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Model and System Identification 00

This manual applies to the following passenqer cars, starting model year 1977
USA Model Year
System Type Model Engine From To Chassis
Heatinq/ventitation and 230 115.954 1977 1978 123023
Air Conditioning System I 2400 616912 1977 1983 123.123
Air Conditioning System II 3000 617.912 1977 1980 123.130
Automatic Climate Control 300 CO 617.912 1978 1980 123150
300 TO 617.912 1979 1980 123190
280 E 110.984 1977 1980 123.033
280 CE 110.984 1978 1980 123053
Air Conditioning System III 3000 617.912 1981 1981 123.130
Automatic Climate Control 3000 Turbo 617.952 1982 1985 123.133
300 CD 617.919 1981 1981 123.150
300 CD Turbo 617.952 1982 1985 123.153
300 TO Turbo 617.952 1982 1985 123.193
280 E 110.984 1981 1982 123.033
280 CE 110984 1981 1982 123053 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 I

Introduced with Model Year (M.Y.l 1977 Models 230 (M.Y. 1977-1978) and 240 0

(M.Y. 1977-1983) 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 II Automatic Climate Control Used From M.Y. 1977-1980

In M. Y. 1977, the Automatic CI imate Control (System II) was introduced in models 300 D/eD/TD and 280 E/CE. The ACC II can be easi Iy recogniced by the vertical row of pushbuttons on the console.

This System is covered in Section 2.

Air Conditioning System III 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 CI imate Control (System" I), which can be identified by the horizontal row of push buttons 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

Certification Tag (left door pillar)

2 Identification Tag

Ileft window post) 3 Chassis No.

4 Engine No.

5 Body No. and Paintwork No.

Diesel Models

6 I nformation Tag California version Vacuum line routing

for emission control system 7 Emission Control Tag

8 Emission Control Tag Catalyst Information

Certification Tag (left door pillar)

2 Identification Tag

(left window post) 3 Chassis No.

4 Engine No.

5 Body No. and Paintwork No.

6 I nformation Tag

3000 TURBO DIESEL, 300 CD TURBO DIESEL California version Vacuum line routing

for emission control system 7 Emission Control Tag

8 Emission Control Tag 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 upward or downward direction. Pay attention to revised scope during removal and installation.

1st version

2nd version

Removal

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

83.4-100/1 F4

5 Disconnect heater hoses.

6 Remove glove box (68-140).

7 Pull both plugs from switch for glove box lights.

8 Unscrew screws on air 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.

B3.4-100/2 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 screw on instrument panel.

83.4-100/3 F4

15 Remove plug and open cable clamps on heater box.

16 Loosen all electrical connections on heater box.

17 Disconnect bowden wi res between control unit on heater box and water valve.

18 Disconnect bowden wi re between blower switch and main air flap.

19 Unscrew nut on righthand upper angle bracket.

20 Remove plug connection from ignition starter switch.

83.4-100/4 F4

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.

83.4-100/5 F4

Installation

Note: Duri ng assembly jobs, do not place small parts on 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 nozz les.

30 Attach heater box to front wall by means of lefthand upper angle bracket.

31 Attach plug connection to ignition starter switch.

83.4-100/6 F2

32 Attach heater box to front wall by means of righthand upper angle bracket.

33 I nstall lower angle bracket in such a manner that the following dimensions are attained:

a = 165 mm b 217 mm

Attention!

Jobs item 34 to 36 are required only for heater box of 2nd vers ion.

34 Attach holding straps.

35 Screw-down holding straps under slight tension.

83.4-10017 F4

36 Mount cover on air flap levers.

37 Connect bowden wires between control unit on heater box and water valve or main air flap.

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 free of tension against opening in water box.

39 Mount plug to heater box.

40 Install electric cable on heater box.

83.4-100/8 F 4

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.

83.4-100/9 F4

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.

83.4-1 00!1 0 F4

83-110 Removal and installation of heat exchanger

Removal

1 Remove heater box (83-100).

2 Remove both clamps on cover.

3 Unscrew screws left and right.

4 Remove both clamps on front end of cover.

83.4-110/1

5 Remove cover from heater box.

6 Knock clamp 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.

83.4-110/2

9 Remove both rubber seals from 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.

83.4-110/3

Installation

13 For installation proceed vice versa, making sure that the rubber seal between the blower and heater box is mounter' .n the recess provided.

83.4-110/4

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 sw itch is connected to left hand rotary sl ide valve.

Removal

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 un it.

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.

83.4-112/1

Adjustment

8 Close heater switch on control unit.

9 Close rotary sl ide valve on water valve by pushing rotary slide valve toward the rear.

10 Adjust bowden wire at square head until wi re coil can be connected to rotary slide valve. The wire is extended by turning square head to the right.

11 Complete function test.

83.4-112/2

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

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 F or installation proceed vice versa.

Note: Prior to attaching bowden wire to water valve, adjust wi reo

83.4-112/1

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 sl ide valve. The wire is extended by turning square head to the right.

11 Complete function test.

83.4-112/2

83-115 Removal and installation of water valve for heater

Removal

, 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.

83.4~115/1

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 wi res for series resistance.

5 Remove screws from blower motor flange.

83.4-120/1

6 Lift blower motor out of blower housing.

Installation

7 For installation proceed vice versa.

83.4-120/2

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.

Removal

1 Push bolt on expanding clamps completely down.

2 Lift expand ing clamps on one side and take out of ornamental grill.

83.4-14011

\

t83-11905

3 Pullout ornamental grill in forward direction.

Installation

4 For installation proceed vice versa.

83.4-140/2

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 half from rear of instrument panel against upper half, making sure that all the four links will engage in recess provided.

7 Attach connecting hose.

8 Mount cover.

83.4-150/1

,

83-52p'

Removal and installation of electromagnetic clutch

A. York refrigerant compressor

Data, test values

Electromagnetic cutout clutch 12 V

Models

4/5 cylinders Pitts 6.0 inch

Models

6 cylinders Pitts 6.7 inch

Designation

. ~~. ~.-"" ... -. ~~~-------~------------------

Power input

Cold 3.5 amps.

Warm 2.8 amps.

Tightening torques

Nm (kpm)

Screws (52) coil to refrigerant compressor Screw (51) pulley to crankshaft

14 20-27

( 1.4) (2.0-2.7)

Special tool

~~-."-- .. _-_ -~-~----

Pulling screw for pulley

100 58900 350U

Conventional tools

------------------------------~ ~~ ..... ----_----~ ..

Double open-end wrench 3/8" x 7/16", 1/2" x 9/16"

Note

For pulling pulley from crankshaft of refrigerant cornpressor (with V-belt mounted) energize electromagnetic clutch (clutch will attract). With refrigerant cornpressor removed, carefully hold pulley with water pump pliers while supporting pliers against fastening screws of coil.

Prior to removing clutch, check power input on clutch. Replace clutch if power input exceeds 6.0 amps.

83.6-526/1 F2

Removal

1 Actuate electromagnetic clutch while switching on ignition, cooling blower and temperature switch.

2 Unscrew screw (51).

3 Pull pulley of electromagnetic clutch (2) from crankshaft of refrigerant compressor (1) with pu Iling 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) or necked-down screw (1) and swivelling pulley tensioning roller in downward direction, or slacken V-belt by means of tensioning screw (2).

Belt-tensioninq roller engines 115, 615, 616, 61 7

Belt-tensioning roller engine 110

83.6-526/2

Bett-tensiorunq roller engine 123

7 Remove belt·tensioning roller of electromagnetic clutch (2) while paying attention to spring washer (54).

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 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 spri ng washer (54) into crankshaft.

83.6-526/3 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: Low-stretch V-belts are correctly tensioned, if they respond elastically to sturdy thumb pressure. New low-stretch V-belts are subject to a slight elongation which occurs on this type of V-belt already after a few minutes of operation. I t 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 switchingon ignition, blower and air-conditioning system. Then tighten screw (51).

