Contents Wiring diagrams Section: Automatic HVAC System All sections

Climate Control (Coupe): Other Smart Fortwo II

Automatic HVAC System 18 illustrations ~4283 words

Notes on handling refrigerant R134a - AH83.30-N-0003-01A

Air conditioning with refrigerant R134a

The refrigerant R134a is colorless and odorless.

At normal temperatures it is neither toxic nor flammable, and will not explode in the air, no matter what its mixing ratio.

The R134a refrigerant may only be used in air conditioning systems for which R134a has been specifically approved.

The refrigerant R134a must not be mixed with other refrigerants (e.g. R12)

Scheme 71

Scheme 71: Notes on handling refrigerant R134a - AH83.30-N-0003-01A

The refrigerant R134a does not contain any chlorofluorocarbons (CFC). In contrast to other refrigerants (e.g. R12) it is not hazardous to the environment at normal temperatures. The refrigerant R134a does not damage the earth's ozone layer.

Despite these benefits, refrigerant R134a may only be extracted by experts with suitable extraction, recycling and filling equipment that includes integral disposal and reprocessing capabilities.

Procedure for a damaged or leaky air conditioning system - AH83.30-N-0004-01A

All models

The air conditioning system should never be operated if it is damaged or when there is evidence of refrigerant loss.

In the event that refrigerant is lost, lubrication can fail. This will lead to damage of the refrigerant compressor.

Evacuate damaged and/or leaking air conditioning refrigerant circuits as quickly as possible using extraction, processing and recharging equipment with integral disposal and reprocessing capabilities.

Protect air conditioning circuit and components from moisture when carrying out repair work - AH83.30-N-0005-01A

All models with air conditioning

Do not carry repair operations out on the air conditioning circuit in the open air during moist weather

Scheme 72

Scheme 72: Protect air conditioning circuit and components from moisture when carrying out repair work - AH83.3

Moisture in the refrigerant circuit reduces the system's refrigeration output and leads to damage to the components. Acidification in the circuit caused by moisture decomposes the drier element installed (e.g. fluid reservoir, filter drier or desiccant cartridge) and thus damages the entire system.

After separating/unscrewing refrigerant lines, immediately seal off the connection openings so that they are airproof using suitable stop plugs (parts kit).

The drier element must be replaced every time the refrigeration circuit is opened.

Always store all spare components in a dry, sealed-off area. Do not remove stop plugs in new components until just before they are installed. Use special care when handling the fluid reservoir with its integral desiccant.

When a fluid reservoir is left open, the drier element quickly becomes saturated with moisture, rendering it useless.

Check drier element packaging for damage. Dispose of drier elements with damaged packaging.

Install the drier element no later than 20 minutes after opening the packaging.

Further protection against moisture is provided by carefully evacuating the air conditioning system following repair operations.

By generating vacuum in the system, the evacuation process removes any moisture that might have penetrated into the system.

Check air conditioning system for leakage - AR83.30-P-1761MCC

MODEL 450 with CODE (I01) Air conditioning Plus with CODE (I29) Air conditioning Plus (with combination filter and outside temperature indicator), smart & passion A/C drained

MODEL 451 with CODE (I01) Air conditioning Plus A/C drained

MODEL 452 with CODE (I01) Air conditioning Plus A/C drained

MODEL 454 with CODE (I01) Air conditioning Plus with CODE (I77) Manual air conditioning A/C drained

Checking Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00-Z-0001-01A Procedure for a damaged or leaky air conditioning system AH83.30-N-0004-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Connect air conditioning service unit and evacuate air conditioning system Air conditioner service unit 2 Fill air conditioning system with nitrogen Fill system with a system pressure of 15 bar only when engine is cold. This system pressure must be maintained for at least 4 hours. Fill high and low-pressure side of air conditioning with nitrogen. Temperature changes during the pressure test can cause pressure surges, e.g. due to weather changes, transition from day to night, cooling down of engine compartment. Make sure the ambient conditions remain constant. Air conditioner pressure and leak tester (mobile) 3 Check A/C circuit for leaks using leak-detecting spray For pressure loss in the A/C. Leak detection spray If a pressure loss is detected and leak in the A/C circuit is not locatable, check A/C for leaks using leak-detecting additive. See: ↓ *BR00.45-Z-1002-03A Check air conditioning system for leakage (Fill A/C) AR83.30-P-1761MCE 4 Drain nitrogen 5 Refill A/C Type 450 AR83.30-P-1760SM Type 451 AR83.30-P-1760MCC Model 452 AR83.30-P-1760RR Type 454 AR83.30-P-1760FF

