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
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
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
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1002-03A | Leak detection spray | Christof 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
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
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
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA83.55-P-1001-01V | Bolt, AC compressor to crankcase | Nm | 20 |
| BA83.55-P-1002-01V | Bolt, AC compressor to oil pan | Nm | 20 |
REFRIGERANT COMPRESSOR
Scheme 75
Scheme 76
- 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.
- Lift vehicle with lifting platform.
- Loosen bolts (2) of refrigerant compressor (A9) at the oil pan (3). The bolts (2) remain on the refrigerant compressor (A9).
- 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
- All welding, brazing and soldering operations on sealed air conditioning systems and in their immediate vicinity are prohibited.
- Never smoke when working with refrigerant, never expose refrigerant to open flames.
- A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms immediately and ventilate thoroughly.
- All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work on the air conditioning circuit or components.
- Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging refrigerant directly into the air is prohibited.
- Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment facilities must be used for evacuating refrigerant.
- 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.
- Avoid all contact with liquid refrigerant.
- Always wear safety glasses and protective gloves when working with refrigerant.
First aid measures
In case of eye contact
- Immediately flush with plenty of running water and consult a physician.
In case of skin contact
- Consult a physician immediately in case of frostbite.
In case of inhalation
- of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm.
- 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
- 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
| Number | Designation | Model 451.3/4 | |
|---|---|---|---|
| BA83.30-P-1001-01L | Refrigerant pressure sensor to AC line | Nm | 10 |
| BA83.30-P-1002-01L | Bolt, refrigerant line to refrigerant compressor | Nm | 20 |
| BA83.30-P-1003-01L | Bolt, expansion valve to vaporizer tube | Nm | 6 |
| BA83.30-P-1004-01L | Nut, refrigerant lines to expansion valve | Nm | 4 |
| BA83.30-P-1005-01L | Screw/bolt at refrigerant line separating point | Nm | 8 |
AIR CONDITIONING
Refrigerant compressor - BA83.55-P-1000-01V
Engine 132, 780.009
| Number | Designation | Engine 132.9 | Engine 780.009 | ||
|---|---|---|---|---|---|
| BA83.55-P-1001-01V | Bolt, refrigerant compressor to cylinder crankcase | Nm | 20 | ||
| BA83.55-P-1002-01V | Bolt, AC compressor to oil pan | Nm | 20 | ||
| BA83.55-P-1003-01V | Bolt, refrigerant line to refrigerant compressor | Nm | 20 | ||
| BA83.55-P-1004-01V | Screw/bolt, refrigerant compressor to engine | M8 | Nm | 20 | |
| M10 | Nm | 40 | |||
| BA83.55-P-1005-01V | Nut, refrigerant line to refrigerant compressor | Nm | 20 | ||
| BA83.55-P-1006-01V | Nut refrigerant line to expansion valve | Nm | 11 | ||
| BA83.55-P-1007-01V | Nut, high-voltage battery circuit heater bracket to body | Nm | 11 | ||
| BA83.55-P-1008-01V | Nut, high-voltage battery circuit heat exchanger bracket to body | Nm | 11 | ||
| BA83.55-P-1009-01V | Screw/bolt, refrigerant line holder to intake side/thrust side refrigerant line | Nm | 11 | ||
REFRIGERANT COMPRESSOR
Stationary heater unit - BA83.70-P-1000-01G
Model 451.3/4 with engine 132.9
| Number | Designation | Model 451.3/4 with engine 132.9 | |
|---|---|---|---|
| BA83.70-P-1001-01G | Nut, tank remover to fuel pump with fuel level sensor | Nm | 5 |
HEATER UNIT OF STATIONARY HEATER
Air conditioning - BF83.30-P-1000-01C
Model 450, 451, 452, 454
| Refrigerant filling capacity | Model 452.3/4 | |
|---|---|---|
| 2.8.07 | Refrigerant, filling capacity | Model 451.3/4 |
MODIFICATION NOTES
| Number | Designation | Model 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-1001-01C | Refrigerants | Filling capacity | G | 590 (+25) | 400 (+50) | 430 (+0/-20) |
| Specifications for Operating Fluids | Sheet | |||||
AIR CONDITIONING SYSTEM
| Number | Designation | Model 451.391/491 | Model 452.3/4 | Model 454 | ||
|---|---|---|---|---|---|---|
| BF83.30-P-1001-01C | Refrigerants | Filling capacity | G | 550 | 660 (-25) | 430 (±20) |
| Specifications for Operating Fluids | Sheet | |||||
AIR CONDITIONING SYSTEM
Ventilation system, function - GF83.10-P-2000MCU
MODEL 451.3 /4
Scheme 77
The ventilation system prevents the windows from misting up and ensures that there is a uniform, pleasant temperature in the vehicle interior.
