Tempmatic, Climate Control

EXIT
Tempmatic, climate control 83
cardiagn.com
EXIT
83 Tempmatic climate control
Operation
Operation and components of Tempmatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-020
climate control
A. General information. ...................................................
6. Function of temperature control ...........................................
C. Pushbotton switch unit with electronic temperature control .........................
D Temperature sensor and feedback potentiometer for flap position. .....................
E. Vacuum elements and switchover valves .......................................
F. Recirculating pump for hot water ...........................................
G. Evaporator housing with evaporator and fresh air/recirculating air flap. ..................
H. Blower switch and blower motor. ...........................................
J. Refrigerant (air conditioning) compressor. .....................................
K. Function and components of compressor cutout .................................
L. Expansion valve and lines ................................................
M. Condenser, auxiliary fan and receiver drier .....................................
Controlsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 028
cardiagn.com
A. Wiring diagrams. ......................................................
8. Vacuum diagram ......................................................
Testing refrigerating capacity of air conditioning system (quick test) ........................ 035
Testing refrigerating capacity and suction/high pressure of air conditioning system .............. 036
Testing control quality at different temperature adjustments, as well as heating capacity ........... 038
Testing system with socket box, volt and ohmmeter, and remedies ......................... 039
Testing compressor cutout and remedies .......................................... 040
A. Testing with electromagnetic clutch of refrigerant compressor not connected ..............
8. Testing cutout of electromagnetic clutch of refrigerant compressor via control unit
compressor cutout .....................................................
Testing vacuum system for blend air flaps, fresh air/recirculating air flap, defroster nozzle flaps,
legroom flaps and heater valve for leaks........................................... 045
Removal and installation of heater box ........................................... 100
Removal and installation of heat exchanger ........................................ 110
Pushbutton switch unit ..................................................... 112
A. Removal and Installation ................................................
8. Renewing bulbs for lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Removal and installation of wood panelling ....................................
D. Removal and installation of temperature wheel (without potentiometer) .................
Removal and installation of blower switch ......................................... 113
Removal and installation of heater valve .......................................... 115
Removal and installation of recirculating pump ...................................... 117
Removal and installation of blower motor ......................................... 120
Removal and installation of aspirator blower for in-car temperature sensor .................... 122
Removal and installations, testing of in-car temperature sensor ........................... 130
Removal and installation, testing of outside temperature sensor ........................... 132
Removal and installation, testing of temperature sensor for air conditioning system .............. 133
Removal, testing, installation and adjustment of potentiometer for flap position ................ 134
Removal and installation, testing of switch for fresh air/recirculating air flap. .................. 138
Removal and installation of cover at air inlet. ....................................... 140
Removal and installation of outlets on instrument panel outside and center ................... 150
83/l
EXIT
. . . . . . . . . . . . . . . . . . . . 83-153
Removal and n s t a l l a t i o n o f s w i t c h o v e r v a l v e u n i t w i t h 4 o r 5 c o n n e c t i o n s
Removal and installation of vacuum elements ....................................... 165
A. Vacuum element (37) for blend air flaps ......................................
B. Vacuum element (38) for defroster nozzle flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Vacuum element (39) for legroom flaps .......................................
D. Vacuum element (40) for fresh air/recirculating air flap ............................
Removal and installation cf rpm sensor on Nippondenso refrigerant compressor ................ 516
Removal and installation of rpm sensor on starter ring gear (model 201.122) .................. 517
Checking oil level in refrigerant compressor. ........................................ 520
Removal and installation of refrigerant compressor ................................... 522
A. Delco refrigerant compressor (engine 102) .....................................
B. Nippondenso refrigerant compressor (engine 601) ................................
Reconditioning refrigerant compressor. ........................................... 524
B. Nippondenso refrigerant compressor (engine 601) ................................
Removal and installation of electromagnetic clutch ................................... 526
B. N ippondenso refrigerant compressor (engine 601) ................................
cardiagn.com
Removal and installation of condenser. ........................................... 528
Removal and installation of receiver-drier ......................................... 530
Checking or removing and installing pressure switch for refrigerant compressor in receiver-drier ...... 531
Testing or removing and installing pressure switch for auxiliary fan in receiver-drier .............. 532
Removal and installation of expansion valve ........................................ 534
Removal and installation of evaporator ........................................... 538
Removal and installation of auxiliary fan .......................................... 546
8312
EXIT
83-020 Operation and components of Tempmatic climate control
A. General information
Model 201 has a blend air heating system in combi-

nation with air conditioning - Pempmatic climate
control. The cooling and heating air temperatures
are automatically controlled.
For adaptation to weather conditions, a number of

functions, including air distribution, can be push-
button-controlled (b), independent of in-car
temperature. Open, close or adjust dashboard
center and side outlets as required. ::_
::_ . . . . . . . . . . . . . . . . .._...._._.................._._...._.___..._.___ ,__,,___,,
.
cardiagn.com
1633-12673
The blower can be manually adjusted except for

modes
A change from fresh air to recirculated air intake

can be made at any time by means of switch (26).
5 Control unit consists of:

a Temperature selector wheel
b Pushbutton switch with 6 functions
c Air conditioning switch (mode buttons)
15 Blower switch
26 Fresh/recirculated air switch
The “cooling” mode requires the pressing of button

(c) into position @ (max. dehumidification) or @
(normal) and to push one of the buttons
of pushbutton switch (b).
The system operates only with the engine running.
83.11-020/l
EXIT
B. Function of temperature control
The in-car temperature is controlled by blend air

flaps. If “heating” is required, the heater valve is
fully opened by a vacuum element (41) and remains
fully open during the heating period.
The blend air flaps (arrow) mix unheated air with

the heated air, routed through the heat exchanger.
The position of the blend air flaps is indicated by a
feedback potentiometer for flap position (4) flanged
to the shaft of the blend air flaps, and transmitted
to the electronic system in the control unit.
cardiagn.com
The blend air flaps are operated via levers by a
vacuum element (37). The vacuum element is con.
netted to 2 switchover valves.
The switchover valve (11.4) supplies the vacuum ele-

ment with vacuum through an orifice, so that the
blend air flaps are moving toward “cold”. The
second switchover valve (11.3) connects the vacuum
element to atmosphere also through an orifice, so
that the blend air flaps are moved in the direction of
“warm” by the spring in the vacuum element.
From max. cooling or not heating up to max. heat-
ing and vice versa the blend air flaps require approx.
20 seconds each.
83.11-02012
EXIT
Example:
If there is a temperature difference between in-car

sensor and preset value on temperature wheel (e.g.
too cold by 0.3 “C) the electronic system will
energize the switchover valve “warm”. Valve ( 1 1.3)
opens and slowly connects the vacuum element (37)
to atmosphere by an orifice. The spring in vacuum
element moves the blend air flaps in direction of
“warm” until the feedback potentiometer for flap
position (4) indicates the resistance value which
corresponds with the temperature difference. The
switchover valve (11.3) “warm” will then close and
the blend air flaps will stop. Vice versa, the switch-
over valve (11.4) “cold” is opened. The vacuum
element is supplied with vacuum until the proper
position of the blend air flaps has been attained.
The switchover valve (11.4) “cold” will then close.
If no heating is required, the heater valve is closed
and the blend air flaps are resting against the “cold”
stop. In such a case, the temperature in evaporator
is probed and the air conditioning system is switched
cardiagn.com
on, if required.
C. Pushbutton switch unit with electronic temperature control
T_he pushbutton switch unit consists of a temperature

wheel (a), a pushbutton switch (b) with 6 push-
buttons and a mode switch for air conditioning (c).
The pushbutton switch unit houses the electronic
system for controlling interior temperature and
1 relay each for connecting the current for the
electromagnetic clutch of the refrigerant compressor
(air conditioning compressor) and auxiliary coolant
pump.
a Temperature wheel
b Pushbutton switch unit with 6 functions (buttons)
c Mode switch for air conditioning system with 3 functions
(buttons)
A fuse (g) is located at the rear of the pushbutton

switch unit as protection for the electronic system
and conductors against short-circuits.
g Fuse, 2 amps
63.1 I -020/3
EXIT
Temperature wheel (a)
The temperature wheel (a) provides stepless interior

temperature control in a temperature range from
approx. 16 ‘C to 32 ‘C. If the temperature wheel is
set at the end position “MIN”, the system operates
at full cooling capacity, provided the air condition-
ing system has been switched on. If it is set at the
end position “MAX”, the system operates at full
heating capacity.
Rotation of the temperature wheel changes the

resistance (potentiometer), transmitting the new
resistance value into the electronic system of the
temperature control.
Pushbutton switch (b) with function selection
cardiagn.com
Function (pushbutton) selection
The blower runs at max. speed in 4th stage at 100 %

fresh air supply, provided the switch fresh air/
recirculating air is set to fresh air.
The blower switch and the temperature wheel are

bypassed (inoperative) and the recirculating pump
runs continuously. The windshield is provided with
max. heated air depending on motor temperature.
The air feed to center and side outlets can be set
manually using the levers. The center outlets should
be closed.
The functions of the air conditioning mode switch

are bypassed (cancelled) and the air conditioning
system operates at max. capacity similar to adjust-
ment Q , provided the outside temperature is
above 0 “C. To guarantee perfect function of
“defrost”, the fresh air/recirculating air switch
should always be set to fresh air.
Function (pushbutton) selection
The blower runs in the stage to which the blower

switch has been set, but at least in 1 st stage. The
blower stages can be changed by the blower switch.
The heating or cooling capacity is controlled in
accordance with nominal value adjustment on the
temperature wheel in combination with the mode
switch of the air conditioning system (c). If the air
conditioning has been switched on, with the switch
for fresh air/recirculating air (26) set to fresh air and
the temperature difference (preset temperature on
temperature wheel in relation to outside tempera-
ture) is greater than 8 ‘C, the system will automa-
tically switch to recirculating air.
83.11-020/4
EXIT
The recirculating air mode is also influenced by the

interior temperature. From interior temperatures of
25 “C to 50 “C the temperature difference is con-
stantly reduced toward 0 “C. If the temperature
difference (outside temperature drops) reduces to
approx. 5 ‘C, the system is again switching to fresh
air.
With the heater valve opened, the recirculating

pump runs continuously in heating mode.
All the air flow is directed to the windshield. Air

flow to center and side outlets can be adjusted
manually using the respective levers.
Pushbutton selection
Similar to pushbutton selection @ except for air

distribution, defroster nozzle flaps and legroom
flaps opened.
cardiagn.com
Pushbutton selection e
Similar to pushbutton selection e except for air

distribution, leak air from defroster nozzles, legroom
flaps fully opened.
Pushbutton selection
Similar to pushbutton selection e except for air

distribution. Air out of center and side outlets
only. Center and side outlets must be opened
manually.
Pushbutton selection @
Blower is switched off and the fresh air/recirculating

air flap is closed.
Recirculating pump is not running. Temperature

control continues operating and the heater valve is
opened or closed as required. Air conditioning is
switched off.
Note: If none of the selection pushbuttons is de-

pressed, this function conforms to selection e .
Air conditioning mode switch (c) with pushbutton