16 Check electromagnetic clutch for function.

83.6-526/4

B. Delco refrigerant compressor

Data, test values

Designation

engines 615, 616, 617.912, 617.952

Electromagnetic cutout clutch 12 V

Delco 4.9 inch

Power input in amps. at 13.5 V

cold 3.9 warm 3.4

Nm (kpml
11 (1.1)
50 ± 3 (5 ± 3)
13 ( 1.3)
60 + 10 (6 + 1)
29-37 (2.9-3.7)
29-37 (2.9-3.7) Tightening torques

Screws (8) belt pulley/clutch

Screw M lOx 30 pipeline to refrigerant compressor

Nut (1) on drive shaft

Screws (5 and 6) M 12 refrigerant compressor on carrier

Hose line (14) from evaporator to pipeline 7/8"

Hose line (15) from pipeline to condenser 7/8"

Special tools

Holding device for refrigerant compressor

116 589 14 31 00

11004 -8103

Holding wrench for clutch

116 589 04 40 00

Disassembling tool for clutch plate

~~!

11004-6201

000 589 07 35 00

Assembl ing tool with spacer for spring plate

000 589 49 43 00

Guide piece

,

~

11004-6203

116 589 05 63 00

Double-claw removing tool

i

r rl

~- 1 '_

000 589 88 33 00

Knocking·out mandrel

115 589 02 35 02

Pressing·off plate for refrigerant compressor

.• ~ .'ri.

.,.. "pJ

"004-7632

109589002500

83.6-526/5 F 4

Conventional tools

Socket 14 mm, 3/8" square

Feeler gauge (set)

Langbeck pliers 72 A (internal lock)

e.g. made by Hazet, 5630 Remscheid

e.g. made by Hazet, 5630 Remscheid order No. 2147

e.g. made by Hazet, 5630 Remscheid order No. 1846 a-1

Pliers for retaining ring J 2 (external lock)

Self-made tool

e.g. made by Hazet, 5630 Remscheid order No. 1846 c-2

Disassembling tool for a-ring

Note

Removal and installation of spring plate, of clutch with belt pulley and magnet coil, as well as shaft seal ing may only be performed with the refrigerant compressor removed.

The clutch with support, the belt pulley and the magnet coil are forming one assembly. I n 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 installation of spring plate

Removel

Evacuate air-conditioning system (83-516).

2 Remove refrigerant compressor (83-522).

3 Attach holding device to refrigerant compressor and clamp into vise. Screw-off pipeline (7) from refrigerant compressor (1). For this purpose remove screw (8 and 21). Then close opening by means of pressing-off plate.

83.6-526/6 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 tool by 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 a 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 through spacer and screw assembling tool to shaft end.

12 Secure hex. head of tool and screw-in the central screw unti I there is a play of approx. 0.5-1 mm between 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 diameter of nut directed toward shoulder of shaft) and tighten. Check play once again.

15 I nstall refrigerant compressor (83-522).

1 Nut on drive shaft 2 Spring plate

3 Clutch

5 Locking ring

6 Support for cl utch 7 Belt pulley

8 Screw with lock 9 Magnet coil

10 Locking ring 11 O·ring

12 Slip ring

13 Shaft seal ing 14 Drive shaft

20 Housing cover

83.6-52618 F2

b) Remove and install clutch together with belt pulley, magnet coil and bearing

Removal

16 Remove spring plate (83--526, section a, item 1 to 7).

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.

21 Take off belt pulley from clutch and remove magnet coil from belt pulley.

83.6-526/9 F2

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 pressout bearing (6). For removal of the bearing, the notches need not be removed.

I nstallation 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 1200 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

183 ~'5010

183 "5019

Installation

25 Insert magnet coil (9) into belt pulley (7).

26 Slip clutch (3) into belt pulley (7) and provisionally screw-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.

83.6-526/11 F2

3

30 Rotate belt pulley together with clutch in order to determine whether the belt pulley is in 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).

83.6-526/12 F2

83-500

General description and operation of air-conditioning system

1 Temperature vacuum switch 2 Blower switch

3 Lateral ventilation (cooling air outlet) 4 Cooling air outlet center

5 Cooling air outlet from defroster nozzle on windshield

6 Cooling air outlet in leg room (with temperature vacuum

switch pulled)

7 Operating lever cooling air outlet center 8 Heater switch lefthand vehicle section

9 Heater switch righthand vehicle section

The air-conditioning system supplies cooled and dehumidified air for cooling the interior of the vehicle. The system operates with outside air and recirculated air cooling.

2 For normal cooling the blower switch (2) is set to stage I, " or III. On vehicles to 07/80 the temperature vacuum switch (1) is turned to the right and adjusted depending on desired refrigerant output in range between 0 and mark on blue graduated scale, upon which 100 % fresh air will blow through evaporator.

Version up to 07/80

83.6-500/1 F4

10 Operating lever for cooling air distribution

Lever left = Air for windshield and lateral ventilation

Lever center = Air for windshield and lateral ventilation, as well as for driver's

and rear compartment leg room with knob of temperature vacuum switch (1) pulled

Lever right = Air for lateral ventilation as well as for driver's and rear compartment leg room With knob of temperature vacuum switch pulled

3 For maximum cooling, temperature vacuum switch (1) is set in range between mark and end of blue

scale, so that approx. 80% of recirculated air and approx. 20% of outside air are guided through evaporator. Heater switches (8 and 9) should be at position O.

4 On vehicles starting 08/80 the temperature dial (1) is turned out of end position "0". Step less increase of refrigerant output continues up to position "Max".

5 Upon engagement of selector dial in "Max" position, the system switches from fresh air cooling to recirculating air cooling (80 % recirculating air, 20 % fresh air).

Version starting 08/80

6 The air-conditioninq 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 vacuum 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 - temperature vacuum switch up to position 3/4 cooling capacity = approx. 2000 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 vehicle is drawn out of leg room and approx. 20% outside air (fresh air) through a leak of recirculating air flap.

83.6-500/2 F4

183-11488

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 guided 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 exchangers to the defroster nozzles, to the lateral ventilation 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. 300 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 right hand 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 sufficient cooling, all the air outlet openings may be opened. However, to obtain an

air distribution free of draft, it is recommended to let all the cooling air escape through defroster nozzle behind windshield glass following sufficient cooling down. With this adjustment, the outside of the windshield glass will become foggy in moist and cool weather. I n such a case, increase the air temperature

or close the cooling air outlet toward windshield glass.

83.6-500/3 F4

Important between seasons

14 Between seasons in periods of high humidity (fogging of window glass from inside) the air-conditioning system may be engaged in addition to vehicle heater. As a result, depending on position of temperature 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.

83.6-500/4 F4

83-502

Refrigerant circuit

1833 -7472

Diagrammatic view of an air-conditioning system

The refrigerant compressor (1) driven by the engine will suck up the heated, gaseous refrigerant R 12 for delivery to condenser (2). The head wind will flow through condenser located in front of radiator and will cool the refrigerant vapor which has been additionally heated and put under high pressure, until it is fluid. The fluid refrigerant will then flow to the receiver dehydrator (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 perm its 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 pressure 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.

83.6-502/1

i------4

9

,---8

1

2

3

Layout of refrigerant circuit

1 Refrigerant compressor with electromagnetic clutch 2 Condenser

3 Receiver dehydrator with filter drier and sight glass 4 Expansion valve

5 Evaporator

6 Temperature switch (auxiliary fan) 7 Pressure switch

8 Fuse

9 Temperature regulator (up to 07/80) Temperature dial (starting 08/80)

Low pressure ~ gaseous

••••••••

Low pressure ~ fluid

I 11111! II1II IIIIi

High pressure ~ gaseous

High oressure+ fluid

83.6~502/2 F4

83-504

Safety nneasures

The air conditioning system is filled with safety refrigerant R 12. This refrigerant is colorless and odorless. At normal temperature it is 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 eye.

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 kg

2 Oneway Frigen Baby bottle, contents approx. 430 g

c) Never clean components of system with hot steam.

Unse only hydrogen, R 12 and R 11 for cleaning.

d) 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-toxic at normal temperatures, will decompose into hydrochloric acid and hydrofluoric acid when touched by a flame. Among others, the decomposition products also contain chlorine and phosgene. Since these products are detrimental to health, pertinent

care is essential.

e) If a part of the air conditioning system is damaged or leaking, e.q. by a vehicle accident, leave system switched off since otherwise the refrigerant compressor may suffer damage due to the absence of cooling and lubrication.

83.1-504/1

83-506

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. I n 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 Store all spare parts dry and in enclosed condition.

