Climate Control (Coupe): Removal & Installation Smart Fortwo II

Replace combination filter - AP83.00-P-8384MCC

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

Scheme 20

MODIFICATION NOTES

Remove/install 1 Adjust left seat to the rear 2 Remove foot support on passenger side On vehicles with code (RHD) right-hand drive vehicle AR68.30-P-1340MCC 3 Unscrew bolts (2) on cover (1) Only if the bolts (2) are fitted. 4 Unclip bracket (arrows) on cover (1) and remove cover (1) If the brackets (arrows) on the cover (1) are damaged, then cover (1) is fastened with bolts (2). Installation: Pay attention to the correct retention of the bracket (arrows) on the cover (1). If necessary fasten cover (1) with bolts (2). 5 Remove combination filter (3) from the air conditioner housing Installation: Observe installation position of combination filter (3). Replace combination filter (3). 6 Install in the reverse order

Scheme 21

Scheme 22

Air recirculation unit, remove/install - AR83.10-P-0100MCU

MODEL 451.3 /4

Scheme 23

Remove/install 1 Remove heater/air conditioner housing (3) Model 451 (except 451.391/491) with code (I01) Air conditioning Plus AR83.30-P-5200MCU Model 451 (except 451.391/491) without code (I01) Air conditioning Plus AR83.25-P-1000MCU Model 451.391/491 AR83.30-P-5200MEV 2 Disconnect electrical connector (2) from air recirculation flap actuator motor (M39) On vehicles with code (I01) Air conditioning Plus 3 Release air recirculation unit (1) from heater/ air conditioner housing (3) by twisting and remove Installation: Ensure that the seal (4) is correctly located. 4 Remove air recirculation flap actuator motor (M39) from air recirculation unit (1) When replacing the air recirculation unit (1) in vehicles with code (I01) Air conditioning Plus. 5 Install in the reverse order

Remove/install flexible shaft for air distribution - AR83.10-P-1401MCC

MODEL 451.3 /4

Shown on heater/AC operating unit with code (I01) Air conditioning Plus

Scheme 24

Remove/install 1 Remove heater/AC operating unit (N23) With code (I01) A/C Plus up to 30.8.10 AR83.25-P-1124MCC With code (I01) A/C Plus as of 31.8.10 AR83.25-P-1124MCF Without code (I01) A/C Plus up to 30.8.10 AR83.20-P-1850MCC Without code (I01) A/C Plus as of 31.8.10 AR83.20-P-1850MCF 2 Flexible shaft (1) on operating unit Unclip heater/AC operating unit (N23) and remove 3 Install in the reverse order

Remove/install actuator motor for fresh and recirculated air flaps - AR83.10-P-2001MCU

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

Scheme 25

Remove/install 1 Remove top part of instrument panel AR68.10-P-1020MCU 2 Disconnect electrical connector (1) from air recirculation flap actuator motor (M39) 3 Remove bolts (2) and remove air recirculation flap actuator motor (M39) 4 Install in the reverse order 5 Carry out function test on air recirculation flap actuator motor (M39)

Remove/install blend air flap actuator motor - AR83.10-P-2026MCC

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

Scheme 26

Remove/install 1 Move right seat toward rear 2 Disconnect electrical connector (1) at blend air flap actuator (M16/8) 3 Remove bolts (2) and remove blend air flap actuator (M16/8) Installation: Counterhold driver shaft of blend air flap actuator (M16/8) on the opposite side on air conditioner housing (arrow). 4 Install in the reverse order 5 Carry out function test on blend air flap actuator (M16/8)

Remove/install fresh-air intake - AR83.10-P-3220MCU

MODEL 451.3 /4

Scheme 27

Scheme 28

Remove/install 1 Remove windshield washer fluid reservoir AR82.35-P-6000MCU 2 Release coolant hose (5) from bracket (arrow B) on fresh-air intake (1) 3 Unclip brake fluid reservoir (2) in the area marked (arrow A) using a suitable screwdriver (3) and place to one side 4 Unscrew nuts (4) on fresh-air intake (1) 5 Remove fresh-air intake (1) Installation: Ensure that gasket (6) is properly seated. 6 Install in the reverse order