selection
Functioning of the air conditioning mode switch

requires engagement of one of the selections on the
pushbutton switch unit: @ e e
83.11-020/5
EXIT
Pushbutton selection Q
This selection dehumidifies the fresh air, while also

dehumidifying the vehicle’s interior air.
The refrigerant compressor is constantly switched

on and the evaporator temperature is constantly
regulated to 0 ‘C - i-2 “C.
If necessary, the temperature set on the temperature

wheel is achieved by additional heating.
Pushbutton selection @ (normal adjustment)
With this mode selection the refrigerant compressor

is also engaged as necessary. During the heating
operation and as long as no cooling is required, the
system operates (refrigerant compressor off) similar
to mode selection @ . But if the temperature in the
vehicle increases by approx. 0.8 “C above nominal
cardiagn.com
value (wheel value), the compressor begins to
operate. The air conditioning output is then regu-
lated according to deviation between nominal/actual
value.
An additional requirement for engagement of the

refrigerant compressor is that the blend air flaps and
the heater valve are closed. The outside temperature
should also be > 0 “C.
Pushbutton selection @ (economy)
In this position, the refrigerant compressor is

switched off and the system operates with 100 %
fresh air. If the temperature in the vehicle rises
above the value set on the temperature wheel, un-
heated outside air will be routed into the vehicle.
Note: If none of the air condit ioning mode buttons

is depressed, it will correspond with selection @ .
83.11-020/6
EXIT
D. Temperature sensor and feedback

potentiometer for flap position
In-car temperature sensor

_ _
The in-car temperature sensor (1) is located in roof

frame lining, in range of interior lamp.
The resistance of current flow through the in-car
temperature sensor is influenced by the temperature
of the passenger compartment and fed into the elec-
tronic system of the pushbutton switch unit.
An aspirator blower (141, which is connected to the

sensor by a hose and runs with the ignition switched
on, provides continuous air flow past the in-car
temperature sensor. This increases the accuracy of
temperature control inside vehicle.
cardiagn.com
Locatlon of aspirator blower (14) for
In-car temoerature sensor
Ambient sensor and temperature sensor for air

conditioning
The ambient sensor (2) is located on the top of the

evaporator housing. The sensor transmits its resis-
tance value under influence of outside temperature
into the electronic system of pushbutton switch
unit.
The temperature sensor air conditioning system (3)
is located in evaporator housing. It senses the evapo-
rator rib temperature and transmits its resistance
into the electronic system of the pushbutton switch
unit.
Location of amblent sensor (2) and
temperature sensor air conditioning (3)
Note: These temperature sensors have a negative

temperature coefficient (NTC) of resistance, allow-
ing the sensor resistance to decrease with increasing
temperature. For testing of temperature sensor refer
to (83-039).
83.1 l-02017
EXIT
Feedback potentiometer for flap position
The feedback potentiometer for flap position (4) is

located on top of heater box. It is actuated by the
vacuum element (37) together with the blend air
flap (refer to function of temperature control).
The quality of the temperature control depends on

the adjustment of the feedback potentiometer for
flap control, particularly during the cooling mode.
For testing and adjusting refer to (83-039).
Location of feedback potentiometer for flap position (4)
cardiagn.com
E. Vacuum elements and switchover valves
There are 3 vacuum elements on the heater box, of

which 2 vacuum elements (38 and 39) actuate the
air flaps at top and bottom and 1 vacuum element
(37) actuates the blend air flaps.
Without vacuum of vacuum elements (37 and 38)

the defroster nozzle flaps are opened and the blend
air flaps are in position “full heating”.
Location of vacuum elements for blend air

flaps (37) and defroster nozzle flaps (38)
Without vacuum to vacuum elements (39 and 40)

the legroom flaps are closed and the fresh air/
recirculating air flap is in the fresh air mode
position.
Location of vacuum element for legroom

flaps (39) and fresh air/recirculating air
flap (40)
83.11-020/8
.................................. EXIT
The vacuum element (41) with heater valve is

located below the air intake grille next to the evapo-
rator housing. The heater valve is actuated by the
vacuum element (4 1).
With vacuum applied, the heater valve is “closed”;

without vacuum the heater valve is “opened” (refer
to vacuum diagram 83-028, section B).
Location of vacuum element (41) wtth

heater valve
Switchover valves
The switchover valves for the vacuum elements,

comprising 2 units, switchover valve strip (1 1)
4 connections and switchover valve strip (12) 5
cardiagn.com
connections, are located one above the other under
instrument panel, right.
Location of switchover valves
11 Swltchover valve strip, 4 connectlons

12 Swltchover valve strip, 5 connections
F. Recirculating pump for hot water
The recirculating pump is located in the return flow

of heating water circuit and is running continuously
along in heating mode.
As soon as no more heat is required, i.e. when the

blend air flaps and the heater valve are closed, the
electronic system in pushbutton unit disconnects
the recirculating pump. The recirculating pump is
also disconnected during pushbutton (mode)
Location of recirculating pump (13)
83.11-020/9
EXIT
G. Evaporator housing with evaporator and

fresh air/recirculating air flap
TIqe 6-row evaporator with 6 inlets and its housing

iS located in component compartment, between
frlant wall and bulkhead.
34 Evaporator housing
a Evaporator tube
b Fins
C Condensate water drain hose left
(right side mirror image)
d Fresh air/recirculating air flap
e Condensate water tray
40 2-stage vacuum element
The fresh air/recirculating air flap (d) and the 2-stage

vacuum element (40) for the fresh air/recirculating
air flap are located on the evaporator housing,
The evaporator tubes and the fins are made of alu-
cardiagn.com
minum (a).
H. Blower switch and blower motor
The blower motor is controlled by the 4-speed

blower switch. If the speed control lever is against
the lefthand stop, the blower motor runs in 1st
speed, when one of the pushbuttons is pressed:
The blower can only be switched off with button
Location of blower switch (15)
A radial blower with two fan wheels (four-flow) and

123 mm fan diameter is used as blower motor. The
power input in 4th blower stage and 13 V battery
voltage amounts to approx. 21 amps.
Location of blower motor (8)
83.1 l-020/10
EXIT
J. Refrigerant (air conditioning) compressor
The diesel engine has a swash plate refrigerant com-

pressor, made by Nippondenso.
Vehicles with gasoline engine up to model year 84

have a Delco R 4 refrigerant compressor and
starting model year 85 the Nippondenso compressor.
The filling capacity of air conditioning system is
1 .l kg refrigerant R 12 on both models.
cardiagn.com
Location of refrigerant compressor (143)
Nlppondenso on engine 601
Location of refrigerant compressor (143)

Delco R 4 on engine 102 up to model
year 84
Locatlon of refrigerant compressor (143)

N lppondenso on engine 102 starting
model year 85
83.1 l-02011 1
EXIT
K. Function and components of compressor cutout
General information
On engine 601 starting model year 84 and on engine

102 starting model year 85 the accessories and
therefore the refrigerant compressor are driven by
one common V-belt. To ensure continued operation
of the accessories in case of a jammed refrigerant
compressor the compressor’s electromagnetic clutch
is switched off by a control unit.
Components of compressor cutout

1. Rpm sensor
2. Control unit
3. Microswitch
(on vehicles with automatic transmission only)
cardiagn.com
1. Rpm sensor
The rpm sensors are measuring the rpm of the engine

and the refrigerant compressor. They consist of a 14
magnetic core and a coil. When the ring gear or shaft
of refrigerant compressor rotates, an alternating
voltage is induced in coils of rpm sensor, which is
used as an input signal to the control unit.
1600
Location of rpm sensor for refrigerant compressor (144)
The alternating voltage and thereby the frequency

increases or decreases depending on rpm.
Note: The engine speed of model 201.024 is picked

up from terminal TD on line connector of diagnosis
plug.
Location of rpm sensor engine 601 on ring

gear of flywheel (132)
2. Control unit for compressor cutout
The control unit compares the two speeds (rpm) of

engine and refrigerant compressor and will cut out
the refrigerant compressor at a difference in speed
of approx. 30 %.
Location of control unit for compressor

cutout (141)
83.1 l-02011 2
EXIT
3. Microswitch on model 201.122 with automatic

transmission only
At engine speeds between 1050 and 2150 rpm (/min)

with full load, the compressor is cut out by the
microswitch via control unit (141) for improved
moving-off conditions (improved low engine speed
performance).
Location of microswitch (134/l) only

connected on vehicles with automatic
transmission
Functional description of compressor cutout
If the ignition and the air conditioning are switched

on and the engine is not running, the refrigerant
compressor remains switched off.
cardiagn.com
After starting the engine on vehicles up to model
year 84 the refrigerant compressor is activated by
the control unit (141) as from an engine speed of
approx. 500 rpm.
On vehicles as from model year 85 the refrigerant
compressor will be activated only after approx.
10 seconds as soon as an engine speed of approx.
600 rpm has been attained (to stabilize the engine
speed).
The control unit compares the two speeds of the
ring gear and the refrigerant compressor 2 seconds
after the compressor comes on (to compensate for
clutch slippage during cut-in). If there is an rpm
difference of more than 30 % as soon as the com-
pressor comes on, this condition is checked for a
period of 200 milliseconds. If the rpm difference
equalizes within 200 milliseconds, the compressor
remains engaged. If the rpm difference remains (i.e.
due to a jammed compressor) the control unit will
immediately cut out the compressor. This process is
again repeated when the ignition is switched off and
the engine is restarted.
To prevent thermic overloading of engine 102, the

refrigerant compressor is switched off at approx.
110 ‘C coolant temperature by temperature switch
(23), by switching to ground, via control unit (141).
The temperature switch opens at approx. 103 ‘C
and the refrigerant compressor is again on.
83.fl-020/13
EXIT
On model 201 .122 with automatic transmission the

refrigerant compressor is switched off at full load at
approx. 1050 rpm engine speed. After attaining an
engine speed of approx. 2 150 rpm the refrigerant
compressor is again switched on. If the accelerator
pedal is released before an engine speed of 2150 rpm
is attained, the control unit will immediately
connect the refrigerant compressor. This will im-
prove moving-off conditions of vehicle.
L. Expansion valve and lines
The expansion valve is similar to the block valve

used on models 123 and 126, with a cooling capacity
of 6.9 kW (6000 kcal/h).
cardiagn.com
Locatlon of expansion valve (82) o n
evaporator housing
M. Condenser, auxiliary fan and receiver drier
The condenser (63) is attached to a rubber mount

on radiator supporting frame. On model 201 .122 it
has a block depth of 22 and on model 201.024 of
26 mm. Its tubes having a diameter of 8 mm are
made of aluminum. The condenser has a dual
flow system, i.e. the refrigerant vapor flows through
two parallel lines (arrows).
All models with air conditioning system have an

electric auxiliary fan.
L o c a t i o n o f c o n d e n s e r ( 6 3 ) a n d auxiliary
f a n (21)
83.11-020/l 4
EXIT
T h le auxiliary fan is activated for one by the pres-

SUI-e switch (19) in receiver drier, via relay (17) and
via I pre-resistor (18). In parallel with pressure switch,

the 3 auxiliary fan is directly activated by the tempera-
tul re switch 100 ‘C (16) on engine via relay (20).
Location of receiver drier and pre-resistor