7 Blowout refrigerant hoses, pipe lines, condensers and 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 dehydrator). An unclosed receiver dehydrator with filter drier VIii I I be saturated with moisture and unfit for use after a short period.

83.1-506/1 F 2

83-508

Control of air-conditioning system

A. Electrical function of air-conditioning system, standard version and @

9

9a

12

13

~ -- .... - ....• -- .... - .... --)

r---.~

Elektrical wiring diagram air-conditioning system 1 st version with York refrigerant compressor, standard version and @

1 Blower switch with light

2 Pre-resistors

3 Blower

4 Main fuse box supplementary fuse C

(16 arnps., with supplementary heater 25 arnps.l 5 Main fuse box fuse no. 10 (16 arnps.]

6 Main fuse box fuse no. 12 (8 arnos.)

7 Pressure switch receiver dehydrator

[ctutch refrigerant compressor)

8 Temperature regulator with light

9 Relay I air-conditioning system (code no. 12)

9a Relay II air-conditioning system (without code no.l 10 Electromagnetic clutch

12 Changeover valve for speed stabilization (model 123.033)

13 Relay supplementary tan (code no. 6) 0

14 Temperature switFh (4-cylinder models 52 C.

other models 62 C) 0

15 Temperature switch (100 C) 16 Supplementary fan

a Rotary light switch terminal K

b 1 st version and USA model 123.023 Starter or cable con nector termi nal 50

2nd version, coupler terminal 4, for supplementary harness backup lamp switch - transmission tunnel

c I nstrument cluster terminal 58 d

83.6-508/1 F4

9 :-. - .- ... -~.-----:

"~lW

'I '

I . I

!I ', as • 1l"Al'

~ 4 1 2

I

16A·

I

L 15/54 30 i

._._._-__j

2

T

~

r! .~

I t..: I 14 LJH _j

Electric wiring diagram air conditioning system 2nd version with Delco refrigerant compressor, up to 08/80 model 123.1 standard version and § up to model year 1980

I

1.5 rl/sw =:!J .---/-- 0,75 swirl

1 Blower switch with light 2 Pre-resistors

3 Blower

4 Main fuse box supplementary fuse C

(16 amps., with supplementary heater 25 arnps.] 5 Main fuse box fuse no. 10 (16 arnps.)

6 Main fuse box fuse no. 12 (8 amps.)

7 Pressure switch receiver dehydrator

(clutch refrigerant compressor)

8 Temperature regulator with light

9 Relay I air-conditioninq system (code no. 12)

T

1833 - 8283/3

10 Electromagnetic clutch

13 Relay supplementary fan (code no.6)

14 Temperature switch (4·cylinder models 520C) 16 Supplementary fan

a Rotary I ight switch terminal K

b Coupling terminal 4, for auxiliary back-up lamp switch-transmission tunnel

c I nstrument cluster terminal 58d

83.6-508/2 F4

~

~l

~

6 T ;} i": ~

b ~ I 1_ 1

~

Q"

_j

!T 1; 81! _,~_

tt",,,,~ ~EM;;It;

, '"(.11lI»> ',""""""""".;

3l Q I ~'EHW})I

1

I

1 It;;

IJl It-

!

8

7

10

13

9

1833-9862

Electric wiring diagram air-conditioning system 3rd version with Delco refrigerant compressor starting 08/80, model 123.1 standard version and @ starting model year 1981

1,5rlis ...

1 swi't

a

1 Blower switch with light 2 Pre-resistors

3 Blower

4 Main fuse box supplementary fuce e

(16 amps. with supplementary heater 25 arnps.) 5 Main fuse box fuse no. 8 (16 amps.)

6 Main fuse box fuse no. 12 (8 arnps.)

7 Pressure switch receiver dehydrator

(clutch refrigerant compressor) 8 Temperature dial with light

9 Relay I air-conditioning system (code no. 12) 10 Electromagnetic clutch

13 Relay supplementary fan (code no. 6) 14 Temperature switch (52 =c:

16 Supplementary fan

17 Temperature sensor air-conditioning system

18 Switchover valve for fresh air-recirculating air flap

a Rotary light switch terminal 8

b Instrument cluster terminal 58 d

83.6-508/3 F4

B. Electrical function of supplementary fan

Supplementary harness for air-conditioning system and supplementary fan 1 st version with York refrigerant compressor standard version and @

21

Color code of supplementary harness
Line Harness Color code Cross
no. from to section
mm2
a Connecting bushings
Main fuse box terminal 30 supplementary 6·pole coupling terminal 3 red/black 1.5
fuse C, 16 amps. (with supplementary (relay fan [13J terminal 30)
heater 25 amps.I
2 Main fuse box terminal 15 fuse no. 12, 6·pole coupling terminal 4 black/red 1.0
8 amps. (relay fan [13] terminal 86)
3 6·pole coupling terminal 1 (relay fan [13] 2·pole coupling supplementary fan yellow 1.5
terminal 87
4 6-pole coupling terminal 5 (relay fan [13] Temperature switch 62°C brown Iyell ow 0.75
terminal 85) (receiver dehydrator)
5 Temperature switch 62°C Temperature switch 100°C brown/blue 0.75
(receiver dehydrator) (coolant temperature)
6 Ground Temperature switch (receiver dehydrator) brown 1.5
7 Temperature switch 62°C 2'pole coupling supplementary fan brown 1.5
(receiver dehydrator) ground
8 6-pole coupling complete 6'pole coupling terminal 3 (relay I air- black/red 1.0
(relay fan [13J terminal 86) conditioning system [9) terminal 30)
9 Temperature regulator (8) 6-pole coupling terminal 4 (relay I air- brown/blue 0.75
conditioning system [9 J terminal 86)
10 Ground 6-pole coupling terminal 5 (relay I air- brown 0.75
conditioning system [9) terminal 85)
11 6-pole coupling terminal 5 (relay I air- 6·pole coupling terminal 3 (relay II air- blue 1.0
conditioning system (9) terminal 87) conditioning system [9a) terminal 30)
12 6'pole coupling terminal 2 (relay II Pressure switch (7) blue/white 1.0
refrigerant compressor [9a) terminal 87a)
13 I ntermediate plug terminal 4 6-pole coupling terminal 4 (relay II air· violet 0.75
(4·pole coupling backup light switch) conditioning system [9a) terminal 86)
14 6-pole coupling terminal 5 (relay I air- 6-pole coupling terminal 5 (relay II air- brown 0.75
conditioning system [9] terminal 85) conditioning system [9a) terminal 85)
15 Rotary light switch terminal k 2-pole coupling temperature regulator (8) gray Iviolet 0.75
16 Ground 2·pole coupling temperature regulator (8) brown 0.75
17 6-pole coupling terminal 2 (relay II air- 2·pole coupling switch-over valve (12) black/red 0.76
conditioning system [9a] terminal 85) yellow
18 6-pole coupling terminalS (relay II air- 2-pole coupling switch-over valve (12) brown 0.75
conditioning system [9a) terminal 85)
19 2-pole coupling temperature regulator (8) Ught socket brown 0.75
20 2-pole coupling temperature regulator (8) Ught socket brown 0.75
21 Pressu re swi tch (7) Refrigerant compressor cable connector (10) blue/white 1.0
22 Ground Refrigerant compressor (10) ground brown 1.0 83.6-508/10 F4

Supplementary harness for air-conditioning system and supplementary fan 2nd version with Delco refrigerant compressor model 123.1 standard version and @