Remove/install heat exchanger - AR83.20-P-1100MCU

MODEL 451.3 /4 (except 451.391 /491)

Scheme 29

Removing 1 Drain coolant AR20.00-P-1142MCU 2 Remove foot support on passenger side AR68.30-P-1340MCC 3 Remove bolt (2) and remove cover (1) 4 Use rag (7) to protect battery and battery recess against escaping coolant 5 Release clamps (4) at coolant lines (3) and detach 6 Pull coolant lines (3) out of heater heat exchanger (5) Make sure that coolant does not run over the battery or into the battery recess, as this may damage the on-board electrical system, the battery or the body. 7 Pull heater heat exchanger (5) out of the heater/air conditioner housing and put down Make sure that coolant does not run over the battery or into the battery recess, as this may damage the on-board electrical system, the battery or the body. Install 8 Insert heater heat exchanger (5) into the heater/air conditioner housing 9 Position coolant lines (3) on heater heat exchanger (5) and secure in place using clamps (4) Replace seals (6). 10 Top up with coolant and check cooling system in area of heater heat exchanger (5) and coolant lines (3) for signs of leaks AR20.00-P-1142MCU 11 Insert cover (1) into heater/air conditioner housing in the marked areas (arrows) and tighten bolt (2) 12 Remove rag (7) 13 Install foot support on passenger side AR68.30-P-1340MCC

Remove/install heater control cable - AR83.20-P-1400MCU

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

Scheme 30

Remove/install 1 Remove heater/AC operating unit (N23) Up to 30.8.10 AR83.20-P-1850MCC As of 31.8.10 AR83.20-P-1850MCF 2 Press back catch hook (3) and remove eyelet (2) on heater/AC operating unit (N23) 3 Press catch hook (4) together using suitable pliers, slide cable (1) out of bracket on heater/AC operating unit (N23) in direction of arrow and remove 4 Install in the reverse order

Remove/install heater/ventilation operating unit - AR83.20-P-1850MCC

MODEL 451.3 /4 up to 30.8.10 except CODE (I01) Air conditioning Plus

Scheme 31

Remove/install 1.1 Remove center stowage compartment on center part of dashboard For vehicles without code (C50) smart radio 10 or without code (C57) smart radio 9 AR68.10-P-1620MCC 1.2 Remove smart radio 9 or smart radio 10 For vehicles with code (C50) smart radio 10 or with code (C57) smart radio 9 AR82.60-P-7502MCC 2 Turn air distribution control lever (1) to footwell ventilation position 3 Move temperature control lever (2) to lowest position 4 Set fan speed control lever (4) to speed 2 5 Remove screws (3) on heater/air conditioning operating unit (N23) 6 Use a suitable screwdriver (10) to release bracket (arrow C) of flexible shaft (6) and detach flexible shaft (6) from guide wheel (11) 7 Press back catch hook (arrow B) and remove eyelet (8) from relay lever (9) 8 Press catch hook (arrows A) together using suitable pliers and press cable (7) out of bracket on heater housing in direction of arrow 9 Release electrical connectors (5) and disconnect from heater/AC operating unit (N23) 10 Remove heater/air conditioning operating unit (N23) Note installation position of flexible shaft (6) and cable (7). 11 Remove cable (7) When the operating unit is replaced Heater/AC (N23). AR83.20-P-1400MCC 12 Remove flexible shaft (6) When the operating unit is replaced Heater/AC (N23). AR83.10-P-1401MCC 13 Install in the reverse order 14 Perform function test on heater/air conditioning operating unit (N23)