(18) for auxiliary fan
19 Pressure switch for auxiliary fan

22 Pressure switch, refrigerant compressor
a Vacuum valve
cardiagn.com
Location of relay (17) for auxiliary fan
via pre-resistor (18)
Location of relay (20) for auxiliary fan
Location of temperature switch 100 ‘C

(16) for auxiliary fan on engine 102 up to
model Year 84
83.1 l-020 15
EXIT
Location of temperature switch (16)

100 OC for electromagnetic clutc :h engine
fan and 110 ‘C for auxiliary fan on engine
102 starting model year 85
cardiagn.com
Location of temperature switch 100 Oc
(16) for auxiliary fan on engine 601 up
to model year 84
Location of temperature switck I (16)

100 OC for electromagnetic clul :ch engine
fan and 110 ‘C for auxiliary far -r on engine
601 starting model year 85
83.11-020/l 6
. . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . _ _ . . . . . . . . . . . . . . EXIT
83-028 Control system
A. Wiring diagrams
cardiagn.com
L,_ _.... .._:
l&32-11862/2
Tempmatic control system, model 201.024 up to model year 84
In-car temperature sensor

Ambient sensor, outside air
temperature
9 Pre-resistor, blower motor
10 Electrical center with fuses
Fuse 1 =16A
1; Blower switch
Temperature switch 100 ‘C for
auxiliary fan
Temperature sensor, air conditioning Fuse3’16A 17 Relay auxiliary fan pre-resistor
Feedback potentiometer for flap 11 Swrtchover valve unit,4 connections 18 Pre-resistor auxiliary fan
position 11.4 Switchover valve for blend air 19 Pressure switch auxiliary fan
Pushbutton switch unit, consisting of: flaps (“cold”) On 20 bar/Off 15 bar
a Temperature wheel 11.3 Switchover valve for blend air 20 Relay auxiliary fan
b Pushbutton switch unit flaps (“warm”) 21 Auxiliary fan
c Mode switches for air conditioning 11.5 Switchover valve for heater 22 Pressure switch refrigerant
@ Air conditioning on, controlled valve (“closed”) compressor
vta temperature sensor (3) to 11 .l Switchover valve for heater On 2.6 bar/Off 2.0 bar
0 OC evaporator temperature valve (“open”) 26 Switch, fresh air/recirculating air
@ Air conditioning controlled via 12 Switchover valve unit, 5 connectrons 143 Electromagnetic clutch
pushbutton switch unit (elec- 12.8 Switchover valve for legroom Refrigerant compressor
flaps A To electronic control unit
@ ~~&r%YiZ?r!ng off 12.9 Switchovervalve for fresh air/ (CIS-E) terminal 19
d Relay for refrigerant compressor recirculating air flap (small C To hazard warning switch
e Relay for recirculating pump stroke) (connection terminal 15)
f Lights 12.10 Switchover valve for fresh air/ cl From seat belt indicator,
g Fuse: 2 amps recirculating air flap (large terminal 8
h 12-pin connector at left side of stroke) (connection terminal 15)
pushbutton switch unit 12.6 Switchover valve for defroster Ml Common ground (behind instru-
i 12-pin connector, at right side of nozzle valves (small stroke) ment cluster)
pushbutton switch unit 12.7 Switchover valve for defroster M5 Ground connection, engine
Connector terminal 58d nozzle flaps (large stroke) (unit screwed Into engine)
Starter switch 13 Recirculating pump M9 Ground connection, front left
Blower motor 14 Aspirator blower for in-car (near headlight)
temoerature sensor Ml0 Ground connection, battery
83.11-028/l
EXIT
cardiagn.com
Tempmatic control system, model 201.024 starting model year 85
In-car temperature sensor 11 Switchover valve unit,4 connections 20 Relay auxiliary fan
Ambient sensor, outside air 11.4 Switchover valve for blend air 21 Auxiliary fan
temperature flaps (“cold”) 22 Pressure switch refrigerant
Temperature sensor, air conditioning 11.3 Switchover valve for blend air compressor
Feedback potentiometer for flap flaps (“warm”) On 2.6 bar/Off 2.0 bar
position 11.5 Switchover valve for heater 23 Temperature switch 110 ‘C for
Pushbutton swatch unit, consisting of: valve (“closed”) compressor cutout
a Temperature wheel 11 .l Switchover valve for heater 26 Switch, fresh air/recirculating air
b Pushbutton switch unit valve (“open”) 30 Socket (diagnosis) with line
c Mode switches for air conditioning 12 Switchover valve unit, 5 connections connector TD
@ Air conditioning on,controlled 12.8 Switchover valve for legroom 141 Control unit compressor cutout
vta temperature sensor (3) to flaps 143 Electromagnetic clutch
0 OC evaporator temperature 12.9 Switchover valve for fresh air/ Refrigerant compressor
@ Air conditioning controlled via recirculating air flap (small 144 Rpm sensor, refrigerant
pushbutton switch unit (elec- stroke) compressor
12.10 Switchover valve for fresh air/ A To electronic control unit
@ ~p,nbZZoY~ng off recirculating air flap (large (CIS-El terminal 19
d Relay for refrigerant compressor stroke) C To hazard warning switch
e Relay for recrrculating pump 12.6 Switchover valve for defroster (connection terminal 15)
f Lights nozzle valves (small stroke) D From seat belt indicator,
g Fuse: 2 amps 12.7 Switchover valve for defroster terminal 8
h 12-pin connector at left side of nozzle flaps (large stroke) (connection terminal 15)
pushbutton switch unit 13 Recirculating pump E To electrically heated windshield
i 12-pin connector, at right side of 14 Aspirator blower for in-car washer nozzle (terminal 15)
pushbutton switch unit temperature sensor F To electromagnetic clutch
6 Connector terminal 58d 15 Blower motor engine fan
Starter switch 16 Temperature switch Ml Common ground (behind instru-
: Blower motor a 100 OC for electromagnetic ment cluster)
9 Pre-resistor, blower motor clutch, engine fan M5 Ground connection, engine
10 Electrical center with fuses b 110 ‘C for auxiliary fan (unit screwed into engine)
Fuse 1 = 16 A 17 Relay auxiliary fan pre-resistor M9 Ground connection, front left
Fuse 3 = 16 A 18 Pre-resistor auxiliary fan (near headlight)
19 Pressure switch auxiliary fan Ml0 Ground connection, battery
On 20 bar/Off 15 bar
83.1 l-02812
EXIT
cardiagn.com
144
1632-ll661/'2
Tempmatic control system, model 201 ,122 up to model year 84
In-car temperature sensor 11 Switchover valve unit,4 connections 21 Auxiliary fan

Ambient sensor, outside air 11.4 Switchover valve for blend air 22 Pressure switch refrigerant
temperature flaps (“cold”) compressor
Temperature sensor, air conditioning 11.3 Switchover valve for blend air On 2.6 bar/Off 2.0 bar
Feedback potentiometer for flap flaps (“warm”) 26 Switch, fresh air/recirculating air
position 11.5 Switchover valve for heater 127 Switchover valve rpm stabilization
Pushbutton switch unit, consisting of: valve (“closed”) (with automatic transmission only)
a Temperature wheel 11 .l Switchover valve for heater 132 Rpm sensor ring gear for flywheel
b Pushbutton switch unit valve (“open”) 134/I Microswitch for compressor cutout
c Mode switches for air conditioning 12 Switchover valve unit, 5 connections at full load (connected only on
@ Air conditioning on, controlled 12.8 Switchover valve for legroom vehicles with automatic trans-
via temperature sensor (3) to flaps mission)
0 OC evaporator temperature 12.9 Switchover valve for fresh air/ 141 Control unit compressor cutout
@ Air conditioning controlled via recirculating air flap (small 143 Electromagnetic clutch
pushbutton switch unit (elec- stroke) Refrigerant compressor
12.10 Switchover valve for fresh air/ 144 Rpm sensor, refrigerant
Q EnEorZ~~iYZ~ng off recirculating air flap (large compressor
d Relay for refrigerant compressor stroke) A To 4-pin plug connection, interior
e Relay for recirculating pump 12.6 Switchover valve for defroster B To relay kickdown limit,
f Lights nozzle valves (small stroke) terminal 2
g Fuse: 2amps 12.7 Switchover valve for defroster C To hazard warning switch
h 12-pin connector at left side of nozzle flaps (large stroke) (connection terminal 15)
pushbutton switch unit 13 Recirculating pump 0 From seat belt indicator,
i 12-pin connector, at right side of 14 Aspirator blower for in-car terminal 8
pushbutton switch unit temperature sensor (connection terminal 15)
6 Connector terminal 58d 15 Blower motor E To switchover valves for EGR
Preglow start switch 16 Temperature switch 100 ‘C for (California only)
: Blower motor auxiliary fan Ml Main ground (behind instru-
9 Pre-resistor, blower motor 17 Relay auxiliary fan pre-resistor ment cluster)
10 Electrical center with fuses 18 Pre-resistor auxiliary fan M5 Ground connection, engine
Fuse 1 = 16 A 19 Pressure switch auxiliary fan (unit screwed into engine)
Fuse 3 = 16 A On 20 bar/Off 15 bar M9 Ground connection, front left
20 Relay auxiliary fan (near headlight)
M l 0 Ground connection, battery
83.11-02813
EXIT
cardiagn.com
Tempmatic control system, model 201 ,122 starting model year 85
in-car temperature sensor 11 Switchover valve unit,4 connections 22 Pressure switch refrigerant
Ambient sensor, outside air 11.4 Switchover valve for blend air compressor
temperature flaps (“cold”) On 2.6 bar/Off 2.0 bar
Temperature sensor, air conditioning 11.3 Switchover valve for blend air 26 Switch, fresh air/recirculating air
Feedback potentiometer for flap flaps (“warm”) 132 Rpm sensor ring gear for flywheel
position 11.5 Switchover valve for heater 134/I Microswitch for compressor cutout
Pushbutton switch unit, consisting of: valve (“closed”) at full load (connected only on
a Temperature wheel 11 .l Switchover valve for heater vehicles with automatic trans-
b Pushbutton switch unit valve (“open”) mission)
c Mode switches for air conditioning 12 Switchover valve unit, 5 connections 141 Control unit compressor cutout
8 Air conditioning on, controlled 12.8 Switchover valve for legroom 143 Electromagnetic clutch
via temperature sensor (3) to flaps Refrigerant compressor
0 OC evaporator temperature 12.9 Switchover valve for fresh air/ 144 Rpm sensor, refrigerant
@ Air conditioning controlled via recirculating air flap (small compressor
pushbutton switch unit (elec- stroke) To electromagnetic clutch
tronic system) 12.10 Switchover valve for fresh air/ engine fan
Air conditioning off recirculating air flap (large To control unit emission control,
d Relay for refrigerant compressor stroke) terminal 6
e Relay for recirculating pump 12.6 Switchover valve for defroster To hazard warning switch
f Lights nozzle valves (small stroke) (connection terminal 15)
g Fuse: 2amps 12.7 Switchover valve for defroster From seat belt indicator,
h 12-pin connector at left side of nozzle flaps (large stroke) terminal 8
pushbutton switch unit Recirculating pump (connection terminal 15)
i 12-pin connector, at right side of :: Aspirator blower for in-car E To control unit emission control,
pushbutton switch unit temperature sensor terminal 4
6 Connector terminal 58d 15 Blower motor F To control unit electronic idle
Preglow starter switch 16 Temperature switch speed control terminal 10
: Blower motor a 100 OC for electromagnetic G To kickdown switch
9 Pre-resistor, blower motor clutch, engine fan H To switchover valves for EGR
10 Electrical center with fuses b 110 ‘C for auxiliary fan Ml Main ground (behind instru-
Fuse 1 = 16 A 17 Relay auxiliary fan pre-resistor ment cluster)
Fuse 3 = 16 A 18 Pre-resistor auxiliary fan M5 Ground connection, engine
19 Pressure switch auxiliary fan (unit screwed into engine)
On 20 bar/Off 15 bar M9 Ground connection, front left
20 Relay auxiliary fan (near headlight)
21 Auxiliary fan M l 0 Ground connection, battery
83.1 l-02814
EXIT
8. Vacuum diagram
cardiagn.com
Mode selectron cooling - fresh arr
11 Swrtchover valve unrt, 4 connectrons 30 Vacuum connection on intake bl = blue