Color code of supplementary harness
Line Harness Color code Cross
no. from to section
rnrn?
a Connecting bushings
Main fuse box. terminal 30 supplementary 6-pole coupling terminal 3 red/black 1.5
fuse C. 16 amps. (with supplementary (relay fan [13] terminal 30)
heater 25 amps.l
2 Main fuse box. terminal 15 fuse no. 12, 6-pole coupling terminal 4 black/red 1.0
8 amps. (relay fan [13] terminal 86)
3 6-pole coupling terminal 1 (relay fan [13] 2-pole coupling supplementary fan yellow 1.5
terminal 87)
4 6-pole coupling terminal 5 (relay fan [13] Temperature switch 52°C brown/yellow 0.75
terminal 85) (receiver dehydrator)
6 Ground Temperature switch (receiver dehydrator) brown 1.5
7 Temperature switch 52 DC (fluid reservoir) 2-pole coupling supplementary fan brown 1.5
ground
8 Temperature regulator (8) 6-pole coupling terminal 3 (relay I air- black Ired 1.0
conditioning system [9] terminal 30)
10 Ground 6-pole coupling terminal 5 (relay air- brown 0.75
conditioning system [9] terminal 85)
12 6-pole coupling terminal 2 Pressure switch (7) blue/white 1.0
(relay refrigerant compressor terminal 87a)
13 Intermediate plug terminal 4 6-pole coupling terminal 4 (relay air- violet 0.75
(starter terminal 50) conditioning system [9] terminal 86)
15 Rotary light switch terminal K 2-pole coupling temperature regulator (8) gray /violet 0.75
16 Ground 2-pole coupling temperature regulator (8) brown 0.75
19 2-pole coupling temperature regulator (8) Light socket brown 0.75
20 2-pole coupling temperature regulator (8) Light socket brown 0.75
21 Pressure switch (7) Refrigerant compressor (10) blue/white 1.0
cable connector
22 Ground Refrigerant compressor (10) ground brown 1.0 83.6-508/11 F4

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

Color code of supplementary harness
Line Electric line Color code Cross
no. from to section
rnrn?
1 Fuse C terminal 30 Relay supplementary fan terminal 30 red/black 1.5
2 Fuse 12 terminal 15 Relay supplementary fan terminal 86 black/red 1.0
3 Relay supplementary fan terminal 87 Supplementary fan yellow 1.5
4 Relay supplementary fan terminal 85 Temperature switch 52°C brown/yellow 0.75
6 Ground Temperature switch 52 °c brown 1.5
7 Temperature switch 52°C Supplementary fan brown 1.5
8 Relay supplementary fan terminal 86 Relay refrigerant compressor term. 30 black/red 1.0
9 Temperature dial terminal 2 Relay refrigerant compressor term. 86 black/red/green 0.75
10 Ground Relay refrigerant compressor term. 85 brown 0.75
12 Relay refrigerant compressor term. 85 Pressure switch refrigerant compressor blue/white 1.0
13 Resistor group Temperature dial terminal 3 blue/black 0.75
14 Temperature dial terminal 4 Ground brown 0.75
15 Rotary light switch terminal K Socket, bulb gray /purple 0.75
16 Switchover valve fresh air-recirculating air Temperature dial terminal 1 blue/yellow 0.75
17 Switchover valve fresh air-recirculating air Ground brown 0.75
19 Temperature dial terminal 4 Socket bulb brown 0.75
21 Pressure switch refrigerant compressor Refrigerant compressor blue/white 1.0
22 Ground Refrigerant compressor brown 1.0 83.6-508/12 F4

C. Pneumatic function of air-conditioning system

1

13

12

A ___
2
~ ...

=
16 17
4-- 19
20 11

Diagram vacuum control air-conditioning system 123 (tst version) lefthand steering up to 02/79, righthand steering up to 10179

1 Evaporator housing with blower 2 Heater box

3 Temperature switch

4 Vacuum rotary switch for recirculating air flap 5 Vacuum pull switch for legroom flap

6 Intake manifold or on diesel engines vacuum line from

vacuum pump to brake unit 7 Rubber hose

8 Check valve

9 Distributor

10 Rubber grommet in front wall

11 Reservoir

12 Vacuum element for recirculating air flap 13 Recirculating air flap

14 Vacuum element for legroom flap

15 Driver's or rear compartment legroom flap

Cutting-in angle and function of temperature vacuum switch

Cutting-in angle

0-300 300

30 - 450 450

Air conditioner off - leg room flaps open Switchover point of leg room flaps

Leg room flaps closed

Air conditioner on - minimum cooling capacity

Outside air open - recirculatmq air closed Switchover point recirculating air - outside air

45 - 2470 2470

83.6-508/20 F 4

16 Vacuum line color code gray-light blue

17 Vacuum line color code medium green-yellow 18 Vacuum line color code medium green-light blue 19 Vacuum line color code medium green-orange 20 Vacuum line color code medium green-white

A Fresh air

U Recirculating air

Vd to evaporator

a Recirculating air flap (13) in position "recirculating air"

b Recirculating air flap (13) in position "fresh air"

c Legroom flaps (15) in position "closed"

d Legroom flaps (15) in position "open"

e Air outlet legroom or rear compartment legroom

Cutting-in angle

247 - 3150

3150

45 - 3150

0-3150

Recirculating air open - outside air closed (with outside air share)

End - max. cooling capacity ~ end stop Leg room flaps can be opened by pulling on knob

Total rotary range

8

6

I

/16

1-3

24-

4~

23

22 I

13 I

12

I

11

Diagram vacuum control air-conditioning system 123 (2nd version, lefthand steering) lefthand steering starting 03/79, righthand steering starting 11/79 up to 08/80

1 Evaporator housing with blovver 2 Heater box

3 Temperature switch

4 Vacuum rotary switch for recirculating air flap 20 5 Vacuum pull switch for legroom flap

6 Intake manifold or on diesel engine vacuum line from

vacuum pump to brake unit 7 Rubber hose

8 Check valve

9 Distributor

10 Rubber grommet in front wall 11 Reservoir

12 Vacuum element for recirculating air flap 14 Vacuum element for legroom flap

15 Driver's or rear compartment legroom flap 16 Vacuum line color code red-gray

17 Vacuum line color code green-yellow

18 Vacuum line color code green-light blue 20 Vacuum line color code green-white

21 Distributor

22 Vacuum line color code green-white

23 Vacuum element for defroster nozzle flaps 24 Defroster nozzle flaps

A Outside air (fresh air) U Recirculating air

Vd to evaporator

a Recirculating air flap (13) in position "recirculating air"

b Recirculating air flap (13) in position "outside air"

c Leg room flaps (15) in position "closed"

d Leg room flaps (15) in position "open"

e Air outlet leg room or rear compartment leg room

Cutting-in angle and function of temperature vacuum switch

Cutting-in angle

°

0-30

30° 30-45° 45°

45-247° 247°

83.6-508/21 F 4

Air conditioner off - leg room flaps open Switch over point of leg room flaps

Leg room flaps closed

Air conditioner on - minimum cooling capacity

Outside air open - recirculating air closed Switch over point recirculating air - outside air

Cutting-in angle

247-315° 315° 45-315°

0-315°

Recirculating air open - outside air closed (with outside air share I

End - max. cooling capacity = end stop Leg room flaps can be opened by pulling on knob

Total rotary range

(/

I

16 !

,

9 8

<-===-----== ....•••••. = ••..•••••••••••• =-' ••••.•.•.•.•.•• ~ •.•..•.•.•.. ~ID=i~7-=---->]

6

10

11

1832 9829.'1

13

12

! 17

I

Diagram vacuum control air-conditioning system 123 (3rd version) starting 08/80

1 Evaporator housing with blower

6 Intake manifold or on diesel engines vacuum line from

vacuum pump to brake unit 7 Rubber hose

8 Check valve

9 Distributor

10 Rubber grommet in front wall

11 Reservoir (not on model 123.11

12 Vacuum element for recirculating air flap 13 Recirculating air flap (position fresh air) 14 Vacuum element for leg room flap

83.6- 508/22 F 4

15 Driver's or rear compartment leg room flap

16 Vacuum line color code gray-light blue (not on model 123.1)

17 Vacuum line color code medium green·yellow 18 Switchover valve fresh air-recirculating air

(position fresh air)

20 Vacuum hose color code black 21 Orifice (on model 123.1 only)

A Fresh air

U Recirculating air

Vd to evaporator

a Recirculating air flap (131 in position "recirculating air"

b Re~rculating air flap (13) in position "fresh air"

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 gasoline engines.

Vacuum connection on vehicles with diesel engine

Vacuum connection on vehicles with gasoline engine

a To intake pipe or vacuum line (22) 8 Check valve

9 Distributor (branch)

16 Vacuum line to reservoir

17 Vacuum line to temperature vacuum switch

2 Vacuum reservoir (11) guarantees operation of 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 1979).

83.6-508/23 F 4

3 By switching-on temperature vacuum switch (starting at approx. 300 cutting-in angle) the vacuum pull switch which is set to passage (knob of temperature vacuum switch pushed) is operated via the vacuum rotary switch (4) so that the vacuum element (14) is activated and the leg room flaps are closed.