NumberDesignationOrder number
BR00.45-Z-1002-03ALeak detection sprayChristof Fischer GmbH, Augsburger Str. 289-293, 70327 Stuttgart Germany Tel. +49 711 30502-0 Fax +49 711 30502-10 www.kaeltefischer.de

REPAIR MATERIALS

Check air conditioning system for leakage - AR83.30-P-1761MCE

MODEL 450 with CODE (I01) Air conditioning Plus with CODE (I29) Air conditioning Plus (with combination filter and outside temperature indicator), smart & passion A/C filled

MODEL 451 with CODE (I01) Air conditioning Plus A/C filled

MODEL 452 with CODE (I01) Air conditioning Plus A/C filled

MODEL 454 with CODE (I01) Air conditioning Plus with CODE (I77) Manual air conditioning A/C filled

Checking Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00-Z-0001-01A Procedure for a damaged or leaky air conditioning system AH83.30-N-0004-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Check complete engine compartment using a UV lamp, remove any contrast agent by washing the engine UV leak detector kit for air conditioning systems 2 Check refrigerant circuit for leaks using leak-detector additive Carry out steps as per the operating instructions of the UV leak detection kit. Use only the approved MB leak detector additives. If it is proven that a different leak detector additive has been used, we will refuse to reimburse costs inside the warranty and goodwill term. Daimler AG reserves the right to perform reexaminations. UV leak detector kit for air conditioning systems

Cleaning the evaporator - AR83.30-P-5555MCC

MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

Scheme 73

Scheme 73: Cleaning the evaporator - AR83.30-P-5555MCC

Removing Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00-Z-0001-01A Procedure for a damaged or leaky air conditioning system AH83.30-N-0004-01A 1 Close air recirculation flap 2 Switch off ignition, blower and air conditioning 3 Remove evaporator temperature sensor AR83.30-P-8085MCC 4 Remove combination filter AP83.00-P-8384MCC 5 Expose condensation drain (1) and place suitable collecting pan underneath 6 Fill disinfection cleaner into disinfection cleaning equipment with connected spray probe (2) Use short spray probe (2). 7 Connect disinfection cleaning equipment to compressed air hose and adjust pressure up to 10 bar Cleaning the evaporator 8 Insert spray probe (2) through opening of evaporator temperature sensor into evaporator housing 9 Cover opening of combination filter slot No disinfection cleaner must enter the interior. 10 Place thumb on plate on spray probe (2) This sets the spray direction of the spray probe (2). When spraying through the evaporator temperature sensor opening, the plate on the spray probe (2) must point towards the vehicle interior. 11 Actuate disinfection cleaning equipment and move back and forth with the spray probe (2) Spray using approx. 0.5 liters of disinfection cleaner. Allow disinfection cleaner to work in for at least 30 min. 12 Check whether disinfection cleaner escapes through the condensation drain (1), clean condensation drain (1) if necessary If disinfection cleaner is only dripping, check condensation drain (1) for contamination and clean. 13 Adjust rotary switch (3) of ventilation system as shown in picture A 14 Start engine, switch on air conditioning system, open all air vents and allow blower to run at highest setting for at least 10 min. Leave the doors on the vehicle open. The evaporator is flushed out. Only when these instructions are complied with exactly is the evaporator cleaned completely and the odor eliminated. Position rotary switch (3) after 5 min as shown in picture B. 15 Switch off ignition Install 16 Remove collecting pan and install condensation drain (1) 17 Replace combination filter AP83.00-P-8384MCC 18 Install evaporator temperature sensor AR83.30-P-8085MCC

