increase, the switchover valve is detective 6 Test electric function of valve by applying voltage. Valve will now open. Readout on tester returs to 2210, 7 Connect tester to connection B. Close connection ‘A with blind plug, apply voltage and evacuate. Vacuum should remain at permissible values 8 Disconnect voltage on switchover valve. Readout (on tester returns to 2er0. 9. Reconnect vacuum li diagram according to function 10 Reconnect electric coupling (2-point) 1 t0 5. 83.8-628'2 1834-10032/1 Se Fie, CMY Ace mera aes o83-630 Removal and installation of recirculating pump. Removal 1 Drain coolant 2 Loosen hose straps (53) and pull off hoses. 3. Remove electric plug connection (60) from holder and separate. 4. Unscrew recirculating pump (30) from holder (59). Note: For removing holder for recirculating pump, loosen 2 serews M 6 x 10 from below. Installation 5 Clip recirculating pump (30) into holder (59), 6 Plug electric plug connection (60) together and push into holder 7 Plug-on both hoses, tighten hose straps (53) 30 8 Fillin coolant and check cooling system for leaks. © Check recirculating pump and automatic climate control for function, pushing DEF button for this purpose 228-620183-635 Removal, installation and disassembly of control unit A. Removing control unit 1. Disconnect battery, 2 Pull control knobs from radio, 3. Remove radio molding 4 Unclip molding for cantrol unit (arrow and screwdriver} 5. Unscrew both serews left and right top (arrow). 6 Slightly pull out holder for control unit at top {arrow) and then lift out in upward direction 7 Pull off 12:point couplings teft and right, as well {8 sockets for instrument lights. 83.8-695!78 Unserew three screws (arrow) and remove control unit. Control unit sem B. Removal and installation of temperature dial Removal 1 Force out clip (63) and the one underneath, pull temperature dial (3) from control unit Installation 2 Plug temperature ial (3) to control unit and fit both clips, verve 93.8-698/2C. Removal and installation of blower switch 1 Remove plastic cover (refer to arrow) from control Unit, starting at blower switch (5), so that pushbuttons are falling out individually, Push out clip (68) 2. Unclip blower switch (5) from control unit and pull off Installation 3 Press blower switch (5) with clip (64) against control unit, mount plastic cover. Put back push: buttons under slight pressure with a rotating motion (pay attention to sequence and position of symbols) D. Installing control unit 1 Place control unit into holder and tighten with three screws larrow) 2 Plugon 12.pale couplings left and right, as well 1s lamp sockets for instrument lights. 3 Insert holder for control unit from above into cutout and press on (arrow). e24-625/94. Fasten both screws left and right at top (arrow). 5 Clipin molding for contro! unit. 6 Presson radio molding 7. Plug-on control knobs of radio, 8 Connect battery, 9. Check automatic elimate control for function. Control unit ansean 83.8-636/483-640 Removal and installation of i ‘car temperature sensor Data Resistance at + 15 °C ambient temperature 18.7 05K2 + 25°C 10.0*05k2 +36°C 6.02052 + 60°C 25+ 05k2 1. Disconnect battery, 2 Remove glove box 2 Pall off air hose 4 Pull off electric coupling (2-point) 5 Pull off temperature sensor lower half in downwvard direction, while raising holders slightly panel in upward direction oS ‘ — y Instaation j é 7 . 7 Test in-car temperature sensor (7) with ohmmeter. 8 Insert in-car temperature sensor (7) from above into instrument panel and fasten to lower halt 9 Plug-on 2-pole coupling, Slip air hose on in-car temperature sensor lower hal while paying attention to installation free of kinks (arrows) 10 Connect battery. 11. Check automatic climate control for function. 3.8640183-643 Removal and installation of air jet nozzle Note Be sure to instal ar hose in such @ manner that no change of cross section (inside) will occur 1 Remove legroom cover atthe rigth 2 Pall both air hoses trom air jet nozzle (47). 3 Unscrew screw of holder for air jet nozzle (47) 4 Pull air jet nozzle (47) out of blower box 5. For installation proceed vice versa 6 Check automatic climate contro! for function. Operational arrow) airjetnozste (a9) Defective ar jt nozzie eaa-6aait83-645 Removal and installation of temperature sensor for heat exchanger Data Resistance at + 15 °C ambient temperature 18,720.52 + 25°C 100+ 05k +35C 65+05K2 + 80°C 152052 1 Control unit (83-635) 2 Pull 2point coupling from temperature sensor (6) and then pull temperature sensor out of heater box. Installation 3. Test temperature sensor (6) with ohmmeter. Then slip sensor into heater box and mount 2-point coupling 4 Install control unit (83-635) 5 Check automatic climate contro! for function. c < 6 22.8-645/183-650 Removal and installation of ETR switch Data Cutout temperature °C ont Note Changing adjustment of ETR switch in direction of “ealder" is not permitted. In the event of trouble or if the cutout point is not correctly set, always re: place switch 1) Remove righthand cover under instrument panel (68- 150) Bh] SE 2 Pull of electric Hat plug and unscrew serows at i. the right and left from ETR switch (29), se 3 Carefully pull ETR switch (29) toward the rear and then pull capillary from ETR switch out of guide tube in air conditioner housing, making sure that a counterhold is applied to guide tube. Installation 4 Slip capillary of ETR switch up to red mark into guide tube in air conditioner housing 5 Screw ETR switch (26) 10 air conditioner housing by means of 2 screws. 6 Mount electric flat plug 7 Install righthand cover under instrument panel 8 Check automatic climate control for function (83-607), 838-650183-660 — Removal and installation of switchover valves Removal 1 Remove optional switeh, 2. Remove cover for optional switch, Pail off vacuum lines from switchover valve (13, 14, 15, 17, 18}, check color code of vacuum lines first and mark, if required 4. Pull off electric coupling (2-point) and unscrew switchover valve from holder on air conditioner housing VR 349 SE Sn Switchover valves for 13 Canter nozzie lap 18 Legroom flap, 15 Detroster nate fap 17 Maina fap, 18 Fresh wirvececulting ai flap Installation 5 Check switchover valves (83-628), 6 For installation proceed vice versa while paying attention to electric wiring diagrams and vacuum circuit diagrams 7. Check automatic climate control for funetion, ea.a-e60r,83-665 Removal and installation of vacuum elements Data Permissible leaking of vacuum elements 20 mbar/min at 300 mbar vacuurn Plugon length of connections Special too! 116 689 26 21 00, Tester for vacuum systems A. Vacuum element (40) for center nozzle Removal 1. Remove instrument panel (68-100) 2 Pull vacuum line from vacuum element (40). 3 Remove locks from holder by means of screw: driver (arrow) 4 Loosen linkage on center nozzle flap (arrow) and ‘remove vacuum element (40), 83.8-665/1Installation 5 Install vacuum element (40) and fasten linkage to ‘center nozzle flap using a new lock. 6 Attach vacuum element (40) with new locks (with rubber washers underneath) to holder. 7. Connect tester for vacuum systems and check vacuum element (40) for function and leaks. Then pplugon vacuum line 8 Install instrument pane! (68-100), 9. Check automatic climate control for function, B. Vacuum element (38) for defroster nozzles Removal 1 Remove cover at left under instrument panel 2 Pull vacuum lines from 2tage vacuum element (38) 3. Remove locks from holder by means of a screw driver. 4 Loosen linkage from lever for defroster nozzle flap and remove vacuum element (38), 83.8-668/2