4 As soon 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). as 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

to 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 rotary switch (4).

1 st version

12 double·acting vacuum element

83.6-508/24 F 4

~a;~ -11.%7/3

6 Starting at 3/4 cooling capacity, the vacuum rotary switch will activate the front chamber of vacuum element (12) (1 st 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 drawn-in through a leak of recirculating air flap.

2nd version

7 Since 08/80 the vacuum element for fresh airrecirculating air flap is controlled by an electromagnetic 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 recirculating air flap is set to recirculating air under spring force.

3rd version

83.6-508/25 F 4

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

or assembly tester

~ 200 C to + 700 C

1 High pressure gauge

5 Thermometer

1 bar vacuum (atu) to lObar gauge pressure (atu)

0-- 40 bar gauge pressure (atu)

Hygrometer

Note

Two test methods are available for checking air-conditioning system:

A. Quick test

For air-conditioning systems, free of complaints. Test after minor repairs, extended period of inoperation or the I ike.

B. Function test

In the event of complaints or for trouble diagnosis.

A. Quick test

Test method for ambient temperatures of + 200 C to + 400 C. Check values can be read after approx. 5 minutes.

Test conditions

Vehicle should not be exposed to sunshine before and during the test.

2 Switch-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.

83.6-510/1 F 4

3 Heater switch (8 and 9) in position O.

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 SI ide lever (10) to the right.

up to 07/80

7 Starting 08/80 engage temperature dial (1) at "Max."

8 Set levers (10 and 11) to inside stop.

starting August 1980

9 Slide lever (7) to the left (cooling air outlet center opened).

10 Open air nozzles (3).

11 Insert one thermometer into center nozzle (4).

12 Attach one thermometer for ambient temperature (room temperature) approx. 2 m 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 temperature 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 + 10 c.

Details on adjustment of temperature vacuum switch (83-542).

A = air outlet temperature 0 Ta = ambient temperature ( C)

83.6-510/2 F 4

26
24 A
22
20
18
°C 16
14
12
10
8
6
4
20 30 Ta

25

35

40 °C

1834·739014

B. Function test

Note: Observe safety rules when working on air-conditioning 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 according to the following test method which is suitable

for room temperatures (ambient temperatures) from + 20° to + 40° C. A II check data can be read after

10 minutes of constant operation.

Test conditions

15 Vehicle should not be exposed to sunshine before and during the test.

16 Check tension of V-belt for compressor drive.

17 Switch-on air-conditioner and watch reservoir on sight glass (1) to check whether the refrigerant flows free of bubbles soon after switching on electromagnetic clutch. Add refrigerant if required. If the refrigerant 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 fu II cooling capacity.

21 Slide lever (10) to the right.

upto07/80

83.6-510/3 F4

22 Starting 08/80 engage temperature dial (1) at "Max".

23 Set levers (10 and 11) to inside stop.

24 Slide lever (7) to the left (cooling air outlet center 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 temperature (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 a pressure pin in center.

30 Check angle of rotation of temperature regu lator by turning knob of temperature vacuum switch (1) to the right up to stop.

The marking on knob of temperature vacuum switch should arrive at end of blue key. If the angle of rotation 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 coupler from temperature switch 100°C (20) and connect to ground, so that the electromagnetic fan will run along during entire test procedure.

33 Run engine at approx. 2000/min.

34 After approx. 10 minutes of operation, read values on thermometers and pressure gauges, as well as on hygrometer.

Note: Specified values are max. values and may not be exceeded.

83.6-510/4 F4

35 Check suction and high pressure in dependence °C
20 25 30 35 40
of ambient temperature (room temperature) by means 28
of table. Check air outlet temperature (mean value of 26
24
the four cold air outlet temperatures) also according 22
to values on table. (The difference between the coldest 20
and the warmest outlet temperature should not ex- 18
ceed 3°C). °C 16
14
12
36 Check cutout temperature of temperature regula- 10
tor, for this purpose insert a thermometer into center 8
nozzle (4). Set blower switch (2) to stage 1 and tem- 6
4
perature vacuum switch (1) to full cooling capacity 10
or on vehicles starting 08/80 engage temperature dial 6 ,
B
at "Max". Run engine at approx. 2000/min. bar 6
After 3rd cutout of electromagnetic clutch the air 4
2
outlet temperature should amount to approx. + 3°C, 0
but should not be less than plus 1 DC. 26
24
22
bar 20
18
16
14
All models (except with engine 102)
1) Relative humidity of the air 0
Ta Outside temperature (DC)
A Air outlet temperature (DC)
B Pressure in front of compressor (bar)
C Pressure following compressor (bar) 25
0 Coolant temperature (DC) .-_ .. __ -
1833-n7014 37 Adjust temperature vacuum switch (83 -542).

38 The supplementary fan in front of condenser for coolant temperature (100 DC) and refrigerant temperature (62 DC, on 4 and 5-cylinder vehicles 52 DC) is switched on at higher outside temperatures.

Engine 102

1) Relative humidity of the air Ta Outside temperature (DC)

A Air outlet temperature (DC)

B Pressure in front of compressor (bar) C Pressure following compressor (bar) o Coolant temperature (DC)

83.6--510/5 F4

40
36
32
28
24
°c 20
16
12
8
4
0
4
bar 3
2
0
36
32
28
bar 24
20
16
12
8
120
"c 110
100
90
20 25 30 35 40
Ta °c
1833-10046 39 When refrigerant loss is high or pressure in receiver 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 circuit 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).

83.6-510/6 F4

83-512

Leak test and evacuation

Special tools

Remover and installer for valve insert

0005892461 00

Conventional tools

Wrench 1/2 x 9/16"

Assembly tester with 3 filling hoses and vacuum pump

or evacuating and filling equipment for air-conditioning systems

e. g. made by Christof Fischer, Reichenhaller Stra~e 55-59 0-7000 Stuttgart 50

Leak tester (R ilo-senior-Ieak detector)

Leak test

If a checkup shows that the air-conditioning system holds 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, e.g. 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.

83.6-512/1

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 level in compressor first (83-520).

If there is a leak, the pressure gauge reading will increase, that is, the vacuum is reduced. For accurate determination of the leaking point, fill system with approx. 100 g refrigerant R 12 and perform leak test with a leak tester.

Evacuation

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 connection (C) of assembly tester or on connection of both service valves is connected (hoses without pressure pin cannot be used here).

3 Completely open valves (A and B) on assembly tester (2). Close valves on filling cylinder (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).

83.6-512/2

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 0.15, 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 g refrigerant (gaseous) into system. Check entire system for leaks with leak tester and seal leaks. Then evacuate system again.

8 Close valves (A and B).

9 Fill system with refrigerant R 12 (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).

8

I

c

11

A

I

5

6

Assembly tester and filling cylinder with all connections

11183-569611

14

17

A Valve on suction pressure gauge 3 Suction pressure gauge 8 Hose line 13 Upper valve
B Valve on hiqh-pressur e gauge 4 Hiqh-pressurs gauge 9 Hose line 14 Lower valve
C Schrader valve on assembly tester 5 Hose line 10 Hose line 15 Pressure gauge
1 Refrigerant compressor 6 Service valve (suction end) 11 Vacuum pump 16 Refrigerant bottle with R 12
2 Assembly tester 7 Service valve (pressure end) 12 Filling cylinder 17 Valve on refrigerant bottle 83.6-512/3 F4

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 valve (21) and switch off vacuum pump.

17 If the vacuum meter shows a steady pressure increase, the air-condition ing system has a leak.

Evacuation with vacuum meter (Torr meter)

Note: A vacuum meter (18) is located on the evacuating and filling device (service unit) between assembly tester (2) and vacuum pump (11).

The max. attainable vacuum can be measured by means of the vacuum meter. A leak in air-conditioning 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) or to valve (21) will remain open.

Upon evacuation, valve (19) should always remain closed. If the 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 9 refrigerant, then check entire system for leaks with a 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 R 12 (83-514).