Scheme 74

Scheme 74

PARTS ORDERING NOTES Part no. Designation Quantity A 000 581 00 04 Set consisting of pressure-feed spray gun with 2 spray probes and accessories (disinfection cleaning equipment) 1 A 009 989 61 71 Mercedes-Benz Contra Sept disinfection cleaner for air conditioning systems (contents 1 l) 1 Replacement parts Only order when required A 000 997 15 03 Mixed use 1 A 005 997 47 89 Quick coupling 1 A 016 997 91 45 Flat sealing ring 1 A 000 581 00 05 954 mm spray probe 1 A 000 581 01 05 1054 mm spray probe 1

Detach/attach refrigerant compressor - AR83.55-P-5300-04MCU

NumberDesignationEngine 132.9
BA83.55-P-1001-01VBolt, AC compressor to crankcaseNm20
BA83.55-P-1002-01VBolt, AC compressor to oil panNm20

REFRIGERANT COMPRESSOR

Scheme 75

Scheme 75

Scheme 76

Scheme 76
  1. Loosen bolt (1) of refrigerant compressor (A9) at cylinder crankcase above the right wheel well by half a thread. Attachment: Use suitable Torx wrench insert to tighten to the specified tightening torque.
  2. Lift vehicle with lifting platform.
  3. Loosen bolts (2) of refrigerant compressor (A9) at the oil pan (3). The bolts (2) remain on the refrigerant compressor (A9).
  4. Install in the reverse order.

Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. - AS83.00-Z-0001-01A

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.

Potential risks

Risk of explosion

When closed air conditioning systems (charged or empty) become heated, high pressures are produced that can ultimately cause the system to burst. For this reason, all welding and soldering operations on or near closed air conditioning systems are prohibited.

High pressure levels can combine with refrigerant vapors to produce a mixture that is potentially explosive when exposed to atmospheric air.

Risk of poisoning

Refrigerant can decompose when overheated. The resulting substances are toxic and should never be inhaled.

Risk of injury

Refrigerant vapors are heavier than air; this means that escaping gases pose a risk of suffocation for anyone in a work pit beneath the vehicle.

Contact with liquid refrigerant may cause chilblain-like damage to the skin (due to undercooling).

Safety instructions/precautions

  1. All welding, brazing and soldering operations on sealed air conditioning systems and in their immediate vicinity are prohibited.
  2. Never smoke when working with refrigerant, never expose refrigerant to open flames.
  3. A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms immediately and ventilate thoroughly.
  4. All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work on the air conditioning circuit or components.
  5. Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging refrigerant directly into the air is prohibited.
  6. Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment facilities must be used for evacuating refrigerant.
  7. Even after the system has been evacuated, residual pressure may still be present in the system when loosening couplings. Therefore, loosen the couplings carefully, so that the pressure can dissipate slowly.
  8. Avoid all contact with liquid refrigerant.
  9. Always wear safety glasses and protective gloves when working with refrigerant.

First aid measures

In case of eye contact

  1. Immediately flush with plenty of running water and consult a physician.

In case of skin contact

  1. Consult a physician immediately in case of frostbite.

In case of inhalation

  1. of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm.
  2. If the victim's breathing is shallow, or the individual has stopped breathing altogether, tilt the head back and administer artificial resuscitation. Call a physician.

In case of ingestion

  1. Consult a physician immediately.

Safety information: Climate control - AS83.00-Z-9999ZZ

MODEL all

Hazard from contact with parts conducting high voltages. MODEL all with CODE (H25) Eberspacher D 30 W with CODE (H26) Webasto DW 300 AS83.70-Z-0001-01A Risk of death caused by contact with current conducting parts when repairing parts of the external power supply MODEL 639, 903... AS83.00-Z-0002-01A Risk of explosion caused by fuel vapors igniting, risk of poisoning caused by inhaling combustible gases and risk of injury caused by burns during and after operation of heater unit MODEL all mit Zuheizer, Zusatzheizung oder Standheizung AS83.70-Z-0002-01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. MODEL all AS83.00-Z-0001-01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning. Poisoning may result from inhaling overheated refrigerant vapors. Risk of injury. Contact with liquid refrigerant may result in injury to the skin and eyes. MODEL 240 AS83.00-P-0001-01H Risk of explosion from liquified petroleum gas flowing out and from fuel vapors. Risk of poisoning from inhaling combustion gases. BODY 940, 972... AS83.70-Z-0004-01A Risk of poisoning due to inhalation of heater exhaust gases MODELS 901, 902, 903, 904, 905 for underfloor heaters AS83.70-Z-0005-01A