Remove/install heater/ventilation operating unit - AR83.20-P-1850MCF

MODEL 451.3 /4 as of 31.8.10 except CODE (I01) Air conditioning Plus

Scheme 32

Remove/install 1 Remove center air vent AR68.10-P-1150MCF 2 Remove bolts (1) 3 Unhook heater operating unit / A/C (N23) from bracket (arrow) at left and right and remove Note installation position of flexible shaft (2). 4 Remove flexible shaft (2) When the operating unit is replaced Heater/AC (N23). AR83.10-P-1401MCC 5 Remove heater control cable When the operating unit is replaced Heater/AC (N23). * not for USA AR83.20-P-1400MCC * for USA only AR83.20-P-1400MCU 6 Install in the reverse order 7 Perform function test on heater/air conditioning operating unit (N23)

Remove/install heater housing - AR83.25-P-1000MCU

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

Scheme 33

Scheme 34

Scheme 35

Remove/install 1 Remove front CBS AR88.00-P-1010MCC 2 Drain coolant AR20.00-P-1142MCU 3 Release clamps (1) on coolant hoses (2) and then remove 4 Remove crossmember below instrument panel AR62.30-P-1250MCU 5 Disconnect heater or AC connector (X85/10) 6 Place right front floor covering in area of heater housing (3) to one side 7 Unclip retaining clip (6) of electrical wiring harness (7) on heater housing (3) 8 Place left front floor covering in area of heater housing (3) to one side 9 Unscrew nuts (4) on heater housing (3) 10 Remove heater housing (3) from firewall and route to the rear until the coolant hoses (2) are accessible 11 Detach coolant hoses (2) Make sure that the interior is not contaminated by any escaping coolant, as contaminated parts will have to be cleaned or replaced. Note installation position of coolant hoses (2). Installation: Position clamps (1) on coolant hoses (2), slide coolant hoses (2) onto connections on heater housing (3) and fasten clamps (1) in place. Position openings of clamps (1) such that they face upward or to the right and that they do not come into contact with the coolant hoses (2). 12 Remove heater housing (3) from vehicle Make sure that the interior is not contaminated by any escaping coolant, as contaminated parts will have to be cleaned or replaced. 13 Detach fresh air case (11) from the heater housing (3) by turning and remove When replacing the heater housing (3). 14 Detach electrical connector (9), release lock and detach blower motor (M2) by turning it counterclockwise and then remove from the heater housing (3) When replacing the heater housing (3). 15 Detach electrical connector (10) and release series resistor group for blower motor (R14) by turning it clockwise and then remove from the heater housing (3) When replacing the heater housing (3). 16 Expose electrical wiring harness (13) on heater housing (3) and remove When replacing the heater housing (3). 17 Remove bolt (5) and remove cover (8) When replacing the heater housing (3). 18 Pull heat exchanger (12) out of heater housing (3) When replacing the heater housing (3). 19 Install in the reverse order

Remove and install air conditioning control and operating unit - AR83.25-P-1124MCC

MODEL 451.3 /4 up to 30.8.10 with CODE (I01) Air conditioning Plus

Scheme 36

Remove/install 1.1 Remove center stowage compartment on center part of dashboard For vehicles without code (C50) smart radio 10 or without code (C57) smart radio 9 AR68.10-P-1620MCC 1.2 Remove smart radio 9 or smart radio 10 For vehicles with code (C50) smart radio 10 or with code (C57) smart radio 9 AR82.60-P-7502MCC 2 Turn air distribution control lever (1) to footwell ventilation position 3 Set temperature control lever and fan stage control lever to center position 4 Remove screws (2) on heater/air conditioning operating unit (N23) 5 Use a suitable screwdriver (5) to release bracket (arrow) of flexible shaft (3) and detach flexible shaft (3) from guide wheel (4) 6 Detach electrical connector (6) from heater/ air conditioning operating unit (N23) 7 Release locks (8) and detach electrical connectors (7) 8 Remove heater/air conditioning operating unit (N23) 9 Remove flexible shaft (3) When the operating unit is replaced Heater/AC (N23). AR83.10-P-1401MCC 10 Install in the reverse order 11 Perform function test on heater/air conditioning operating unit (N23)

Remove and install air conditioning control and operating unit - AR83.25-P-1124MCF