11 .5 Swrtchover valve for heater manifold drt = dark red
valve (“closed”) 31 Check valve ge = yellow
11.4 Swrtchover valve for blend arr 33 Vacuum reservoir gn = green
flaps (“cold”) 34 Evaporator housing with fresh air/ gr = grey
11.3 Swrtchover valve for blend arr recirculating air flap hbl = light blue
tlaps (“warm”) 37 Vacuum element for blend air flaos mgn = middle green
11 .l Swrtchover valve for heater (“cold”) rt = red
valve (“open”) 38 Vacuum element for defroster ws = white
12 Switchover valve unrt, 5 connectrons outlet flaps (flaps “closed”)
12.10 Swrtchover valve for fresh air/ 39 Vacuum element for legroom flaps
recirculatrng air flap (flaps “closed”)
(large stroke) 40 Vacuum element for fresh air/
12.9 Swrtchover valve for fresh air/ recirculating air flap (flap “open”)
recirculating air flap 41 Vacuum element for heater valve
(short stroke) (heater valve “closed”)
12.8 Swrtchover valve for legroom 41a Orifice
flaps 47 Closing cap
12.7 Swrtchover valve for defroster 48 Orifice (vented within 20 seconds)
nozzle flaps (large stroke) 49 3-point distributor
12.6 Swrtchover valve for defroster 50 Connecting hose
nozzle flaps (short stroke)
83.11-028/5
EXIT
83-035 Testing refrigerating capacity of air conditioning system (quick test)
Data
Difference between coldest and warmest outlet temperature max.

(cutting out/cutting in time of refrigerant compressor)
Coldest air outlet temperature out of center nozzle (center outlet) 3.5 Oc
Conventional tools
2 thermometers -20 Oc to + 70 “c
cardiagn.com
(4.5 m cable length) ” ’
Supplier e.g.:
Switzerland: Kent-Moore (Europe) AG
P.O. Box, Cl-l-6340 Baar
Germany: Fa. Kalte-Fischer
Postfach 266, Augsburger Str. 289-291
D-7000 Stuttgart 60
Digital temperature measuring instrument with

4 measuring probes
Therm 2263-2
Measuring point changeover switch
with 4 connections 2235-4
Air temperature measuring probe w 453-5
(3 m cable length)
Supplier e.g.:
Germany: Ahlborn Me& und Regelungstechnik
in der Eichenfeldstraae l-3, D-81 50 Holzkirchen
Quick test
For air conditioning systems free of complaints.

Test after minor repairs, longer stationary periods or
the like.
Test procedure for ambient (interior) temperatures

from +20 ‘C to +40 “C. Check values can be read
after approx. 5 minutes.
83.11-035/l
EXIT
Test conditions
1 The vehicle should not be in the sunlight during

test.
2 Check tension of V-belt for compressor drive.
3 Check auxiliary fan for function, while switching

on ignition and bypassing the two flat plugs on pres-
sure switch (191, or connecting 1 -pin connector of
100 “C switch to ground. Pay attention to direction
of rotation of auxiliary fan (clockwise).
4 Check fluid level in air conditioning system; for

this purpose, pull one line from pressure switch (221,
run engine at idle (> 700/min) and engage air con-
ditioning system by means of function selection 8.
Clean sight-glass (arrow) in receiver drier. Watch
sight-glass while simultaneously plugging line on
pressure switch (22). Refrigerant should rise shortly
after switching on electromagnetic clutch and
cardiagn.com
should then flow free of bubbles (i.e. refrigerant no
longer visible).
Attention1
In the event of major refrigerant losses or an empty
system, the voltage for the refrigerant compressor is
interrupted by the pressure switch (22). When the
pressure increases to 0.6 bar above the cutout pres-
sure, the circuit is again closed.
5 Check whether the heater shuts off in selector

wheel position “MI N”. For this purpose, let engine
run at idle and engage air conditioning system with
function selection @ . Set temperature selector
wheel (a) to “MIN”. Refrigerant compressor should
be on after 20 seconds at the latest.
Note: If the refrigerant compressor is not engaging,

bridge lines from pressure switch (22) and check
fluid level according to item 4. If the refrigerant
compressor is still not engaging, test entire system
with socket box and volt-ohmmeter, refer to
83-039. On model 201.024 starting model year 85
and on model 201 .122 there may be an additional
fault on compressor cutout, for testing refer to
83-040.
83.11-035/2
EXIT
Testing
1 Set temperature selector wheel (a) to ‘MIN”.
2 Switch on function selection of pushbutton

switch (b) and function selection @ of switch
air conditioning system (c).
3 Set blower switch (15) to 2nd blower stage.
4 Open center and side outlets and switch off

switch (26) (fresh air).
5 Insert one thermometer into lefthand or right-

hand center outlet (25).
6 Position one thermometer for ambient tempera- 26

1834 12381
ture (room temperature) approx. 2 m from driver’s 24

22
side outside vehicle.
cardiagn.com
20
18
7 Open window and close vehicle doors. Run 18
engine at approx. 2000/min. OC 14
12
10
8
6
Diagram for model 201.024 4
25 35 40
Ta = Outside temperature “C OC
8 After approx. 5 minutes read air outlet tempera-

ture at center outlet and outside temperature and
compare with data of diagrams.
Diagram for model 201 .122

Ta = Outside temperature ‘C
Attention!
The air outlet temperature on center outlet should
not be below +3.5 ‘C. If the value is less than speci-
fied, check temperature sensor of air conditioning
system and renew, if required, refer to 83-l 33 or
test electric lines from temperature sensor for air
conditioning to pushbutton switch unit for ground
short. If there is no remedy, renew pushbutton
switch unit.
83.11-035/3
EXIT
83-036 Testing refrigerating capacity and suction/high pressure of air conditioning system
Data
Difference between coldest and warmest outlet temperature max.

3 °C
(cutting out/cutting in time of refrigerant compressor)
Coldest air outlet temperature out of center nozzle (center outlet) 3.5 “c
Conventional tools
1 suction pressure gauge 1 bar vacuum to

10 bar gauge pressure
or assembly tester
O-40 bar gauge
1 high pressure gauge
pressure
2 thermometers -20 Oc to + 70 “c
cardiagn.com
1 hygrometer

4 measuring probes
Robbi temp 90020
Air temperature measuring probe 90023
(4.5 m cable length)
Supplier e.g.:
P.O. Box, CH-6340 Baar
D-7000 Stuttgart 60

4 measuring probes
Therm 2263-2
(3 m cable length)
Supplier e.g.:
in der Eichenfeldstral3e 1-3, D-81 50 Holzkirchen
83.11-03611
EXIT
Functional test
In the event of complaints on air conditioning

system or for trouble diagnosis.
For a checkup in workshop in the event of com-

plaints owing to insufficient cooling capacity or for
a trouble diagnosis on air conditioning systems,
proceed according to test method applicable for
ambient temperatures from +20 ‘C to +40 ‘C.
All test values can be read after 10 minutes constant
operation.
Test conditions
1 The vehicle should not be in the sunlight during

test.
cardiagn.com
2 Check tension of V-belt for compressor drive.
3 Check auxiliary fan for function, while switching

on ignition and bypassing the two flat plugs on pres-
sure switch (191, or connecting 1 -pin connector of
100 ‘C switch to ground. Pay attention to direction
of rotation of auxiliary fan (clockwise).
4 Check fluid level in air conditioning system; for

this purpose, pull one line from pressure switch (22),
run engine at idle (> 700/min) and engage air con-
ditioning system by means of function selection @ .
Clean sight-glass (arrow) in receiver drier. Watch
sight-glass while simultaneously plugging line on
pressure switch (22). Refrigerant should rise shortly
after switching on electromagnetic clutch and
should then flow free of bubbles (i.e. refrigerant no
longer visible).
Attention!
In the event of major refrigerant losses or an empty
system, the voltage for the refrigerant compressor is
interrupted by the pressure switch (22). When the
pressure increases to 0.6 bar above the cutout pres-
sure, the circuit is again closed.
5 Check whether the heater shuts off in selector

wheel position “MI N”. For this purpose, let engine
run at idle and engage air conditioning system with
function selection @ . Refrigerant compressor
should be on after 20 seconds at the latest.
83.11-036/2
EXIT
Note: If the refrigerant compressor is not engaging,

bridge lines from pressure switch (22) and check
fluid level according to item 4. If the refrigerant
compressor is still not engaging, test entire system
with socket box and volt-ohmmeter, refer to
83-039. On model 201.024 starting model year 85
and on model 201 ,122 there may be an additional
fault on compressor cutout, for testing refer to
83-040.
Testing
1 Set temperature selector wheel (a) to ‘MI N”.
2 Switch on function selection of pushbutton

switch (b) and function selection @ of switch
air conditioning system (c).
3 Set blower switch (15) to 4th blower stage.
cardiagn.com
4 Open center and side outlets and switch off
5 Insert one thermometer into lefthand or right-

hand center outlet.
6 Position one thermometer for ambient tempera-

ture (room temperature) approx. 2 m from driver’s
side.
7 Place a hygrometer into tray of center console.
8 Unscrew closing caps (1). Then connect hose line

of suction pressure or high pressure gauge to service
valves. Make sure that the connecting nipple of the
hose lines has a pressure pin in center.
1 Closing cap of suction line

on all models
9 Open window and close vehicle doors.
1 Closing cap on pressure

line engine 102 up to
model year 84
83.11-036/3
EXIT
1 Closing cap on pressure line

engine 601 and engine 102
starting model year 85
13 Pull 1 -pin connector from temperature switch