83.6-512/4 F4

"83-56961'

83-514

Refilling or replenishing air-conditioning system

Filling capacity

kg

1.2

Refrigerant R 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 or evacuating and filling unit (service unit) for airconditioning system

Line connection-reduction piece 7/16"- 1 /4" for refrigerant bottle or tapping valve for Frigen-baby-bottle

Filling aid type CH 200 and angle piece 900 with rapid screw connection 7/16"

Wrench 1/2" x 9/16"

e.q, made by Christoff Fischer, Augsburger Strafle 289 D-7000 Stuttgart 60

Note

The jobs for refilling and filling up of air-conditioning system are in principle alike. When refilling, evacuate system first (83-512).

Note: Fill ing requ ires a supply bottle (1) with refrigerant, which is commercially available just like e.g.

a supply bottle with oxygen or acetylene gas. In addition there are small cans (2) [Frigen-babies]). containing approx. 1/2 Liter R 12. If hard to obtain, contact one of the specialist companies manufacturing or operating refrigerating units.

83.6-514/1

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, it is 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 pressure 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

Remove closing caps (1) from service valves.

2 Screw line connection reduction piece (26) on supply bottle (16). Connect filling hose (5) to reduction piece (26) and blow through for a short moment with refrigerant to remove remains of dirt and moisture, if any, then connect filling hose (5) to connection (6) (suction side) of service valve (offset end with pressure pin of hose line}.

83.6-514/2

3 Run engine at approx. 1000/min and set temperature selector knob to highest cooling capacity and blower switch to full blower speed. In rooms with temperatures above 22°C blowout 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 flows free of bubbles past sight glass of receiver dehydrator.

5 When refilling, fill in approx. 100-200 g refrigerant. 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 air-conditioning system (item 1 to 3).

8 Close valve on supply bottle and stop engine. D isconnect filling hose (5).

9 Screw closing caps (1) to service valves.

10 Check air-conditioning system for function (83-510).

83.6-514/3

83-516

Draining of air-conditioning system

Conventional tools

Wrench 1/2 x 9/16"

Assembly tester with 3 filling hoses and vacuum pump

or evacuating and filling unit for air-conditioning systems

e.g. made by Christof Fischer, Reichenhaller Str. 55-59 D-7000 Stuttgart 50

--~------------------------------------------------------------------------------ ---~-

Note

In the event of repairs on air-conditioning system, drain entire system.

Attention!

Pay attention to safety measures (83-504).

Draining the system

Unscrew closing caps (1) of both service valves.

2 Connect assembly tester, evacuating and fill ing 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

or into the open air. If quickly drained, the refrigerant will carry the oil from system and refrigerant compressor 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 overpressure, 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.

83.6-516/1

83-518

Cleaning of air conditioning system

Tightening torques

Nm

(kpm)

Thread connection 5/8" - 18 UNF

15-18

(1.5-1.8)

3/4" -16 UNF

14-28

(1.4-2.8)

7/8" - 14 UNF

29-37

(2.9-3.7)

Conventional equipment

1 Cleaning unit R 11

e.g. made by Christof Fischer Augsburger Straf!e 289 7000 Stuttgart-60

Order no.: 835-3900 DB

Scope of delivery: (mounted on cleaning unit)

2 PVC hoses, 1.6 rn, 12 mm inside width with bead connection on both sides and coupling nut 3/4" UNF, 1 connection 450 offset.

PVC hose for nitrogen 1.5 rn, 5 mm inside width, with quickly closing 7/16" UNF/hose grommet for reduction valve.

2 Reduction nipples 3/4" x 7/8" 2 Reduction nipples 3/4" x 3/4" 2 Reduction nipples 3/4" x 5/8" 2 Reduction nipples 3/4" x 1"

2 Seals

2 Reduction nipples 5/8" x 3/4" Screw connection 3/4" x 5/8" Screw connection 3/4" x 7/8" Wrench for container lock

Can of filling material for filter drier (KC dry pearls can: 1 kg)

15-kg container, filled with R 11

601-2129 601-2103 601-2123 628-2400 628-2401 628-2402 601-2165 601-2166

731-9000 808-3902

1 Nitrogen bottle

Conventional tool

Double open-end wrench 2 each

1/2 x 9/16", 5/8 x 3/4", 7/8 x 15/16", 1 xl 1/8"

83.1-518/1

Note

Dirt or 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 contamination 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 air 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 R 11.

If cleaning of air conditioning system is required, always replace receiver dehydrator.

Cleaning with nitrogen

Drain air conditioning system (83-516).

2 Remove receiver dehydrator (83-520).

3 Unscrew hose lines on refrigerant compressor.

83.1-518/2 F 2

4 Connect tapping hose on reduction valve (9) of nitrogen bottle (11 ).

5 Blowout air conditioning system in two stages for approx. 2 minutes by means of tapping hose.

a) from hose line receiver dehydrator - evaporator to hose line evaporator - compressor.

b) from hose line refrigerant compressor condenser.

6 Install new receiver dehydrator. Then check oil level in refrigerant compressor (83-520).

7 Check sealing rings and connections on refrigerant compressor and moisten with cold-flowing oil.

8 Mount hose lines on refrigerant compressor or pipe line.

9 Evacuate air conditionng system, fill up and check for leaks.

Cleaning with R 11 cleaning unit

Note: The boiling temperature of the R 11 cleaner is at + 23.80 C. For this reason, store R 11 in cool place and keep container well closed.

R 11 in cleaning unit may evaporate through pressure relief valve (7) if its temperature is above 240 C. It is therefore recommended to return the contents of the cleaning unit to supply tank after flushing.

83.1-518/3 F 2

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 R 11 gas in high concentration. Vent closed rooms after flushing.

10 Drain air conditioning system (83-516).

11 Disconnect all parts installed in refrigerant circuit such as expansion valve, receiver dehydrator and lines on refrigerant compressor.

12 Connect hose line from compressor to condenser with feed and return I ine and I ine connectors (10) (the hose I ine and the condenser are flushed first).

83.1-518/4

183-13334/1

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 connected circuit is forced back into container of flushing unit (well visible through PVC hose)_

18 Close valve on pressure gauge (9).

19 Disconnect flushing unit.

20 Also flush evaporator and hose line from evaporator to compressor or pipe I ine as well as pressure hose from receiver dehydrator to E-valve (item 12

to 19).

21 I nstall new receiver dehydrator and new expansion valve. Then check oil level in refrigerant compressor (83-520)_

22 Check gasket and threads on all components and moisten with cold-flowing oil. Connect hose lines to refrigerant compressor.

23 Evacuate air conditioning system, fill up again and 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 oil (for approved cold-flowing oils refer to Specifications for Service Products, page no. 361)

Oil level at min. normal max.
Oil quantity in cc 180 240 300
Refrigerant compressor Dipstick depth (rnrn) 22 25 28
Tightening torque Nm (kpm)
Oil check plug 6-8 (0.6-0.8) Conventional tools

Open-end wrench 1/2 x 9/16"

Assembly tester with 3 filling hoses or evacuating and filling device for air-conditioning system

e.g. made by Christof Fischer, Augsburger Str. 289 0-7000 Stuttgart 60

Self-made tool

Oil dipstick for refrigerant compressor

3 notches each at specified spacings

flat length: 210 mm

material: brass wire dia. 3 mm

A = horizontal installation B = 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 oi I.

83.6-520/1 F4

Oil level in compressor should never be below a minimum level of 180 cc or a maximum of 300 cc.

Too much oil is detrimental for operation of system and will also result in reduced efficiency of air-conditioning 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 refrigerant 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 level checkup is required.

Checking the oil level

Drain air-conditioning system (83-518).

2 Slowly turn out oil check screw (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 screw.

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 screw or compressor housing.

83.6-520/2 F 4

B. Vehicles with Delco refrigerant compressor

Oil capacity

Oil type cold·flowing oil (for approved cold-flowing oils refer to Specifications for service products, page No. 362)

Oil filling capacity new in refrigerant compressor

170 cc

Oil capacity when working on system

Jobs

Quantity of cold-flowing oil to be filled in

Renew refrigerant compressor

(system not flushed with R 11) oil quantity drained from old compressor above 40 cc. 1)

Drain cold-flowing oil from removed compressor and measure quantity. Also drain cotd-tlowinq oil on new compressor and store in closed condition.

Fill same quantity as in removed compressor into new compressor (fresh oil).

Renew refrigerant compressor

(system not flushed with R 11), oil quantity drained from old compressor below 40 cc. 1)

see above, but fill in 90 cc cold-flowing oil.

Renew refrigerant compressor (System flushed with R 11 first). 1)

Do not fill-in cold-flowing oil.