MODEL 451.3 /4 as of 31.8.10 with CODE (I01) Air conditioning Plus

Scheme 37

Remove/install 1 Remove center air vent AR68.10-P-1150MCF 2 Remove bolts (1) 3 Unhook heater operating unit / A/C (N23) from bracket (arrow) at left and right and remove Note installation position of flexible shaft (2). 4 Remove flexible shaft (2) When the operating unit is replaced Heater/AC (N23). AR83.10-P-1401MCC 5 Install in the reverse order 6 Perform function test on heater/air conditioning operating unit (N23)

Remove and install blower motor - AR83.25-P-1200MCU

MODEL 451.3 /4

Scheme 38

Shown on vehicle with Code (I01) AC Plus

Remove/install 1 Adjust left seat to the rear 2 Detach electrical connector (2) on blower motor (M2) 3 Release lock (1) on blower motor (M2) 4 Detach blower motor (M2) by turning in counterclockwise direction and removing from air conditioning or heater housing 5 Install in the reverse order 6 Perform function test on blower motor (M2)

Remove and install series resistor for heater blower - AR83.25-P-1250MCC

MODEL 451.3 /4

Scheme 39

Remove/install 1 Disconnect electrical connector (1) 2 Release blower motor series resistor group (R14) by turning clockwise and remove 3 Install in the reverse order

Remove/install air conditioner housing - AR83.30-P-5200MCU

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

Scheme 40

Scheme 41

Scheme 42

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Remove front CBS AR88.00-P-1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 3 Disconnect fully automatic air conditioning service station Air conditioner service unit 4 Remove front module AR62.30-P-1575MCU 5 Drain coolant AR20.00-P-1142MCU 6 Unclip brake fluid reservoir (8) in the area marked (arrow) using a suitable screwdriver (7) and place to one side 7 Disconnect electrical connector (6) from refrigerant pressure sensor (B12) 8 Unscrew nut (2) *BA83.30-P-1004-01L 9 Pull out refrigerant lines (3) at expansion valve (1) and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting. 10 Loosen clamps (5) on coolant hoses (4) and detach coolant hoses (4) Collect discharged coolant in a suitable container. 11 Remove crossmember below dashboard AR62.30-P-1250MCU 12 Disconnect heater or AC connector (X85/10) 13 Remove retaining clip at right front floor covering (22) and place right front floor covering (22) in area of air conditioner housing (13) to one side 14 Detach condensation water drain hose (23) from air conditioner housing (13) Installation: It must be ensured that the condensation water drain hose (23) is correctly aligned and engaged at the connection to the air conditioner housing (13). 15 Unclip retaining clip (20) of main wiring harness (21) at air conditioner housing (13) 16 Place left front floor covering (22) in area of air conditioner housing (13) to one side 17 Unscrew nuts (9) from air conditioner housing (13) 18 Remove air conditioner housing (13) from vehicle Ensure that the interior is not dirtied by discharged coolant, as dirty parts will have to be cleaned or replaced. 19 Disconnect electrical connector (19) from air recirculation flap actuator motor (M39) When replacing the air conditioner housing (13). 20 Release air recirculation unit (18) from air conditioner housing (13) by twisting and remove When replacing the air conditioner housing (13). 21 Disconnect electrical connector (14), remove bolts (15) and remove blend air flap actuator (M16/8) When replacing the air conditioner housing (13). Installation: Counterhold driver shaft on the opposite side on air conditioner housing (13). 22 Disconnect electrical connector (16) and pull evaporator temperature sensor (B10/6) out of air conditioner housing (13) When replacing the air conditioner housing (13). 23 Disconnect electrical connector (11), release lock (10) and loosen blower motor (M2) by turning counterclockwise and pull out of air conditioner housing (13) When replacing the air conditioner housing (13). 24 Disconnect electrical connector (12) and release blower motor series resistor group (R14) by twisting clockwise and remove When replacing the air conditioner housing (13). 25 Detach air conditioner housing wiring harness (17) from air conditioner housing (13) and remove When replacing the air conditioner housing (13). 26 Remove heat exchanger When replacing the air conditioner housing (13). AR83.20-P-1100MCU 27 Remove combination filter When replacing the air conditioner housing (13). AP83.00-P-8384MCC 28 Install in the reverse order