100 ‘C (16) and connect to ground, so that the
auxiiliary fan runs along during entire test procedure.
cardiagn.com
16 Temperature switch 100 OC
engine 102 up to model
year 84
16 Temperature switch 100 ‘C

engine 102 starting model
year 85

engine 601 up to model
year 84
83.1 I-03614
EXIT

engine 601 starting model
year 85
14 Run engine at approx. 2000 rpm.
15 After operating engine for approx. 10 minutes,

read values on thermometers and pressure gauges,
as well as on hygrometer.
cardiagn.com
Note: Specified values, refer to diagram, are max.
values and must not be exceeded.
34
16 Check intake and high pressure in dependence 32
of ambient temperature, using the diagrams for this 28
24
purpose. Also check air outlet temperature (mean
20
value of two cold air outlet temperatures) also "c 16
according to diagram values. (The difference between 12
the coldest and the warmest outlet temperature 8
4
should not be higher than 3 “C). Check temperature
sensor, if required, renew, if necessary (refer to 4
83-133) or connect new pushbutton switch unit 3
for a tryout. bar 2
1
0
bar 26
22
18
14
120
Diagram for model 201.024 110
1I Relative humidity
OC 100
Ta Outside temperature (‘Cl 90
A Air outlet temperature (‘Cl 80
B Pressure in front of compressor (bar) 20 25 30 35
C Pressure following compressor (bar) Ta
D Coolant temperature (‘C) 1633.12367
83.1 l-03615
EXIT
bar
38
34
30
26
bar
22
18
Diagram for model 201 .I 22

I
_ I
J--L--
I 1
“C I i I III
)
1 Relative h u m i d i t y 100
Ta Outside temperature (‘C) 90
A Air o u t l e t t e m p e r a t u r e (‘(2)
B Pressure In front of compressor (bar)
--
a0
20 25 30 35 40
C Pressure followlng c o m p r e s s o r (bar)
OC
cardiagn.com
D Coolant temperature (‘ Cl
Ta
1633 12366
17 Check cutout temperature, setting blower

switch (15) to stage 1 for this purpose. Run engine
at approx. 2000 rpm. Following 3rd cutout of
electromagnetic clutch the air outlet temperature at
center outlet should not be less than approx.
+3.5 Oc.
Note: If the respective value is less than specified,

check temperature sensor of air conditioning system
and renew, if required, refer to 83-133 or test elec-
tric lines from temperature sensor of air condition-
ing system to pushbutton switch unit for ground
short. If there is no remedy, renew pushbutton
switch unit.
18 Take hose lines from service valves and close

service valves again with closing caps.
19 Plug 1 -pin connector to temperature switch

100 ‘C (16).
20 Remove thermometer and hygrometer from

vehicle.
83.1 l-036/6
EXIT
83-038 Testing control quality at different temperature adjustments, as well as heating

capacity
Conventional tools

4 measuring probes
Robbi temp 90020
Air temperature measuring probe 90023
(4.5 m cable length)
Supplier e.g.:
P.O. Box, CH-6340 Baar
D-7000 Stuttgart 60
cardiagn.com
4 measuring probes
Therm 2263-2

(3 m cable length)
Supplier e.g.:
in der EichenfeldstraBe l-3, D-81 50 Holzkirchen.
Data
Temperature to be attained at
Adjustment of temperature wheel
headroom level ‘C
Engage prior t o “Ml N” 162 1

22 22+ 1
Engage prior t o “ M A X ” 30 + 2
Note
Perform test not in workshop, but on cooled-out

vehicle parked overnight in the open air. In-car
temperature < 20 “C.
83.11-038/l
EXIT
Test conditions
1 Outside temperature < 15 ‘C (possibly in the

morning).
2 Driving time up to starting measurements

approx. 10 minutes. At outside temperatures < 0 “C
a longer measuring drive will be required.
3 Windows and sliding roof closed.
4 Do not run engine to operating temperature

first.
Testing control quality
1 Apply measuring probe at sun vizor (right)

(arrow) and connect to measuring instrument.
Then switch on measuring instrument.
cardiagn.com
2 Engage mode selection e of pushbutton switch
unit (b) and mode selection @ of switch air con-
ditioning (c).
3 Set blower switch (15) to stage I I and switch off

4 Close center outlet.
5 Set temperature wheel (a) to 22.
6 Start engine and drive off immediately (approx.

30-35 mph).
7 After approx. 1 O-l 5 minutes, read temperature

on measuring instrument. Nominal value 22 + 1 ‘C.
If the temperature is not attained, test system with
socket box volt and ohmmeter (refer to 83-039).
Note: Depending on complaint, test temperature

prior to “MIN” engaged (corresponds to 16 + 1 “C)
or prior to “MAX” (corresponds to 30 t 2 “C).
Following each adjustment of temperature selector
wheel, wait for approx. 7 minutes. If during adjust-
ment prior to “MAX” the temperature is not
attained, check heating capacity.
83.11-03812
EXIT
Checking heating capacity
1 Plug one measuring probe (arrow) each into left-

hand and righthand defroster nozzle.
2 Engage mode selection @ of pushbutton switch

unit.
3 Run engine at operating temperature at approx.

2000 rpm for 5 minutes. Nominal value: > 55 “C.
Note: If the temperature is not attained, check

whether the blend air flaps are fully open (perceived
by the air coming out of righthand outlet, arrow)
and recondition, if required. If in order, renew
heater valve for a tryout and flush cooling system, if
required. If there is no remedy, renew heat
cardiagn.com
exchanger.
83.1 l-03813
EXIT
cardiagn.com
EXIT
83-039 Testing system with socket box, volt and ohmmeter, and remedies
Special tools
:
Socket Test table
box for
socket box
I 124 589 00 21 00 124 589046300
Note
cardiagn.com
Perform test program if cause of trouble is unknown
or if the in-car temperature set on temperature wheel
is not attained.
Prior to starting the following test, check fuses 1

and 3 in electric center.
Preparations for test
1 Remove pushbutton switch unit (refer to

83-l 12).
2 Connect socket box to harness for pushbutton

switch unit by connecting the line of socket box
marked red with lacing of harness marked red
(pushbutton switch unit remains disconnected up
to test step 3).
83.11-039/l
EXIT
Test program
Test step 1
Testing in-car temperature sensor (1) with lines.
Ohmmeter Ambient Nominal value

on sockets temperature in kL?
in “C
+15 15.2 - 17.2

+20 11.5- 13.5
+25 9.5 - 10.5
1 and 21 +30 7.5 - 8.5
+35 6.0 - 7.0
+40 4.5 - 5.5
+45 3.5 - 4.5
Yes
cardiagn.com
1. Test line 9 of lefthand connector and
line 12 of righthand connector for inter-
ruption or line 9 of lefthand connector
for ground short.
2. Renew in-car temperature sensor (1)

(83-130).
Test step 2
Testing outside temperature sensor (2) with lines.

on sockets temperature in kJ2
in OC
+15 4.0 - 4.6

+20 3.1 - 3.9
+25 2.4 - 3.0
1 and 22 +30 1.9 - 2.3
+35 1.6 - 2.0
+40 1.4 - 1.6
+45 1.1 - 1.3
1. Test line 10 of lefthand connector for

interruption or ground short.
2. Renew outside temperature sensor (2)
83.11-039/2
EXIT
____
Test step 3
Testing temperature sensor air conditioning
system (3) with lines.

on sockets temperature in kfl
in OC
0 57 - 67
+5 46 - 54
+lO 37 - 45
1 and 19 +15 31 -36
+20 24 - 28
+25 20 - 24
+30 14-16
+35 13-15
cardiagn.com
1. Test line 7 of lefthand connector for
interruption or ground short.
2. Renew temperature sensor air con-

ditioning system (3) (83-193).
Test step 4
Testing switchover valve unit with 4 connections
(11) and lines for interruption or ground short.
Ohmmeter Nominal value

on sockets in ZZ
10and 12
10 and 14 60 - 70
10and 16
Yes I No
1. Test lines 1, 2 and 4 of lefthand connector

for interruption or ground short.
2. Renew switchover valve unit with 4 con-

nections (11) (83-l 53).
83.11-03913
EXIT
Test step 5
Testing switchover valve unit with 5 connections
(12) and lines for interruption or ground short.
Ohmmeter Nominal value

on sockets in fl
lOand
lOand
10 and 5 60 - 70
lOand
10and 12
Yes
1. Test lines 1, 2, 3, 5 and 6 of righthand

connector for interruption or ground short.
2. Renew switchover valve unit with 5 con-
cardiagn.com
nections (83-l 53).
Preparations for test step 6-9

Test fuse (g) on pushbutton switch unit with
ohmmeter in installed condition. Then connect
both connectors from socket box to pushbutton
switch unit, while plugging line with red adhesive
tape to lefthand plug of pushbutton switch unit.
Let engine run at idle.
83.1 l-039/4
EXIT
Test step 6
Testing voltage supply for pushbutton switch
units (input).
Voltmeter Nominal value

on socket
Yes No
Fuse No. 11 defective or line
cardiagn.com
Test step 7
Testing voltage supply for blower switch,
recirculating pump and refrigerant compressor
(input).
Voltmeter Nominal value

on socket
I-_” g_“”
9+” lo+“” >ll v
*up to model year 84 **starting model year 85
Yes No
Fuse No. 1 defective or line inter-

rupted.
Test step 8
Testing voltage supply for recirculating pump.
Voltmeter Mode selection Nominal value

on socket button
I_-+ 7__.“”
7 +* 10 +*+ @ >ll v
Yes No
83.11-039/5
EXIT
Test step 9
Testing voltage supply for refrigerant compressor.

on socket buttons after 20 s
>ll v
18+* lo+*” Engage temp.
wheel at “MI N”
Yes
Preparation for test step lo-20

Connect positive of voltmeter to socket 10.
Positive of voltmeter remains connected to
socket 10 up to test step 19.
cardiagn.com
P
Test step 10
Testing voltage supply for blower switch stage
----I
1
to max.

on socket button
4 >ll v
Test step 11
Testing voltage supply for blower switch
stage max.

on socket button
Yes
83.11-039/6
EXIT
Test step 12
Testing voltage supply for switchover valve of
blend air flaps “cold” (11.4).
Voltmeter Mode selection Nominal valut

on socket button after 10 s
13
Engage temp.
wheel at “Ml N”
Yes No
Test step 13
blend air flaps “warm” (11.3).
cardiagn.com
Engage temp.
wheel at “MAX”
Test step 14
heater valve (11.5).
Voltmeter Mode selection Nominal valu

14 >ll v
Engage temp.
wheel at “MI N”
Yes I No
Test step 15
legroom flaps (12.8).

on socket button each
5 then >ll v
83.11-03917
EXIT
Test step 16
fresh air/recirculating air flap, short stroke
(12.9).

on socket button
2 >ll v

fresh air/recirculating air flap, long stroke
cardiagn.com
Mode selection Nominal valu
after 10 s
>ll v
Engage temp.
wheel at “MIN”
I Yes
I No
Nominal value
>ll v
I Yes I No

defroster nozzle flaps, long stroke (12.7).
Mode selection Nominal value
Exchange push-
button switch unit.
83.11-039/8
EXIT
Test step 20
Testing potentiometer for flap position (4).