Recondition refrigerant compressor (drained oil quantity above 40 cc) I)

Fill drained quantity of oil and additionally 30 cc (1 oz) into compressor.

Recondition refrigerant compressor (drained oil quantity below 40 cc) I)

90 cc

Add refrigerant to system (up to 200 g).

Do not fill in cold-flowing oil.

Add refrigerant to system (more than 200 g)

or, in the event of leaks, fill up completely with fresh oil.

30 cc

Renew condenser Renew evaporator

Renew receiver dehydrator

50 cc 70 cc 40 cc

I) Renew receiver dehydrator, but do not add any cold-flowing oil into receiver dehydrator.

83.6-520/3 F 4

Nm (kpm)
60 + 10 (6 + 1)
50 ± 3 (5 ± 0.3)
29-37 (2.9-3.7)
29-37 (2.9-3.7)
-~.---~.~------- Tightening torques

Screws M 12 refrigerant compressor to support

Screw pipeline to refrigerant compressor

Hose line from evaporator to pipeline 7/8"

Hose line from pipeline to condenser 7/8"

Special tools

'. ,

Holding device for refrigeration compressor

116 589 14 31 00

Pressing-off plate for refrigerant compressor

:j, ':J~"

11004-76J2

109589002500

Conventional tools

Double open-end wrench 1/2" x 9/16", 5/8" x 3/4", 7/8" x 15/16", 1" x 11/8" Socket 14 mm, 3/8 square

Assembly testing device with 3 filling hoses or evacuating and filling device for air-conditioning system

e.g. made by Christof Fischer, Augsburger Str. 289, 7000 Stuttgart 60

Oil pump order no. 823-2250

Note

If the system has been flushed with R 11, it is not necessary to drain cold-flowing oil from new refrigerant compressor (no compressor oil need be filled in). Be sure to install a new receiver dehydrator.

I n 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 g 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 oz) of cold-flowing oil. 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 together 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.

83.6-520/4 F 4

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 cold-flowing oil into a measuring cup and drawin 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 pipeline (83-522).

6 Screw-off pi peline (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 accelerated.

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.

836-520/5 F 4

10 Add the same quantity of fresh oil into new refrigerant compressor through suction port if a drained oil quantity of more than 40 cc 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 cc, add 90 cc into new refrigerant compressor.

11 If the refrigerant compressor is reconditioned, let cold-flowing oil run out of refrigerant compressor as described under item 3. If the drained quantity

of oil is more than 40 cc, add the drained quantity and an additional 30 cc of oil into regriferant compressor. 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 Q-ring for correct seat, and provide with cold-flowing oil.

13 I nstall refrigerant compressor together with pipeline (83-522).

83.6-520/6 F 4

83-522

Removal and installation of refrigerant compressor

A. Engine 110 (with York refrigerant compressor)

Oil capacity

Oil type cold-flowing oil (approved cold-flowing oils refer to Specifications for Service Products page no. 361)

-.~- .. ---
min. normal max.
180 240 300
22 25 28
Nm (kpm)
40-45 (4.0-4.5)
30-5 (3.0-0.5)
30 (3.0)
45 (4.5)
30-5 (3.0-0.5)
45 (4.5)
25 (2.5)
6-8 (0.6-0.8) Oil level at

Oil quantity in cc

Refrigerant compressor

Dipstick depth (rnm)

Tightening torques

Suction or pressure hose on refrigerant compressor Screw (7) carrier to cylinder head

Inch screw (4) fastening plate to compressor Screw (9) fastening plate to carrier

Screw (31) holder tensioning roller to cylinder head Necked-down screw (28) belt-tensioning roller

Inch screw (51) coupling to refrigerant compressor Oil check screw

Special tool

Pulling-off screw for pulley

::.o""j,d .•

100589003500

Conventional tools

Double open end wrench 1/2" x 9/16", 5/8" x 3/4", 7/8" x 15/16", 1" x 1 118" Socket 1/2"

Self-made tool

A

Oil dipstick for refrigerant compressor

3 notches each in specified spacings flat length: 210 mm

material: brass wire dia. 3 mm

A = horizontal installation

B = vertical installation

83.6-522/1 F 4

Note

All threaded bores and screws on refrigerant compressor are in inches.

Remove refrigerant compressor together with fastening plate (3)

Check oil charge of refrigerant compressor each time prior to adding fresh refrigerant (83-520).

If the refrigerator must be renewed or reconditioned, insert a strainer into suction connection. For details refer to 83 -524.

Removal

Cover righthand front fender.

2 Switch-on ignition, air-conditioning system and blower (electromagnetic clutch will pull).

3 Unscrew screw (51).

4 Remove pulley of electromagnetic clutch (2) from crankshaft of refrigerant compressor (1) with puller screw (53).

5 Switch-off ignition.

6 Disconnect battery.

7 Drain air-conditioning system (83-516).

83.6-522/2 F 4

8 Loosen necked-down screw (28) for tensioning roller (27).

9 Slacken V-belt (34) with adjusting screw (25) and remove V-belt.

10 Disconnect electric I ine on cable connector (17).

11 Unscrew struts (14 and 19) on compressor, cylinder head and engine carrier.

12 Loosen 3 screws (8 and 9) as well as nut (12) and remove refrigerant compressor with fastening plate (3).

13 Loosen screws (4) and remove fastening plate (3) from refrigerant compressor.

14 Remove pulley of electromagnetic clutch (2), pay attention to spring plate (54).

15 Unscrew 4 screws (52) and remove coil of electromagnetic clutch (2) from refrigerant compressor.

83.6-522/3 F 4

23 17 22

21

19-

20

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 oil check screw (b). For this purpose, unscrew oil check screw for a few threads unti I gas is heard to escape.

17 Screw fastening plate (3) to refrigerant compressor with inch screws (4) and washers (5).

18 Screw electromagnetic clutch to refrigerant compressor.

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 screw (8) and washer (22) to cylinder head, as well as with nut (12) and washer (13) on stud (10).

22 Mount strut (14) with holder for cable connector (17) to refrigerant compressor as well as the cyl inder head.

23 Mount strut (19)

24 Mount V-belt, tension with adjusting screw (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).

83.6-522/4 F 4

27 Connect hose or pipe line to refrigerant compressor 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 lines will result in failure of refrigerant compressor (fluid shock) .

28 Evacuate air-conditioning system and fill up again (83-514).

29 Switch-on ignition, air-conditioning system and blower and tighten screw (51).

30 Check air-conditioning system for function (83-510).

83.6-522/5

B. Engines 115,615,616,617 (with York refrigerant compressor)

Oil capacity

Oil type cold-flowing oil (approved cold-flowing oils refer to Specifications for Service Products page no. 361)

Oil level at

Oil quantity in cc

Refrigerant compressor

Dipstick depth (rnrn)

min. normal max.
180 240 300
22 25 28
Nm (kpm)
40-45 (4.0-4.5)
30 (3)
45-5 (4.5-0.5)
30-5 (3.0-0.5)
30 (3)
50 (5)
50 (5)
45 (4.5)
25 (2.5)
6-9 (0.6-0.8) Tightening torques

Suction or pressure hose on refrigerant compressor Inch screw (7, 12) carrier to refrigerant compressor Screw M 12 x 1.5 (13) carrier to cylinder head Screw M 10 x 40 (14) carrier to cylinder head Screw M 8 x 55 (17) carrier to water pump

Nut M 10 (22) carrier to intake pipe (gasoline engines) Screw M 10 x 25 (18) carrier to intake pipe (diesel engines) Necked-down screw (21) belt-tensioning roller

Inch screw (51) coupling to refrigerant compressor

Oil check screw

Special tool

Pulling screw for pulley

.'.e'-.J ....

100 589 00 35 00

Conventional tools

Double open end wrench 1/2" x 9/16", 5/8" x 3/4", 7/8" x 15/16", 1" x 1 1/8" Socket 1/2"

Self-made tool

Oil dipstick for refrigerant compressor

A

119-

3 notches each in specified spacings

flat length: 210 mm

material: brass wire dia. 3 mm

- -30-l

-- - 25-----

-- 21----

L_:':'- III

A horizontal installation

B = vertical installation

83.6-522/6 F 4

Note

The refrigerant compressor can be removed only together with refrigerant compressor carrier.