Scheme 43

AIR CONDITIONING

Remove/install refrigerant pressure sensor - AR83.30-P-5430MCC

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

Scheme 44

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling refrigerant R134a AH83.30-N-0003-01A 1 Remove front CBS AR88.00-P-1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 3 Disconnect electrical connector (1) from refrigerant pressure sensor (B12) 4 Remove refrigerant pressure sensor (B12) from refrigerant line (2) Close off refrigerant line (2) using appropriate stop plug, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. *BA83.30-P-1001-01L 5 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30-P-6525MCC 6 Install in the reverse order

AIR CONDITIONING

Remove/install expansion valve - AR83.30-P-5520MCU

MODEL 451.3 /4 (except 451.391 /491) with CODE (I01) Air conditioning Plus

Scheme 45

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Remove front CBS AR88.00-P-1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 3 Remove front module AR62.30-P-1575MCU 4 Unscrew nut (2) *BA83.30-P-1004-01L 5 Pull out refrigerant lines (3) at expansion valve (1) and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A 6 Remove bolts (4) *BA83.30-P-1003-01L 7 Remove expansion valve (1) Close off openings at the evaporator connection lines using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal rings at evaporator connecting lines and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A 8 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30-P-6525MCC 9 Install in the reverse order

Scheme 46

AIR CONDITIONING

Remove/install intake manifold filling valve - AR83.30-P-5535MCC

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

Scheme 47

MODIFICATION NOTES

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 2 Disconnect air conditioner service unit from the service valve of the suction line (2) and the service valve of the pressure line (3) Air conditioner service unit 3 Remove valve element (1) on service valve of suction line (2) In model 451.391/491, the valve insert (1) must be removed using a commercially available valve wrench for Schrader valves (connection width 4.5 mm). In model 451 (except 451.391/491), the valve wrench must be used. Valve wrench see scheme 27 4 Install in the reverse order

Scheme 48

Scheme 49

Remove/install condenser filling valve - AR83.30-P-5536MCC

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

Scheme 50

MODIFICATION NOTES

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 2 Disconnect air conditioner service unit from the service valve of the suction line (2) and the service valve of the pressure line (3) Air conditioner service unit 3 Remove valve element (1) on service valve of pressure line (3) In model 451.391/491, the valve insert (1) must be removed using a commercially available valve wrench for Schrader valves (connection width 4.5 mm). In model 451 (except 451.391/491), the valve wrench must be used. Valve wrench see scheme 27 4 Install in the reverse order

Scheme 51

Remove/install dehydrator - AR83.30-P-6525MCC

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

Scheme 52

Scheme 53

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling refrigerant R134a AH83.30-N-0003-01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station 3 Carefully push in pin (arrow) on filling valve (1) of intake line (3) and filling valve (1) of pressure line (2) until air conditioning system is completely unpressurized Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 4 Raise the vehicle using the vehicle lift and remove underfloor panelings Rechargeable drill / screwdriver 5 Carefully pull front CBS (5) forwards and remove screw (6) 6 Screw a suitable screw (9) into the cover (7) 7 Push cover (7) with screw (9) upwards until circlip (8) is relieved 8 Remove circlip (8) and remove cover (7) from below 9 Gently push front module towards the rear and withdraw filter drier (4) from condenser from below 10 Install in the reverse order

Remove/install condenser - AR83.30-P-6540MCU

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

Scheme 54

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling refrigerant R134a AH83.30-N-0003-01A 1 Remove front module AR62.30-P-1575MCU 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 3 Unscrew nut (3) from condenser (1) and detach refrigerant lines (2) from condenser (1) Close off refrigerant lines (2) and condenser (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal rings on refrigerant lines (2). 4 Unclip condenser (1) from catch (4), swivel forwards at the left-hand side and remove 5 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P-6525MCC 6 Install in the reverse order