on socket button each after 40 s
17+ @
l- Engage temp.
wheel at
“MIN”, 3.9 - 4.4 v
then at “MAX” 0.3 - 1.2 V
- Yes No
1. Renew pushbutton switch unit for

tryout.
cardiagn.com
2. Adjust potentiometer for flap position,
renew if required (83-134).
Attention!
If there is no voltage change, test heater
vacuum system for leaks (83-045). If the
vacuum system is leaktight, renew switch-
over valve unit with 4 connections
(83-l 53).
End of test
83.11-03919
EXIT
83-040 ‘Testing compressor cutout and remedies
A. Testing with electromagnetic clutch of refrigerant compressor not connected
Attention!
A prerequisite for test is perfect functioning of
refrigerant compressor activation.
For this purpose:
l Switch on ignition, push mode selection button

and (GJ for air conditioning system.
l Connect voltmeter to blue/white line (input) of

pushbutton refrigerant compressor (22) and up to
model year 84 to vehicle ground, starting model
year 85 to positive. Nominal value: battery voltage.
If there is no voltage, test air conditioning system
cardiagn.com
according to wiring diagram (refer to 83-028).
l Connect voltmeter to blue/red line (output) of

pushbutton switch refrigerant compressor (22) and
up to model year 84 to vehicle ground, starting
model year 85 to positive. Nominal value: battery
voltage.
If there is no voltage, test high pressure of air con-
ditioning system. Renew pushbutton switch (22) at
a pressure of > 3 bar.
Refill air conditioning system at a pressure of
< 2 bar and eliminate leak.
Testing voltage supply for control unit

1compressor cutout (141)
~ Pull control unit (141) from 12-pin connector.
Connect voltmeter to terminal 5 + and terminal
1 - of 12-pin connector.
Nominal value: battery voltage
Test harness according to wiring diagram

(refer to 13-028) and recondition, if
required.
83.11-040/l
EXIT
Testing control voltage for refrigerant compressor

of pushbutton switch refrigerant compressor (221
to control unit (141)
Connect
voltmeter to terminal lo+” 5+**
l-* lo-“”
of 12-pin connector.
*up to model year 84 *“starting model year 85
Nominal value: battery voltage
Test harness from terminal 10 to pressure

switch (22) and recondition, if required.
cardiagn.com
compressor and supply line
Bridge terminal 5 and 7 on 12-pin connection.

Start engine for a short moment and check
whether refrigerant compressor is running.
Test electromagnetic clutch of refrigerant

compressor and renew, if required (refer to
83-526) or recondition supply line for
refrigerant compressor.
Testing rpm sensor refrigerant compressor (144)
Connect voltmeter to terminal 9 and 11 of 12-pin

connector and set voltmeter to alternating
voltage -. Terminal 5 and 7 of 12-pin connectior
remain bridged.
Run engine at idle speed (approx. 750 rpm).
Nominal value: min. 0.3 V -
Stop engine and test resistance of rpm sensor

(144) on terminal 9 and 11.
Nominal value: 530 to 650 s2, renew rpm
sensor, if required (refer to 83-516).
83.11-040/2
EXIT
Model 201 with gasoline engine
Testing transistorized rpm signal (TD)

connector and set voltmeter to DC. Run engine
at idle speed (approx. 750 rpm).
Nominal value: approx. 8.5 V
Model 201 with diesel engine
Testing rpm sensor on starter ring gear

connector and set voltmeter to AC. Run engine
at idle speed (approx. 750 rpm).
Nominal value: approx. 4 V rvl )
’ ) Increasing voltage at increasing engine speed
cardiagn.com
Model 201 with gasoline engine
Eliminate interruption to line connector
of diagnosis socket.
Model 201 with diesel engine

Stop engine and test resistance of rpm
sensor (132) on terminal 1 and 2.
Nominal value: 1.9 * 0.2 ki2, renew rpm

sensor, if required (refer to 83-517).
Renewing control unit (141).
Testing air conditioning for function.
End of test
83.11-040/3
EXIT
B. Testing cutout of electromagnetic clutch

of refrigerant compressor via control unit
compressor cutout (141)
Run engine at idle speed.
2 Engage temperature wheel to “MIN”, set blower

to stage 4 and adjust mode selection buttons
and @
3 Spray with a water jet in-between V-belt and

pulley of electromagnetic clutch of refrigerant com-
pressor until the refrigerant compressor is switched
off, while applying intermittent acceleration. If the
refrigerant compressor is not switched off by con-
trol unit (1411, renew control unit.
Attention!
Following cutout of refrigerant compressor, the
compressor may be started again via control unit
(141) after stopping and renewed starting of
cardiagn.com
engine.
4 On model 201 with gasoline engine, check

whether the refrigerant compressor is switched off
by temperature switch 110 “C (23). For this pur-
pose, start engine again, pull 1 -pin connector from
temperature switch 110 “C (23) and connect to
ground.
The refrigerant compressor must be switched off

immediately. If required, eliminate line interrup-
tion or renew control unit (141).
5 On model 201 with diesel engine and automa-

tic transmission, check whether refrigerant corn:
pressor is switched off by microswitch 134/l, as
follows:
Run engine at idle. Watch electromagnerrc clutch
of refrigerant compressor and apply full throttle
for a short moment. The electromagnetic clutch
must remain switched off up to 2150 rpm and then
switch on again. If the electromagnetic clutch is
not switched off, renew microswitch 134/l or
control unit 141.
83.11-040/4
EXIT
83-045 Testing vacuum system for blend air flaps, fresh air/recirculating air flap,
defroster nozzle flaps, legroom flaps and heater valve for leaks
Data
Permissible leaking per vacuum circuit 30 mbar/min

(without vacuum reservoir) at 400 mbar vacuum
60 mbar in 10 min
Permissible leaking of check valve
at 300 mbar vacuum
20 mbar/min
Permissible leaking of remaining components
at 300 mbar vacuum
Special tools
cardiagn.com
Self-made tool
1 blind plug 0009871145
Note
The vacuum test is subdivided into 5 test circuits

(A to E). In the event of a given fault (e.g. legroom
flaps not opening) the respective circuit can be
tested first.
If a leak is suspected in entire vacuum system for

heating, start with test step “a” and “b” and then
test all the test circuits completely until the faulty
vacuum circuit is found.
83.11-045/l
EXIT
a) Testing check valve (31)
1 Pull vacuum line medium green/red and red/grey

(on model 201.024 only) from check valve (31).
Connect tester (arrow) to one of the two connec-
tions.
2 On model 201.024, close second connection on

check valve with blind plug. Then evacuate with
tester and read pressure gauge.
3 If the pressure gauge indicates an increase in

pressure, renew check valve.
b) Testing vacuum reservoir (33) with vacuum line

red/grey (model 201.024 only)
4 Pull vacuum line red/grey from check valve (31)

an d connect tester (arrow) to vacuum line.
cardiagn.com
5 Evacuate with tester and read pressure gauge.
6 If readout on pressure gauge changes, remove

reservoir (33) and check for leaks. Renew, if
required or renew vacuum line red/grey.
Layout vacuum reservoir (33)

under front fender left
(model 201.024 onlv)
Preparing for test
1 Pull vacuum line medium green/red from check

valve (31) and connect tester to vacuum line.
2 Switch on ignition.
Note: The tester remains connected during entire

test on vacuum line medium green/red.
83.11-045/2
EXIT
A. Testing vacuum circuit 1, vacuum line medium green/red and input of valve unit 11 and 12
1 Push mode selection button @ on pushbutton

switch unit.
2 Evacuate with tester (approx. 400 mbar) and

read pressure gauge.
3 If readout on pressure gauge changes, test

switchover valve unit (11) and (12) individually
and test vacuum line medium green/red and renew,
if required.
cardiagn.com
Note: If a leak shows up on vacuum unit medium
green/red, the leak may also be on connecting hose
(50) (maybe pulled off).
83.11-04513
EXIT
B. Testing vacuum circuit 2, vacuum element (40) for fresh air/recirculating air flap
(short and long stroke) with vacuum lines
1 Push mode selection button on pushbutton

switch unit and engage temperature wheel at
“ M A X ”.

read on pressure gauge.

vacuum element (40) directly or renew (83-165
section “D”) or test vacuum lines medium green/
light blue and medium green/yellow, and renew
if required.
cardiagn.com
Vacuum circuit 2, mode selection and temperature wheel engaged at “MAX”.
40 Vacuum element for fresh air/recirculating air flap
83.11-045/4
EXIT
C. Testing vacuum circuit 3, vacuum element (38) for defroster nozzle flaps
(short and long stroke) with vacuum lines
1 Push mode selection button on pushbutton

switch unit. Temperature wheel remains at “MAX”.


vacuum element (38) directly and renew, if
required (83-165 section “B”), or test vacuum
lines red/light blue and red/white and renew, if
required.
cardiagn.com
V a c u u m circuit 3, mode selectton a n d t e m p e r a t u r e w h e e l e n g a g e d a t “ MAX”
38 Vacuum element for defroster nozzle flaps
83.1 l-04515
EXIT
D. Testing vacuum circuit 4, vacuum element (39) for legroom flaps

with vacuum lines
1 Push mode selection button e on pushbutton

switch unit, temperature wheel remains engaged at
“ M A X ”.


vacuum element (39) directly and renew, if
required (83-165 section “C”), or test
vacuum line medium green/white and renew,
if required.
cardiagn.com
Vacuum circuit 4, mode selection @ and temperature wheel engaged at “MAX”
39 Vacuum element for legroom flaps
83.11-045/6
. . . . . . . EXIT
E. Testing vacuum circuit 5, vacuum element (37 and 41) for blend air flaps and heater valve
with vacuum lines
1 Push mode selection button @ on pushbutton

switch unit and set temperature wheel to “MIN”
(not engaged).
2 Evacuate with tester, wait for approx. 5 seconds

and evacuate again. Repeat approx. 5 times, because
the vacuum element (37) is provided with vacuum
by way of an orifice. Then read pressure gauge.
Note: If the temperature difference (preset tem-

perature at temperature wheel in relation to out-
side temperature) is above 8 ‘C, the vacuum
element (40) for fresh air/recirculating air flap is
also provided with vacuum.
cardiagn.com
3 If readout on pressure gauge changes:
a) Test vacuum element (41) for heater valve

directly and renew, if required (83-1 15) or test
vacuum line dark red and renew, if required.
Note: If the vacuum line dark red shows a leak,

the leak may also be at connecting hose (50).
83.11-04517
EXIT
b) Test vacuum element (37) directly and renew,

if required (83-l 65 section “A”) or test vacuum
line green and renew, if required.
cardiagn.com
Vacuum circuit 5, mode selection e and temperature wheel at “MIN” (not engaged)
37 Vacuum element for blend air flaps

41 Vacuum element for heater valve
50 Connecting hose
83.1 l-04518
EXIT
83-100 Removal and installation of heater box
Self -made tool
Guide plate
Plate thickness approx. 0.8 mm
a 350 mm
b 70 mm
c 180mm
cardiagn.com
d 120mm
Removal
Disconnect battery.
Drain coolant.
Remove instrument panel (68-l 00).
Remove pushbutton switch unit (83-l 12).
Remove radio.
Remove center console top.
Remove cover of air intake (83-140).
Disconnect feed hose (arrow) on engine.
9 Disconnect return hose (arrow) on recirculating

pump (13). Then disconnect and connect vacuum
line on heater valve for a short moment.
10 Set container under return flow hose.
83.1 l-100/1
EXIT
11 Position compression air nozzle (arrow) at feed

hose and blow remaining coolant out of hea t
exehanger.
12 Reconnect feed and return flow hose.
13 Disconnect feed and return flow hose (23rrow)

on I heat exchanger.
cardiagn.com
14 Remove pipe holder (arrow) from holding
bracket bottom left.
15 Loosen nut (a).
16 Unscrew feed pipe (arrow) on heat exct-langer

and pull out of front wail toward the rear.
17 Pull lefthand and righthand air duct for lateral

ven ting from heater box.
83.11-100/2
EXIT
18 Unscrew I.eturn flow pipe (arrow) on heat

exchanger and pull out of frorit wall toward the
rear.
19 Loosen nut (a).
20 Loosen cable strap (arrow ) on heater box and

pull line connector (6) out of IIeater box.
21 Pull both vacuum lines (ar row) from vacuum

element (38).
cardiagn.com
i A
22 Pull vacuum line from vacuum element (39).