Function requirements
- Circuit 15 On
The ventilation allows the following operating modes
- Fresh air mode
- Air recirculation mode (with code (I01) Air conditioning Plus)
The following components are actuated by the heater/AC operating unit
- Blend air flap actuator (M16/8) (with code (I01) Air conditioning Plus)
- 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
- Specified temperature set on the temperature preselection slider switch
- Interior temperature
- Temperature on evaporator
- 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 description | M2 | GF83.10-P-2050MCC |
|---|---|---|
| Actuator motors, component description | M16/8, M39 For code (I01) Air conditioning Plus | GF83.10-P-2201MCC |
| Component description for the heater/air conditioning operating unit | N23 Without code (I01) Air conditioning Plus | GF83.40-P-3001MCC |
| For code (I01) Air conditioning Plus | GF83.40-P-3001MCU |
Heater circuit function - GF83.20-P-2003MCU
MODEL 451.3 /4
Scheme 78
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 description | GF83.20-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
- Heating circuit
- Ventilation
- 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 locations | GF83.25-P-0001-02MCU |
|---|---|
| Ventilation system, function | GF83.10-P-2000MCU |
| Heater circuit function | GF83.20-P-2003MCU |
| Automatic heater control function | GF83.25-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 description | GF83.20-P-3123MCU | |
|---|---|---|
| Blower, component description | M2 | GF83.10-P-2050MCC |
| Component description for the SAM control unit | N10/10 | GF54.21-P-4157MCU |
| Component description for the heater/air conditioning operating unit | N23 | GF83.40-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
- Ventilation
- Heating circuit
- Refrigerant circuit
- 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
- Hot gas shutoff (through integrated sensor in refrigerant compressor)
- High-pressure shutoff in the system (through refrigerant pressure sensor (B12))
- Low-pressure shutoff in the event of missing refrigerant (through refrigerant pressure sensor)
- Overtemperature deactivation (coolant temperature above 115°C)
- 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
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 description | GF83.40-P-2190MCC | |
|---|---|---|
| Condenser, component description | GF83.40-P-2188MCC | |
| Evaporator, component description | GF83.40-P-2189MCC | |
| Component description of refrigerant compressor | A9 * not for USA | GF83.55-P-2108MCC |
| * for USA only | GF83.55-P-2108MCU | |
| Evaporator temperature sensor, component description | B10/6 | GF83.57-P-2126MCC |
| Refrigerant pressure sensor, component description | B12 | GF83.40-P-2193MCC |
| Blower, component description | M2 | GF83.10-P-2050MCC |
Regulation of Automatic air conditioning, function - GF83.40-P-2004MCU
MODEL 451.3 /4 with CODE (I01) Air conditioning Plus
Scheme 80
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
- Evaporator temperature via evaporator temperature sensor
- Refrigerant pressure via refrigerant pressure sensor
- Interior temperature via the interior temperature sensor (N23b1) integrated in the heater/AC operating unit
- Position feedback by the blend air flap actuator
The following information is transmitted to the heater/AC operating unit via CAN
- Outside temperature via the instrument cluster
- Coolant temperature via the ME control unit
The following components are directly actuated by the heater/ AC operating unit
- Blend air flap actuator
- Air recirculation flap actuator motor
The following components are actuated by the heater/AC operating unit via CAN
- 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 description | A1 | GF54.30-P-6000MCU |
|---|---|---|
| Component description of refrigerant compressor | A9 | GF83.55-P-2108MCU |
| Evaporator temperature sensor, component description | B10/6 | GF83.57-P-2126MCC |
| Coolant temperature sensor, component description | B11/4 | GF07.04-P-6040MCC |
| Refrigerant pressure sensor, component description | B12 | GF83.40-P-2193MCC |
| Outside air temperature sender component description | B14 | GF83.57-P-4000MCC |
| Actuator motors, component description | M16/8, M39 | GF83.10-P-2201MCC |
| ME-SFI [ME] control unit, component description | N3/10 | GF07.61-P-6000MCU |
| Component description for the SAM control unit | N10/10 | GF54.21-P-4157MCU |