Air conditioning - BA83.30-P-1000-01L

Model 451

NumberDesignationModel 451.3/4
BA83.30-P-1001-01LRefrigerant pressure sensor to AC lineNm10
BA83.30-P-1002-01LBolt, refrigerant line to refrigerant compressorNm20
BA83.30-P-1003-01LBolt, expansion valve to vaporizer tubeNm6
BA83.30-P-1004-01LNut, refrigerant lines to expansion valveNm4
BA83.30-P-1005-01LScrew/bolt at refrigerant line separating pointNm8

AIR CONDITIONING

Refrigerant compressor - BA83.55-P-1000-01V

Engine 132, 780.009

NumberDesignationEngine 132.9Engine 780.009
BA83.55-P-1001-01VBolt, refrigerant compressor to cylinder crankcaseNm20
BA83.55-P-1002-01VBolt, AC compressor to oil panNm20
BA83.55-P-1003-01VBolt, refrigerant line to refrigerant compressorNm20
BA83.55-P-1004-01VScrew/bolt, refrigerant compressor to engineM8Nm20
M10Nm40
BA83.55-P-1005-01VNut, refrigerant line to refrigerant compressorNm20
BA83.55-P-1006-01VNut refrigerant line to expansion valveNm11
BA83.55-P-1007-01VNut, high-voltage battery circuit heater bracket to bodyNm11
BA83.55-P-1008-01VNut, high-voltage battery circuit heat exchanger bracket to bodyNm11
BA83.55-P-1009-01VScrew/bolt, refrigerant line holder to intake side/thrust side refrigerant lineNm11

REFRIGERANT COMPRESSOR

Stationary heater unit - BA83.70-P-1000-01G

Model 451.3/4 with engine 132.9

NumberDesignationModel 451.3/4 with engine 132.9
BA83.70-P-1001-01GNut, tank remover to fuel pump with fuel level sensorNm5

HEATER UNIT OF STATIONARY HEATER

Air conditioning - BF83.30-P-1000-01C

Model 450, 451, 452, 454

Refrigerant filling capacityModel 452.3/4
2.8.07Refrigerant, filling capacityModel 451.3/4

MODIFICATION NOTES

NumberDesignationModel 450.3/4 (up to 02.01.2003)Models 450.3/4 (as of 03.01.2003)Model 451.3/4 except 451.391/491
BF83.30-P-1001-01CRefrigerantsFilling capacityG590 (+25)400 (+50)430 (+0/-20)
Specifications for Operating FluidsSheet

AIR CONDITIONING SYSTEM

NumberDesignationModel 451.391/491Model 452.3/4Model 454
BF83.30-P-1001-01CRefrigerantsFilling capacityG550660 (-25)430 (±20)
Specifications for Operating FluidsSheet

AIR CONDITIONING SYSTEM

Ventilation system, function - GF83.10-P-2000MCU

MODEL 451.3 /4

Scheme 77

Scheme 77: Ventilation system, function - GF83.10-P-2000MCU

The ventilation system prevents the windows from misting up and ensures that there is a uniform, pleasant temperature in the vehicle interior.

Function requirements

  1. Circuit 15 On

The ventilation allows the following operating modes

  1. Fresh air mode
  2. Air recirculation mode (with code (I01) Air conditioning Plus)

The following components are actuated by the heater/AC operating unit

  1. Blend air flap actuator (M16/8) (with code (I01) Air conditioning Plus)
  2. Air recirculation flap actuator motor (M39)

(with code (I01) Air conditioning Plus)

Fresh air mode

The fresh air is drawn in through the air inlet in the front maintenance flap and passed on into the heater or air conditioner housing (with code (I01) Air conditioning Plus) via the pollen filter. Depending on the preselection via the air distribution rotary switch, the fresh air is passed on via the blend air flap into the vehicle interior through the air ducts and air outlets (arrows). On vehicles with code (I01) Air conditioning Plus, the blend air flap is actuated via the blend air flap actuator, which is actuated by the heater/AC operating unit depending on the following information

  1. Specified temperature set on the temperature preselection slider switch
  2. Interior temperature
  3. Temperature on evaporator
  4. Coolant temperature

On vehicles without code (I01) Air conditioning Plus, the blend air flap is adjusted mechanically by the temperature preselection slider switch in the heater/AC operating unit by means of a cable.