Remove/install refrigerant lines at refrigerant compressor - AR83.30-P-7810MCU

MODEL 451.3 /4 (except 451.391 /491) with CODE (I01) Air conditioning Plus

Shown on model 451.3 up to production date 2.6.08

Scheme 55

MODIFICATION NOTES

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 2 Disconnect air conditioning service unit Air conditioner service unit 3 Release rear drive module AR01.00-P-3050MCU 4 Remove bolt (1, 3) for refrigerant line to be removed (2, 4) and remove refrigerant line (2, 4) from refrigerant compressor (A9) Close off refrigerant lines (2, 4) and their connection to the refrigerant compressor (A9) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal ring at the detached refrigerant line (2, 4) and coat with compressor oil when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A *BA83.30-P-1002-01L 5 Remove rubber retainer (5) 6 Unclip refrigerant lines (2, 4) from bracket (7) and remove bracket (7) On vehicles in which the bracket (7) is still installed. Installation: The bracket (7) may no longer be installed. 7 Open quick-release coupling (6) of refrigerant line to be removed (2, 4) see scheme 35 8 Remove refrigerant line to be removed (2, 4) Installation: Note routing of refrigerant lines (8). They must have a minimum distance of 5 mm to the body, fuel tank or other components, as otherwise noises or damages may be caused by impacts or chafing. 9 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P-6525MCC 10 Install in the reverse order

AIR CONDITIONING

Scheme 56

Remove/install refrigerant line between refrigerant compressor and evaporator - AR83.30-P-7811MCU

MODEL 451.3## /4## (except 451.391 /491) 1# with CODE (I01) Air conditioning Plus

Shown on model 451.4 up to production date 2.6.08

Scheme 57

Scheme 58

MODIFICATION NOTES

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Remove refrigerant line (16) between evaporator and condenser AR83.30-P-7812MCU Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver 3 Remove front bulkhead (17) The front bulkhead is bolted with two nuts. 4 Drain coolant AR20.00-P-1142MCU 5 Remove diagonal struts On model 451.4 AR61.10-P-5138MCU 6 Remove bolts (10) and remove carrier (9) On model 451.4 *BA61.25-P-1003-01B 7 Remove bulkhead wall On model 451.4 AR61.25-P-6600MCU 8 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing. 9 Unclip refrigerant lines (1, 2) from bracket (18) and remove bracket (18) On vehicles in which the bracket (18) is still installed. Installation: The bracket (18) may no longer be installed. 10 Open quick-release coupling (11) of refrigerant line (1) and remove seal ring of refrigerant line (1) Close off refrigerant line (1) and refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace the sealing ring at the refrigerant line (1) and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A see scheme 35 11 Support fuel tank (8) using transmission jack (15) and removal fixture Transmission jack (Scheme 32) 12 Remove bolts (7) *BA47.10-P-1001-01F 13 Carefully lower fuel tank (8) as far as possible When lowering the fuel tank (8), ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced. 14 Unclip brake line (6) from brackets (3, 4) 15 Unclip wiring harness bracket (12) on refrigerant line (1) 16 Pull refrigerant line (1) out of expansion valve 17 Remove supports and swivel radiator unit (14) forward and to one side Aid of helper required. see scheme 39 18 Place coolant hose (13) to one side and lead out refrigerant line (1) towards front Aid of helper required. 19 Secure radiator unit (14) with supports see scheme 39 20 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P-6525MCC 21 Install in the reverse order

FUEL TANK

UNDERBODY FRAME

Scheme 59

Scheme 60

Scheme 61

Remove/install refrigerant line between evaporator and condenser - AR83.30-P-7812MCU