| Component description for the heater/air conditioning operating unit | N23 | GF83.40-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 description | GF83.40-P-2190MCC | |
|---|---|---|
| Condenser, component description | GF83.40-P-2188MCC | |
| Evaporator, component description | GF83.40-P-2189MCC | |
| Heating system heat exchanger, component description | GF83.20-P-3123MCU | |
| Instrument cluster, component description | A1 | GF54.30-P-6000MCU |
| Component description of refrigerant compressor | A9 | GF83.55-P-2108MCU |
| Evaporator temperature sensor, component description | B10/6 | GF83.57-P-2126MCC |
| Coolant temperature sensor, component description | B11/4 | GF07.04-P-6040MCC |
| Refrigerant pressure sensor, component description | B12 | GF83.40-P-2193MCC |
| Outside air temperature sender component description | B14 | GF83.57-P-4000MCC |
| Blower, component description | M2 | GF83.10-P-2050MCC |
| Actuator motors, component description | M16/8, M39 | GF83.10-P-2201MCC |
| ME-SFI [ME] control unit, component description | N3/10 | GF07.61-P-6000MCU |
| Component description for the SAM control unit | N10/10 | GF54.21-P-4157MCU |
| Component description for the heater/air conditioning operating unit | N23 | GF83.40-P-3001MCU |
| Table of contents, automatic air conditioning (AAC) function description | GF83.40-P-0999MCU |
Legend of electrical function diagram for air conditioning - PE83.30-P-2050-60MCU
MODEL 451
| Code | Designation | Coordinates |
|---|---|---|
| A1 | Instrument cluster | 21G |
| A9 | Refrigerant compressor | 3L |
| B10/6 | Evaporator temperature sensor | 12H |
| B12 | Refrigerant pressure sensor | 12H |
| B14 | Outside temperature display temperature sensor | 22E |
| M2 | Blower motor | 9K |
| M16/8 | Blend air flap actuator | 8G |
| M39 | Air recirculation flap actuator motor | 8G |
| N3/10 | ME-SFI [ME] control unit | 17D |
| N10/10 | SAM control unit | 2G |
| N23 | Heater/AC operating unit | 10G |
| R1 | Rear window defroster | 3B |
| R14 | Blower motor series resistor group | 13L |
| S98/1 | Blower switch | 11J |
| X11/4 | Data link connector | 8C |
Document number: pe83.30-p-2050-99mcu
Document title: Electrical function diagram for air conditioning
| Code | Designation | Position |
|---|---|---|
| A1 | Instrument cluster | 21 G |
| A9 | AC compressor | 3 L |
| B10/6 | Evaporator temperature sensor | 12 H |
| B12 | Refrigerant pressure sensor | 12 H |
| B14 | Ambient temperature display temperature sensor | 22 E |
| M16/8 | Blending air flap actuator | 8 G |
| M2 | Blower motor | 9 L |
| M39 | Recirculated air flap actuator motor | 8 H |
| N10/10 | SAM control unit | 2 G |
| N23 | Heater/AC operating unit | 10 H |
| N3/10 | ME-SFI [ME] control module | 17 D |
| R1 | Heated rear window | 3 B |
| R14 | Blower motor preresistor group | 13 L |
| S98/1 | Blower switch | 11 J |
| X11/4 | Data link connector | 8 C |
Scheme 81
Scheme 82
Electrical function diagram for air conditioning - PE83.30-P-2050MCU
MODEL 451
| PE83.30-P-2050-99MCU | Electrical function diagram for air conditioning | PE83.30-P-2050-99MCU | |
|---|---|---|---|
| PE83.30-P-2050-60MCU | Legend of electrical function diagram for air conditioning | PE83.30-P-2050-60MCU | |
| OV00.01-P-1901-03MCC | Use of wiring diagrams | OV00.01-P-1901-03MCC | |
| OV00.01-P-1901MCU | Search aid for all wiring diagram groups | OV00.01-P-1901MCU | |
| OV00.01-P-1001-27MC | Abbreviations for wiring diagrams | OV00.01-P-1001-27MC | |
| OV00.01-P-1001-28MC | Abbreviations of signal and circuit designations for wiring diagrams | OV00.01-P-1001-28MC | |
| GF00.19-P-1000MCU | Location and assignment of line and connectors | GF00.19-P-1000MCU | |
| GF00.19-P-2000MCU | Location and assignment of ground points | GF00.19-P-2000MCU | |
| GF00.19-P-3000MCU | Location and assignment of Z connector sleeves (line connectors in wiring harness) | GF00.19-P-3000MCU | |
| PE07.00-P-1100MCU | Further wiring diagrams | PE07.00-P-1100MCU | |
| PE54.00-P-1100MCU | Further wiring diagrams | PE54.00-P-1100MCU | |
| PE83.00-P-1100MCU | Further wiring diagrams | PE83.00-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 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
| 9.8.07 | Replacement for 203 589 01 10 00 | WS83.00-P-3023K |
|---|---|---|
| Replacement for 454 589 01 33 00 | WS83.00-P-0056B |
MODIFICATION NOTES
Use
Valve wrench for assembling and disassembling the valve element at the high and low-pressure service valves.