Depending on the actuation of the blend air flap, it opens or closes the air passage through the heater heat exchanger.

The blower switch (S98/1) integrated in the heater/air conditioning control unit can be used to regulate the air flow over the blower motor (M2).

Air recirculation mode (with code (I01) Air conditioning Plus)

By actuating the air recirculation switch (N23s3) on the heater/AC operating unit, the air recirculation flap actuator motor is actuated, which closes the air recirculation flap. As a result, supply of outside air is prevented; the air only circulates in the vehicle interior and unpleasant odors and harmful gases are kept out. The visual feedback of air recirculation mode takes place via the light-emitting diode integrated in the air recirculation switch.

Blower, component descriptionM2GF83.10-P-2050MCC
Actuator motors, component descriptionM16/8, M39 For code (I01) Air conditioning PlusGF83.10-P-2201MCC
Component description for the heater/air conditioning operating unitN23 Without code (I01) Air conditioning PlusGF83.40-P-3001MCC
For code (I01) Air conditioning PlusGF83.40-P-3001MCU

Heater circuit function - GF83.20-P-2003MCU

MODEL 451.3 /4

Scheme 78

Scheme 78: Heater circuit function - GF83.20-P-2003MCU

Function

The coolant pump pumps cold coolant through the engine. There, the coolant absorbs the engine heat and then flows over the thermostat to the coolant pump (small coolant circuit).

If the engine has reached its operating temperature, the thermostat opens the large coolant circuit. This subdivides immediately after the thermostat into the cooling circuit and the heating circuit.

In the heating circuit, the coolant flows to the heater heat exchanger via the heating circuit coolant feed pipe. The air flowing through the heater heat exchanger is warmed up in the process and routed into the vehicle interior.

Next, the coolant flows from the heater heat exchanger to the expansion reservoir and from there to the cooler or back to the coolant pump via the coolant return line.

In the cooling circuit, the coolant flows from the thermostat via the coolant feed pipe for the cooling circuit to the cooler and from there onward to the coolant pump via the coolant return line.

Heating system heat exchanger, component descriptionGF83.20-P-3123MCU

Automatic heater (HEAT) function - GF83.25-P-0001MCU

MODEL 451.3 /4 except CODE (I01) Air conditioning Plus

Description

The automatic heater has a mechanically adjustable heating and ventilation system. By means of the automatic heater, the vehicle interior can be heated or ventilated. It is only possible to cool down the vehicle interior to the temperature of the ambient air.

The following functions were realized

  1. Heating circuit
  2. Ventilation
  3. Control

Heating circuit

The coolant is heated up by the engine. After this, the heated-up coolant is routed through the heater heat exchanger, where the heat is given off to the air flowing through the heater heat exchanger. The coolant returns back to the coolant pump via the heater return.

Ventilation

The ventilation system ventilates the interior of the vehicle. The air is drawn in by the blower motor (M2) and passes through the various air ducts to the air distribution flaps which distribute it in the vehicle interior.

Control

A specified temperature is preset on the temperature preselection slider switch. This setting is transmitted to the blend air flap in the heater housing via a cable. Depending on the position of the temperature preselection slider switch, the blend air flap distributes the air flow between the heater heat exchanger and the air outlet nozzles in the vehicle interior.

Automatic heater (HEAT) component locationsGF83.25-P-0001-02MCU
Ventilation system, functionGF83.10-P-2000MCU
Heater circuit functionGF83.20-P-2003MCU
Automatic heater control functionGF83.25-P-2001MCU

Automatic heater control function - GF83.25-P-2001MCU

MODEL 451.3 /4 except CODE (I01) Air conditioning Plus

Function

The automatic heater is regulated mechanically for the most part. The heater/AC operating unit (N23) is the central operating unit for regulating the heater. The air distribution rotary switch makes it possible to adjust which air outlet nozzles the air is to be routed through into the vehicle interior. The intensity of air heating is adjusted via the temperature preselection slider switch.