MODEL 451.3 /4 (except 451.391 /491) with CODE (I01) Air conditioning Plus

Scheme 62

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Remove front CBS AR88.00-P-1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 3 Disconnect air conditioning service unit Air conditioner service unit 4 Remove front module AR62.30-P-1575MCU 5 Unscrew nut (6) *BA83.30-P-1004-01L 6 Pull out refrigerant lines (4, 7) at expansion valve (5) and remove seal rings of refrigerant lines (4, 7) Close off refrigerant lines (4, 7) and expansion valve (5) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (4, 7) and coat with compressor oil when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A 7 Unscrew nut (3) from condenser (2), detach refrigerant lines (1, 4) from condenser (2) and remove seal rings of refrigerant lines (1, 4) Close off refrigerant lines (1, 4) and condenser (2) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (1, 4) and coat with compressor oil when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A 8 Loosen refrigerant line (7) from guide for refrigerant line (4) and remove refrigerant line (4) 9 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P-6525MCC 10 Install in the reverse order

AIR CONDITIONING

Remove/install refrigerant line between condenser and refrigerant compressor - AR83.30-P-7813MCU

MODEL 451.3## /4## (except 451.391 /491) 1# with CODE (I01) Air conditioning Plus

Shown on model 451.4 up to production date 2.6.08

Scheme 63

MODIFICATION NOTES

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A 1 Remove refrigerant line (13) between evaporator and condenser AR83.30-P-7812MCU 2 Disconnect electrical connector from refrigerant pressure sensor (B12). 3 Remove supports and secure radiator unit (14) against falling down using suitable cable ties see scheme 39 Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 4 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver 5 Remove front bulkhead (15) The front bulkhead (15) is bolted with two nuts. 6 Remove diagonal struts On model 451.4 AR61.10-P-5138MCU 7 Remove bolts (10) and remove carrier (9) On model 451.4 *BA61.25-P-1003-01B 8 Remove bulkhead wall On model 451.4 AR61.25-P-6600MCU 9 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing. 10 Unclip refrigerant lines (1, 2) from bracket (16) and remove bracket (16) On vehicles in which the bracket (16) is still installed. Installation: The bracket (16) may no longer be installed. 11 Open quick-release coupling (11) of refrigerant line (2) and remove seal ring of refrigerant line (2) Close off refrigerant line (2) and refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace the sealing ring at the refrigerant line (2) and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P-0362-00A see scheme 35 12 Support fuel tank (8) with a transmission jack and a removal fixture Transmission jack (Scheme 32) 13 Remove bolts (7) *BA47.10-P-1001-01F 14 Carefully lower fuel tank (8) as far as possible When lowering the fuel tank (8), ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced. 15 Unclip brake line (6) from brackets (3, 4) 16 Unclip wiring harness bracket (12) on refrigerant line (1) 17 Lead out refrigerant line (2) between front axle carrier and body and remove Assistant needed to hold radiator unit (14). 18 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P-6525MCC 19 Install in the reverse order

FUEL TANK

UNDERBODY FRAME

Scheme 64

Scheme 65

Scheme 66

Remove and install evaporator temperature sensor - AR83.30-P-8085MCC

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

Scheme 67

Remove/install 1 Move right seat toward rear 2 Disconnect electrical connector (2) at evaporator temperature sensor (B10/6) 3 Pull evaporator temperature sensor (B10/6) out of air conditioner housing (1) 4 Install in the reverse order

Remove/install refrigerant compressor - AR83.55-P-5300MCU

ENGINE 132.910 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus

Scheme 68

Remove/install 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 Protect air conditioning circuit and components from moisture when carrying out repair work AH83.30-N-0005-01A Notes on handling refrigerant R134a AH83.30-N-0003-01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P-1760MCC 2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station 3 Release rear drive module AR01.00-P-3050MCU 4 Remove poly-V belt for refrigerant compressor (A9) AR13.21-P-1202MCU 5 Detach electrical connector (1) for refrigerant compressor (A9) 6 Remove bolts (2), place refrigerant lines (3) to one side and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and refrigerant compressor (A9) using appropriate stop plugs, as otherwise any penetrating dirt and moisture damages components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting. *BA83.55-P-1003-01V 7 Unscrew screws (4) from refrigerant compressor (A9) *BA83.55-P-1001-01V *BA83.55-P-1002-01V 8 Remove refrigerant compressor (A9) 9 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30-P-6525MCC 10 Install in the reverse order

REFRIGERANT COMPRESSOR