Separate plug connection (arrow).
24 Unscrew both nuts (a).
25 Lift heater box out in upward direction.
83.11-100/3
EXIT
Installation
26 Insert guide plate between front wall and con-

densate water pan (arrow).
Attention!
Be sure to insert guide plate, so that the condensate
water pan is not buckling in downward direction
when the heater box is inserted.
27 Insert heater box. Then pull out guide plate in

upward direction.
28 For further installation proceed vice versa.
cardiagn.com
83.11-100/4
EXIT
83-l 10 Removal and installation of heat exchanger
1 Remove heater box (83-100).
2 Unscrew 3 screws (arrow) on heater box.
cardiagn.com
3 Remove rivet (52) and take cover (53) from
heater box.
4 Loosen sealing rubber (54) on lefthand and

righthand defroster nozzle up to half.
5 Pull shaft (55) partially out of lefthand defroster

nozzle while pushing against engaging lug (arrow).
83.11-110/l
EXIT
6 Push clamps (arrows) off at parting point of

heater box
. top
l laterally left and right
cardiagn.com
l bottom
7 Lift both legroom nozzles (arrow) with connect-

ing rod from heater box.
183-27911
83.11-110/2
EXIT
8 Pull heater box apart at parting point.
183-27916
9 Unscrew screws (arrow) on holding frame of

heat exchanger and lift off holder frame.
cardiagn.com
183-27917
10 Lift heat exchanger out of heater box.
11 Install in vice-versa sequence.
Note: When assembling heater box, make sure that

the bearings of the defroster nozzle flaps are cor-
rectly seated on housing and that the lug (arrow) of
shaft (55) engages at lefthand defroster nozzle flap.
83.11-I lO/
EXIT
83-l 12 Pushbutton switch unit
A. Removal and installation
1 Pull out both outlets at instrument panel

center.
cardiagn.com
2 Loosen both screws (arrow) and push center
console top slightly down.
3 Pull knob from blower switch and pull molding

for blower switch out of center console.
4 Pull connector from switch fresh air/recirculating

air.
5 Lift both clamps (arrow) with a pointed tool and

pull out complete pushbutton switch unit.
6 Pull both 12-pin connectors from pushbutton

switch unit.
83.11-112/l
EXIT
B. Renewing bulbs for lamps
1 Remove cover (57) in upward direction, while

pushing against both hooks (arrow).
cardiagn.com
183 - 2792411
2 Push both engaging lugs (arrow) slightly down

and pull lamp socket (58) out to the rear. Then
remove bulbs from lamp socket.
C. Removal and installation of wood

panelling
1 Pull both clamps (arrow) in upward direction.
2 Remove wood panelling in forward direction.
183 - 27924
83.11-11212
................. ... EXIT
D. Removal and installation of temperature wheel (without potentiometer)
Removal
1 Remove wooden panelling (refer to section C).
2 Position temperature wheel between “MI N” and

18 ‘C, then push out drive pin (arrow) with screw-
driver.
cardiagn.com
3 Push engaging lugs (arrow) down and tilt frame
(59) forward.
4 Remove temperature wheel (a) from pushbutton

switch unit.
Installation
5 Insert ball (arrow) and temperature wheel (a) in

position “MIN” to 18 ‘C into pushbutton switch
unit. Then push drive pin into pushbutton switch
unit, while turning temperature wheel until the
drive pin engages in wheel. Continue installation in
vice-versa sequence.
83.11-11213
EXIT
83-l 13 Removal and installation of blower switch
1 Remove pushbutton switch unit (83-l 12,

section A).
2 Unscrew both screws (arrow) and remove blower

switch (15) through opening for pushbutton switch
unit.
cardiagn.com
3 Pull electric connector, glow bulb socket and
light conductor (arrow) from blower switch.
83.11-113/l
EXIT
83-l 15 Removal and installation of heater valve
1 Remove cover on air inlet (83-140).
2 Pull off vacuum line (arrow) on heater valve.
cardiagn.com
3 Loosen hose clamps (arrow) on heater valve.
4 Pull off hoses and remove heater valve.
Attention!
When inserting heater valve, the letters “water
inlet” should face front wall.
83.11-115/l
EXIT
83-117 Removal and installation of recirculating pump
1 Partially drain coolant.
2 Disconnect both hose straps (arrow) on recircu-

lating pump (13).
3 Separate electric plug connection.
4 Unscrew both screws (60).
cardiagn.com
5 install in vice-versa sequence.
6 Fill in coolant and check cooling system for

leaks.
83.11-117/l
............................................................... ....... .... ............
EXIT
83-120 Removal and installation of blower motor
Data
Current input at
21 A
13 V + 0.2 V 4th stage
Blower speed rpm (1 /min)

Detent 1 1800
Detent 2 2600
Detent 3 3500
Detent 4 4100
Air volume at 12 V (kg/h) 550
cardiagn.com
Removal
1 Remove cover on air inlet (83-l 40).
2 1 _oosen bulkhead (621, unscrewing screws

(arrc3~) at left and right for this purpose. Then
pull bulkhead forward up to engine.
3 Remove wiper arm.
4 Unscrew screws (arrow) on wiper linkage and

put wiper linkage with motor aside.
83.1 1 --I 20/l

EXIT
5 Loosen clamping straps (64) and unclip clamps

(arrow) laterally and on top.
6 Lift out cover (65) in upward direction.
7 Unclip holding strap (87) with a pointed tool

(e.g. tracer pin).
8 Pull off flat plug (arrow) and lift out blower

motor (8).
cardiagn.com
Installation
9 Insert blower motor (8) into holder in such a

manner that the connections are pointing in
driving direction and that the motor housing is
held in motor holder.
11 Test blower motor for function, paying special

attention to noises, since fan wheels may wipe
against housing.
83.11-120/2
EXIT
1 Remove glove box.
2 Pull righthand lateral outlet from instrument

panel by means of flat pliers (arrow).
cardiagn.com
3 Push frame (68) for outlet out of instrument
panel, while slightly raising the four detent lugs
(arrow).
4 IJnclip aspitator blower (14) from holder (arrow).
5 F%_~ll hose and 2-pin connector from venting

blower.
Install in vice-versa sequence.
6 Check aspirator blower for function, switch on

ignition for this purpose.
83.11-122/l
........ .................................................................................... .......................... .......... .... ... EXIT
83-l 30 Removal and installations, testing of in-car temperature sensor
Test values
Sensor temperature in OC approx. Resistance in kfi
+20 11.5 t o 13.5

+25 9.5 t o 10.5
+30 7.5 t o 8.5
+35 6.0 t o 7.0
+40 4.5 t o 5.5
+45 3.5 t o 4.5
cardiagn.com
1 Pull out dome lamp.
2 Force off in-car temperature sensor (1) in up-

ward direction.
3 Pull 2-pin connector and vent hose from in-car

temperature sensor.
4 Test temperature sensor with ohmmeter.
83.11-130,l
EXIT
83-132 Removal and installation, testing of outside temperature sensor
Test values
Sensor temperature in OC approx. Resistance in kS2
+20 3.1 t o 3.9

+25 2.4 t o 3.0
+30 1.9 t o 2.3
+35 1.6 t o 2.0
+40 1.4 t o 1.6
+45 1.1 t o 1.3
cardiagn.com
1 Remove heater valve (83-l 15).
2 Loosen cable strap (arrow).
3 Loosen cable strap (arrow) and separate 2-pin

plug connection (2a).
83.11-132/l
EXIT
4 Pull outside temperature sensor (2) from holder.
5 Test temperature sensor with ohmmeter.
Note: Opening of outside temperature sensor

(arrow) should face evaporator housing.
cardiagn.com
83.11-13212
.......................... ..... .... ......
................................
EXIT
Test values -
- -
Sensor temperature in OC approx. Resistance in kL?

- -
+0 57 to 6 7
+5 4 6 to 5 4
+10 3 7 to 4 5
+15 30 to 36
+20 24 to 28
+25 20 to 24
+30 14 to 16
+35 13 to 15
cardiagn.com
1 Remove heater valve (83-l 15).
2 Loosen cable straps (arrow).
3 Separate 2-pin plug connection (arrow).
83.11-133/l
EXIT
Pull temperature sensor (3) out of guide tube.
Test temperature sensor with ohmmeter.
cardiagn.com
83.1 l-13312
............................................................................ ...................................... EXIT
83-134 Removal, testing, installlation and adjustment of potentiometer for flap position
Special tools
l-----l
Test cable
for
socket box
cardiagn.com
Removal
1 Remove instrument panel (68-100).
2 Separate 3-pin plug connection (arrow).
3 On version 1, unscrew 3 screws (arrow) and pull

potentiometer for flap position (4) from lever (a)
of blend air flaps.
1 st version
83 1 l-13411
EXIT
4 On 2nd version, unscrew screw (89). Then

remove nut (75) and spring (76).
5 Unscrew 3 screws (arrow) and lift off potentio-

meter for flap position (4).
2nd version
Testing
6 Connect ohmmeter to terminal 1 and 2 of poten-

tiometer for flap position and slowly move lever
(arrow) from stop to stop. The resistance should be
cardiagn.com
from approx. 8 Sz to 4.4 + 1 ka without interrup-
tion. Renew return potentiometer, if required.
Installation
7 Mount potentiometer for flap position depending

on version on heater box and connect.
Adjustment
8 Connect control unit and socket box, while

plugging electric lines with red adhesive tape to
lefthand connecting plug of control unit.
9 Connect voltmeter positive to socket 17 and

connect ground to socket 1 of socket box.
10 Close oil line for oil pressure gauge and run

engine at idle speed.
11 Engage temperature wheel at “MIN” and wait

for approx. 60 seconds.
83.1 l-l 3412
EXIT
12 Set voltage to 4 + 0.1 bar.
On 1st version adjust to the left or right by bridging

segment on lever (arrow) of potentiometer for flap
position, adjust stop screw (51) slightly, if required.
1 st version
10 On 2nd version, turn adjusting screw (89) to

the left or right.
cardiagn.com
2nd version
11 Engage temperature wheel at “MAX”, wait for

approx. 60 seconds and test voltage 0.3-l .2 V.
Attention!
If the voltage is not attained, check whether the
blend air flaps can be moved from position “full
heating” to “full cooling”. For this purpose, dis-
connect connecting rod from vacuum element and
move on lever of potentiometer from stop to stop.
12 Install instrument panel.
13 Check heater for function.
83.11-l 3413
EXIT
83-138 Removal and installation, testing of switch for fresh air/recirculating air flap
1 Unclip the springs at left and right on switch