The heater heat exchanger located in the air flow of the blower delivers the heat of the coolant to the air blowing by. The strength of the air flow is set on the blower switch (S98/1) on the heater/ AC operating unit. The SAM control unit (N10/10) reads in the blower switch and then energizes the blower motor (M2).

Heating system heat exchanger, component descriptionGF83.20-P-3123MCU
Blower, component descriptionM2GF83.10-P-2050MCC
Component description for the SAM control unitN10/10GF54.21-P-4157MCU
Component description for the heater/air conditioning operating unitN23GF83.40-P-3001MCC

Automatic air conditioning (AAC), function - GF83.40-P-0001MCU

MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

The automatic air conditioning has an electronically controlled cooling and heating system. It controls the temperature of the vehicle interior.

Even at low outside temperatures, the air is first cooled down by the evaporator and dehumidified, it is then routed through the heat exchanger where it is heated up to the desired interior temperature.

The following functions are implemented

  1. Ventilation
  2. Heating circuit
  3. Refrigerant circuit
  4. Safety shutoff

Ventilation

The ventilation system ventilates the interior of the vehicle. The air is drawn in by the blower motor (M2) and passes through the various air ducts to the air distribution flaps, which distribute it in the vehicle interior.

Heating circuit

The coolant is heated up by the engine. The heated coolant is subsequently guided through the heat exchanger, where the heat is emitted into the air in the interior. The coolant returns back to the coolant pump via the coolant return line.

Refrigerant circuit

The refrigerant compressor (A9) driven by the engine compresses the refrigerant vapor which is cooled down in the condenser. The refrigerant liquefies during cooling. The refrigerant flows into the evaporator via the expansion valve and is heated there indirectly by the warm air blowing by on the outside of the evaporator. The refrigerant compressor aspirates the refrigerant which has turned gaseous on account of the heat absorption and then compresses it yet again.

Safety shutoff

To prevent damages to the refrigerant compressor, the following automatically shutoffs are integrated

  1. Hot gas shutoff (through integrated sensor in refrigerant compressor)
  2. High-pressure shutoff in the system (through refrigerant pressure sensor (B12))
  3. Low-pressure shutoff in the event of missing refrigerant (through refrigerant pressure sensor)
  4. Overtemperature deactivation (coolant temperature above 115°C)
  5. Undertemperature shutoff (if temperature on evaporator is below 3°C) At outside temperatures below 3°C, the refrigerant compressor cannot be activated.

Automatic air conditioning (AAC) component locations GF83.40-P-0001-01MCU Electrical function diagram for air conditioning PE83.30-P-2050MCU Wiring diagram of air conditioning PE83.30-P-2000MCU Ventilation system, function GF83.10-P-2000MCU Refrigeration cycle function GF83.40-P-2001MCC Heater circuit function GF83.20-P-2003MCU Regulation of Automatic air conditioning, function GF83.40-P-2004MCU

Refrigeration cycle function - GF83.40-P-2001MCC

MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

Scheme 79

Scheme 79: Refrigeration cycle function - GF83.40-P-2001MCC

Function

The refrigerant compressor driven by the engine aspirates the gaseous refrigerant from the evaporator, compresses it, and pushes it into the high-pressure circuit to the condenser as a hot gas.

The refrigerant gives off the compression heat through the surface of the condenser and liquefies in the process.

When it flows through the desiccant cartridge integrated in the condenser, the refrigerant is dehydrated and cleaned of chemical and mechanical impurities.

The expansion valve sprays the liquid refrigerant into the refrigerant line leading to the evaporator. In the process, the refrigerant pressure drops, whereby the aggregate state of the refrigerant starts to change from liquid to gaseous.

The refrigerant flows through the evaporator. While doing so, thermal energy is supplied to the refrigerant through the air blowing by the outside of the evaporator, which is needed by the refrigerant in order to be able to evaporate completely. At the same time, the air blowing by is cooled down, dried, and routed into the vehicle interior.