All threaded bores and screws on refrigerant compressor are in inches.

Check oil charge of refrigerant compressor each time prior to adding fresh refrigerant 183-520).

Attention!

If refrigerant compressor must be renewed or reconditioned, insert a strainer into suction connection. For details refer to 83-524.

Removal

Cover righthand front fender.

2 Remove air filter. On diesel vehicles, loosen vacuum line on vacuum pump.

3 Switch-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 pulling screw (53).

6 Switch-off ignition.

7 Disconnect ground line of battery.

8 Drain air-conditioning system (83-516).

83.6-522/7 F 4

9 Loosen screw (25), swivel belt-tensioning roller (23) in downward direction and remove V-belt (26).

10 Unscrew screw (24) and unscrew refrigerant lines (15 and 19) from refrigerant compressor. Close connections with bl ind plug.

Model 123.0201023

Model 123.120/123/126

11 Disconnect electric lines from cable connector (70). Unscrew screw (71) and remove holder with cable connector.

Model 123.130

83.6~522/8

12 Remove radiator (not applicable on model 123.130).

13 Remove fan or viscofan coupling.

14 Remove V-belt for alternator and take pulley from water pump.

15 Unscrew screw (13, 14 and 17).

16 Unscrew 2 nuts (16) as well as nut (22) or screw (18).

Engine 115

Carrier on exhaust manifold

17 Remove refrigerant compressor with carrier wh ile paying attention to spacing sleeve (24).

Engine 615, 616, 617 Carrier on exhaust manifold

83.6-522/9

18 Remove pulley of electromagnetic clutch (2), pay attention to spring washer (54).

19 Unscrew 4 screws (52) and remove coil of electromagnetic clutch (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 (e) on connections only, when the gas has been evacuated via oil check screw (b). 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 to 12) to carrier (3).

1 Refrigerant compressor 2 Electromagnetic clutch 3 Carrier

4 Washer (1.5 mm thick)

5 Rubber disc (8.5 mm thick) 6 Sleeve (17mmlong)

7 Inch screw 3/8" - 16 (35 mm long) 8 Washer (2.5 mm thick)

9 Rubber disc (13.5 mm thick) 10 Sleeve (22 mm long)

11 Washer

12 I nch screw 3/8" - 16 (50.8 mm long).

83.6-522/10

D. Engines 615, 616, 617.912, 617.952 (with Delco refrigerant compressor)

Oil capacity

Oil type cold-flowing oil (for approved cold-flowing oils refer to Specifications for service products, page No. 362)

Oil filling capacity new in refrigerant compressor

170 cc

Tightening torques Nm (kprn)
Screws M 12 refrigerant compressor to support 60 + 10 (6 + 1)
Screw pipel ine to refrigerant compressor 50 ± 3 (5 ± 0.3)
Hose line from evaporator to pipeline 7/8" 29-37 (2.9-3.7)
Hose I ine from pipel ine to condenser 7/8" 29-37 (2.9-3.7) Special tools

Holding device for refrigerant compressor

. ...

116 589 14 31 00

11004-8103

Pressinq-off plate for refrigerant compressor

,,1.7

7J' ~

It004-ffi.:n

109589002500

Conventional tools

Double open-end wrench 1/2" x 9/16",5/8" x 3/4", 7/8" x 15/16", 1" xl 1/8" Socket 14 mm, 3/8" square

Assembly testing device with 3 filling hoses or evacuation e.g. made by Christof Fischer,

and filling device for air-conditioning system Augsburger Str. 289, 7000 Stuttgart

...... -- .- ...... ------_----

Attention!

I f the refrigerating compressor must be renewed, e.g. owing to blocking, always renew pipe line with hoses on refrigerant compressor, since small parts (abrasives) of refrigerant compressor may enter pipe line and may then not be completely removed up to 100 % when flushing with R 11.

Removal

Cover front fender

2 Pull plug from clutch and drain air conditioning system.

83.6-522118 F 4

3 Loosen nut 13) on clamping screw (4).

4 Loosen screws (5 and 6), swivel refrigerant compressor (1) inwards and take-off V-belt (2).

1 Refrigerant compressor 3 Nut

4 Clamping screw

5 Screw M 12 x 1 70

6 Screw M 1 2 x 140 7 Pipeline

8 Screw M 10 x 30

1 Refrigerant compressor 2 V-belt

5 Screw-off hose lines (14 and 15) from pipel ine (7) and close connections with plugs.

7 Pipeline

14 Hose line from evaporator to pipeline

7 Pipeline

15 Hose line from pipeline to condenser

83.6-522/19 F 4

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 connections on refrigerant compressor with pressing-on plate.

Installation

9 Check O-rings on refrigerant compressor and screwon pipeline (7).

83.6 522/20 F 4

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 Screw nut (3) on tensioning screw (4).

12 Put v-belt (2) in place and tension by means of nut (3).

1 Refrigerant compressor 3 NUl

4 Tensioning screw 5 Screw

6 Screw

9 Spacer sleeve

10 Spacing washer 5 mm 12 Spacing washer 9 mm 13 Spring washer

13 Tighten screws and nuts (5 and 6).

14 Remove closing caps on pipeline and hose line. Provide a·rings with cold-flowing oil and screw hose lines to pipeline and tighten.

15 Evacuate air-conditioning system and replenish (83-514).

Note:

If oil is 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 25.07.1979).

16 Check air-conditioning system for function and leaks (83-510 and 512).

83.6-522/21 F 4

83-524

Reconditioning of refrigerant compressor

B. Delco refrigerant compressor

Data

Designation

Delco (Frigidaire) Radial 4·cylinder

~~~-.--.--_ .. ~----~-.-.--~-~- . __ .-~- .. ~---- ... -------

Max. speed 1/min

7000

Required input at max. compressor speed kW (HP)

approx. 6.3 (8.5)

Volume of cylinders

164 cc

-~- .. -.~- .... - ---

---- -----

Oil filling capacity

- __ ..... _---

Oil type cold-flowinq oil (for approved cold-flowinq oils refer to Specifications for service products page No. 362)

--- ... -- .. --~

-.--.--~-.-~-
170 cc
Nm (kprn)
1 1 ( 1 . 1 )
50 ± 3 (5 ± 3)
13 ( 1.3)
60 + 10 (6 + 1)
----- ...
29-37 (2.9-3.7)
24-28 (2.4-2.8) Oil filling capacity new in refrigerant compressor

Tightening torques

-~-- ._. __ .--- ----- __ .. _--_._---------_. -------------

Screws (8) belt pulley/clutch

Screw M 10 x 30 pipeline to refrigerant compressor

Nut (1) on drive shaft

Screws (5 and 6) M 12 refrigerant compressor to carrier

Hose line (14) from evaporator to pipeline 7/8"

Hose line (15) from pipel ine to condenser 3/4"

83.6-524/9 F 3

Special tools

Holding device for refrigerant compressor

·i~.

116 589 14 31 00

111004-8103

Holding wrench for clutch

," ".~

~~004-8104

116 589 04 40 00

D isassembl ing tool with spacer for spring plate

'--'.,~~

11004-8201

000589 07 3500

----------_------- --_-

Assembling tool with spacer for spring plate

000 589 49 43 00

Guide piece

{

\~ ..

"004-620]

116 589 05 63 00

Double-claw removing tool

000 589 88 33 00

Knocking-out mandrel

115 589 02 35 02

--------------------------------- ---------_._-----

Disassembling and assembling tool for slip ring

0005892161 00

D isassembl ing and assembl ing tool for shaft seal ing

000 589 65 63 00

Pressing-off plate for refrigerant compressor

109589 00 2500

Conventional tools

Socket 14 mm, 3/8" square

e.q, made by Hazet, 5630 Remscheid

Feeler gauge (set)

e.g. made by Hazet, 5630 Remscheid order No. 2147

Langbeck pliers 72 A (Internal lock)

e.g. made by Hazet, 5630 Remscheid order No. 1846 a-l

Pliers for retaining ring J 2 (external lock)

e.g. made by Hazet, 5630 Remscheid order No. 1846 c-2

Double open-end wrench 1/2" x 9/16", 5/8" x 3/4", 7/8" x 15/16", 1" xl 1/8"

Self-made tool

Disassembling tool for O-ring

63,6-524/10 F 3