The condensation water developing while the air is cooling down is routed to the outside.

The refrigerant compressor aspirates the refrigerant which has turned gaseous on account of the heat absorption and then compresses it yet again.

Expansion valve, component descriptionGF83.40-P-2190MCC
Condenser, component descriptionGF83.40-P-2188MCC
Evaporator, component descriptionGF83.40-P-2189MCC
Component description of refrigerant compressorA9 * not for USAGF83.55-P-2108MCC
* for USA onlyGF83.55-P-2108MCU
Evaporator temperature sensor, component descriptionB10/6GF83.57-P-2126MCC
Refrigerant pressure sensor, component descriptionB12GF83.40-P-2193MCC
Blower, component descriptionM2GF83.10-P-2050MCC

Regulation of Automatic air conditioning, function - GF83.40-P-2004MCU

MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

Scheme 80

Scheme 80: Regulation of Automatic air conditioning, function - GF83.40-P-2004MCU

Function

The automatic air conditioning is regulated via the heater/AC operating unit, which is networked with the vehicle electronics via CAN. This permits the best possible climate control while considering any climate-relevant events, as well as the adaptation of the engine management to the power absorption capacity of the refrigerant compressor.

The following information is directly read in by the heater/AC operating unit

  1. Evaporator temperature via evaporator temperature sensor
  2. Refrigerant pressure via refrigerant pressure sensor
  3. Interior temperature via the interior temperature sensor (N23b1) integrated in the heater/AC operating unit
  4. Position feedback by the blend air flap actuator

The following information is transmitted to the heater/AC operating unit via CAN

  1. Outside temperature via the instrument cluster
  2. Coolant temperature via the ME control unit

The following components are directly actuated by the heater/ AC operating unit

  1. Blend air flap actuator
  2. Air recirculation flap actuator motor

The following components are actuated by the heater/AC operating unit via CAN

  1. Refrigerant compressor via SAM control unit To prevent damage to the climate control system, the refrigerant compressor is switched off at refrigerant pressures above 28 bar.
Instrument cluster, component descriptionA1GF54.30-P-6000MCU
Component description of refrigerant compressorA9GF83.55-P-2108MCU
Evaporator temperature sensor, component descriptionB10/6GF83.57-P-2126MCC
Coolant temperature sensor, component descriptionB11/4GF07.04-P-6040MCC
Refrigerant pressure sensor, component descriptionB12GF83.40-P-2193MCC
Outside air temperature sender component descriptionB14GF83.57-P-4000MCC
Actuator motors, component descriptionM16/8, M39GF83.10-P-2201MCC
ME-SFI [ME] control unit, component descriptionN3/10GF07.61-P-6000MCU
Component description for the SAM control unitN10/10GF54.21-P-4157MCU
Component description for the heater/air conditioning operating unitN23GF83.40-P-3001MCU

Survey of automatic air conditioning (AAC), system components - GF83.40-P-9992MCU

MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

Expansion valve, component descriptionGF83.40-P-2190MCC
Condenser, component descriptionGF83.40-P-2188MCC
Evaporator, component descriptionGF83.40-P-2189MCC
Heating system heat exchanger, component descriptionGF83.20-P-3123MCU
Instrument cluster, component descriptionA1GF54.30-P-6000MCU
Component description of refrigerant compressorA9GF83.55-P-2108MCU
Evaporator temperature sensor, component descriptionB10/6GF83.57-P-2126MCC
Coolant temperature sensor, component descriptionB11/4GF07.04-P-6040MCC
Refrigerant pressure sensor, component descriptionB12GF83.40-P-2193MCC
Outside air temperature sender component descriptionB14GF83.57-P-4000MCC
Blower, component descriptionM2GF83.10-P-2050MCC
Actuator motors, component descriptionM16/8, M39GF83.10-P-2201MCC
ME-SFI [ME] control unit, component descriptionN3/10GF07.61-P-6000MCU
Component description for the SAM control unitN10/10GF54.21-P-4157MCU
Component description for the heater/air conditioning operating unitN23GF83.40-P-3001MCU
Table of contents, automatic air conditioning (AAC) function descriptionGF83.40-P-0999MCU

Legend of electrical function diagram for air conditioning - PE83.30-P-2050-60MCU

MODEL 451

CodeDesignationCoordinates
A1Instrument cluster21G
A9Refrigerant compressor3L
B10/6Evaporator temperature sensor12H
B12Refrigerant pressure sensor12H
B14Outside temperature display temperature sensor22E
M2Blower motor9K
M16/8Blend air flap actuator8G
M39Air recirculation flap actuator motor8G
N3/10ME-SFI [ME] control unit17D
N10/10SAM control unit2G
N23Heater/AC operating unit10G
R1Rear window defroster3B
R14Blower motor series resistor group13L
S98/1Blower switch11J
X11/4Data link connector8C

Document number: pe83.30-p-2050-99mcu

Document title: Electrical function diagram for air conditioning

CodeDesignationPosition
A1Instrument cluster21 G
A9AC compressor3 L
B10/6Evaporator temperature sensor12 H
B12Refrigerant pressure sensor12 H
B14Ambient temperature display temperature sensor22 E
M16/8Blending air flap actuator8 G
M2Blower motor9 L
M39Recirculated air flap actuator motor8 H
N10/10SAM control unit2 G
N23Heater/AC operating unit10 H
N3/10ME-SFI [ME] control module17 D
R1Heated rear window3 B
R14Blower motor preresistor group13 L
S98/1Blower switch11 J
X11/4Data link connector8 C

Scheme 81

Scheme 81

Scheme 82

Scheme 82

Electrical function diagram for air conditioning - PE83.30-P-2050MCU

MODEL 451

PE83.30-P-2050-99MCUElectrical function diagram for air conditioningPE83.30-P-2050-99MCU
PE83.30-P-2050-60MCULegend of electrical function diagram for air conditioningPE83.30-P-2050-60MCU
OV00.01-P-1901-03MCCUse of wiring diagramsOV00.01-P-1901-03MCC
OV00.01-P-1901MCUSearch aid for all wiring diagram groupsOV00.01-P-1901MCU
OV00.01-P-1001-27MCAbbreviations for wiring diagramsOV00.01-P-1001-27MC
OV00.01-P-1001-28MCAbbreviations of signal and circuit designations for wiring diagramsOV00.01-P-1001-28MC
GF00.19-P-1000MCULocation and assignment of line and connectorsGF00.19-P-1000MCU
GF00.19-P-2000MCULocation and assignment of ground pointsGF00.19-P-2000MCU
GF00.19-P-3000MCULocation and assignment of Z connector sleeves (line connectors in wiring harness)GF00.19-P-3000MCU
PE07.00-P-1100MCUFurther wiring diagramsPE07.00-P-1100MCU
PE54.00-P-1100MCUFurther wiring diagramsPE54.00-P-1100MCU
PE83.00-P-1100MCUFurther wiring diagramsPE83.00-P-1100MCU

452 589 00 33 00 Cutting tool set - WS83.00-P-0052B

FG 83/Set B

MODEL 452, 451, 164, 251

Use

Separation of high-pressure/low-pressure A/C lines with connector dimensions 5/8" and 1/2".

Note. smart no.: 001 5804 V000 0000 00 3/8" and 3/4" cutting tools have part number 164 589 03 33 00.

Scheme 83

Scheme 83: 452 589 00 33 00 Cutting tool set - WS83.00-P-0052B

Scheme 84

Scheme 84

203 589 03 10 00 Valve wrench - WS83.00-P-0060A

FG 83/Set A

MODEL 164, 168, 169, 170, 171.4, 202, 203, 204, 207, 209, 211, 212, 216, 220, 221, 230, 240, 245, 251, 451, 454, 461, 463, 414

9.8.07Replacement for 203 589 01 10 00WS83.00-P-3023K
Replacement for 454 589 01 33 00WS83.00-P-0056B

MODIFICATION NOTES

Use

Valve wrench for assembling and disassembling the valve element at the high and low-pressure service valves.

Scheme 85

Scheme 85

Scheme 86

Scheme 86

Scheme 87

Scheme 87

Scheme 88

Scheme 88