(26) by means of a flat, wedge-shaped tool and
pull out switch.
2 Pull connector from switch.
cardiagn.com
Testing
Connect ohmmeter to terminal 3 and 4.
1034-10460
26 26
Switch 26 Nominal value
Push symbol
(arrow, top) ON =Otol !z
Push without symbol l&34- 1034-
(arrow, below) O F F =m H)818 10819
83.11-138/l
EXIT
83-140 Removal and installation of cover at air inlet
1 Open engine hood to 90’ position.
2 Open cover on wiper arm, unscrew nut under-

neath and pull off wiper arm (upper arrow).
3 Push round cover from wiper shaft (lower

arrow).
cardiagn.com
4 Push out clips on partition.
5 Pull rubber seal at left and right from cover at

air inlet and unscrew screws (arrow).
6 Pull out cover at air inlet from lower trimstrip

at windshield pane and remove.
83.11-14011
EXIT
83-150 Removal and installation of outlets on instrument panel outside and center
1 Pad flat pliers with a rag and pull outlet at left

and right out of mount.
cardiagn.com
83.11-150/l
EXIT
83-153 Removal and installation of switchover valve unit with 4 or 5 connections
Removal
1 Install glove box.
2 Pull righthand lateral outlet from instrument

panel.
cardiagn.com
3 Push frame (68) for lateral outlets out of instru-
ment panel while slightly lifting the four detent
lugs (arrow).
4 Remove venting blower (83-122).
5 Unclip switchover valve units (1 1 and 12) from

holder.
6 Pull vacuum lines and both 6-pin connectors

from switchover valve units.
83.11-15311
EXIT
7 Force switchover valve unit (12) to the right

(arrow) from switchover valve unit (1 1).
installation
8 Slip switchover valve unit (12) up to stop on

switchover valve unit (11).
9 Plug vacuum lines according to respective color

identification of switchover valves on pertinent
switchover valves (also refer to vacuum diagram
83-028, section B).
10 Plug 6-pin connector with red adhesive tape

to switchover valve unit (11).
cardiagn.com
83.11-153/2
EXIT
83-165 Removal and installation of vacuum elements
Data
Permissible leaking of vacuum elements 20 mbar/min at 300 mbar vacuum

~_ ~ ~~
Plug-on length of connections lo-12 mm
Special tools
Socket Test cable

box for
socketbox
cardiagn.com
201 589 13 21 00 124 589 00 21 O( 124 58904 63 00
L /
A. Vacuum element (37) for blend air flaps
Removal
1 Remove instrument panel (68-100).
3 Unclip clamp (arrow) from connecting rod (a).
4 Unscrew both screws (73).
Installation
5 Fasten vacuum element to heater box and

mount connecting rod.
6 Connect vacuum tester to vacuum element (37)

and evacuate with tester to approx. 400 mbar
vacuum.
83.11-165/l
EXIT
7 On 1 st version, check whether stop screw (51)

rests against vacuum element (37). Simultaneously,
the blend air flaps (noticed by the air coming out of
lateral outlets at the right, arrow) must be closed.
Adjust stop screw (51), if required.
1 st version
8 On 2nd version, check whether the blend air

flaps (noticed by the air coming out of lateral out-
lets, right) are closed. If required, turn connecting
rod (a) to the left or right.
9 Disconnect vacuum tester and connect vacuum
cardiagn.com
line green to vacuum element (37).
2nd verston
10 Connect socket box on control unit, while

plugging electric lines with red adhesive tape to
lefthand connecting plug of control unit.
11 Connect voltmeter + to socket 17 and - to

socket 1 of socket box.
12 Close oil line for oil pressure gauge and run

engine at idle speed.
13 Engage temperature wheel at “MIN” and wait

for approx. 60 seconds.
14 Set voltage to 4 f. 0.1 V:
On 1st version adjust to the left or right by bridging

the segment on lever (arrow) of potentiometer for
flap position. Slightly adjust stop screw (51), if
required.
1 st version
83.1 l - l 6512
.......................... ... ............. ... .......... EXIT
15 On 2nd version, turn adjusting screw (89) to

the left or right.
2nd version
16 Engage temperature wheel at “MAX”, wait for

approx. 60 seconds and test voltage 0.3-l .2 V.
Note: If the voltage is not attained, check whether

the blend air flaps are moving from position “full
heating” to “full cooling”. Make blend air flaps
cardiagn.com
operable, if required.
17 Close socket box on control unit.
18 Install instrument panel.
19 Check heater for function.
B. Vacuum element (38) for defroster nozzle flaps
1 Remove instrument cluster.
2 Pull both vacuum lines from vacuum element

(38).
3 Take out rivet (77) and remove cover (78).
83.1 l-16513
EXIT
4 Remove clamp (79).
5 Push down detent (arrow) of bayonet lock while

simultaneously turning vacuum element (38) to the
left.
cardiagn.com
C. Vacuum element (39) for legroom flaps
1 Remove center console top (68-200).
2 Pull vacuum line (arrow) from vacuum element

(39).
3 Push off cover (84).
4 Pull connecting rod (81) and clip (82) from

lever for legroom flaps.
5 Push down detent (arrow) of bayonet lock while

simultaneously turning vacuum element (39) to the
left.
83.11-16514
EXIT
D. Vacuum element (40) for fresh air/recirculating air flap
1 Remove vacuum element (39) for legroom flaps

(refer to 83-l 65, section C).
2 Pull both vacuum lines from vacuum element

(40).
3 Turn vacuum element (40) to the left while

slightly lifting vacuum element with a screwdriver
cardiagn.com
(arrow).
4 Push connecting rod of vacuum element from

clip (arrow).
5 Connect vacuum lines (medium green/yellow)

top and (medium green/light blue) in center to
vacuum element (40).
6 Continue installation in vice-versa sequence.
83.11-16515
EXIT
cardiagn.com
EXIT
83-516 Removal and installation of rpm sensor on Nippondenso refrigerant compressor

_ _
Data
Resistance of rpm sensor 590 ? 60 K?
Conventional tool
Pliers for locking ring J2 e.g. Hazet

(inside lock) D-5630 Remscheid
1 Remove refrigerant compressor (83-522).
cardiagn.com
2 Loosen line and plug housing on refrigerant
compressor.
3 Open plug housing and remove both plug pins

for rpm sensor.
4 Remove locking ring (arrow) and pull out rpm

sensor (144).
5 Install in vice-versa sequence, while checking

sealing ring on refrigerant compressor for rpm
sensor. Renew, if required. Moisten sealing ring
with cold-flowing oil.
6 Let refrigerant vapor flow into refrigerant com-

pressor on service valve (arrow). A bottle or filling
cylinder pressure of above 4 bar gauge pressure is
required.
7 In installation position of refrigerant compres-

sor, rotate compressor shaft several times manually
in direction of rotation.
8 Check refrigerant compressor for leaks by means ,600
of leak test.
9 Connect valve on service unit or on filling

cylinder again and remove hose line on service
valve.
10 Install refrigerant compressor (83-522).
11 Evacuate air conditioning system, fill again,

and check for function and leaks (83-036).
83.11-516/l
..................
.................................... .......... ........... ...... .......... EXIT
83-517 Removal and installation of rpm sensor on starter ring gear (model 201.122)
Data
Resistance of rpm sensor 1.8 + 0.2 kS2
Conventional tool
Hex. socket wrench 5 mm
cardiagn.com
1 Remove air cleaner housing.
2 Remove rear engine compartment panelling,

below.
3 Separate 2-pin plug connection (132a).
4 Remove clamp (95).
5 Open line cover (96) and expose line of rpm

sensor (arrows).
6 Unscrew screw (97) and pull rpm sensor (132)

out of oil pan.
83.11-517/l
EXIT
W-520 Checking oil level in refrigerant compressor
Oil filling capacity
Oil type cold-flowing oil (for approved refrigerant compressor oil types refer to Specifications for Service
Products, page No. 362)
Delco refrigerant compressor 170 cc

Oil capacity, fresh oil, in refrigerant compressor
Nippondenso refrigerant compressor 120 cc
Jobs on refrigerant system

During each repair job on refrigerant system renew container of receiverdrier on principle.
Procedure Quantity of compressor oil to be filled in, including

10 cc oil for receiverdrier
cardiagn.com
1. Repair or slow loss of refrigerant
Refilling refrigerant:
Up to 400 g (no leak showing up) Do not fill in compressor oil.
Completely fill system owing to leaks and renew 20 cc fresh oil

receiver-drier.
Renew refrigerant compressor and receiver-drier. Same quantity as from removed compressor and fill
Drain oil from removed compressor and measure an additional 10 cc (for receiverdrier) into new
quantity. Also drain oil from new compressor. compressor, drained oil of new compressor can be
used.
Recondition refrigerant compressor (e.g. front Fill 20 cc of fresh oil into compressor.
shaft seal) and renew container of receiver-drier.
For this purpose, drain refrigerant slowly
(suction end).
2. Sudden discharge of system (e.g. broken line or accident)
Renew defective part and receiver-drier as described Fill in additional 40 cc compressor oil.
under 1. and 3., including specified quantity of oil.
Note
-
Upon evacuation (approx. 30 minutes) fill air conditioning system with approx. 200 g refrigerant R 12 and
check for leaks. Then drain refrigerant again and evacuate again (approx. 15 minutes).
Then fill system with specified quantity of refrigerant and test air conditioning system for function.
3. Replacing components
Renew condenser 20 cc of fresh oil

Renew evaporator 40 cc of fresh oi I
Renew receiver-drier 10 cc of fresh oil
Suction line from evaporator to compressor and 10 cc of fresh oil each
pressure line from compressor to condenser
83.11-520/l
EXIT
Note
If the refrigerant compressor is reconditioned or renewed, pay attention to quantity of cold-flowing oil to be
filled in.
For details refer to oil capacity while working on refrigerant system. But be sure to install a new receiver-drier
each time.
If up to 400 g refrigerant are lost over a longer period, no cold-flowing oil need be added. If more than 400 g of
fresh refrigerant are filled in, check air conditioning system for leaks. If refilling is required, add approx. 20 cc
of cold-flowing oil into system prior to evacuating.
Checking and correcting oil capacity of refrigerant compressor
2 If the refrigerant compressor is renewed, drain
cardiagn.com
oil from refrigerant compressor while holding
refrigerant compressor Delco R 4 with shaft end
in upward direction and holding refrigerant com-
pressor Nippondenso with pressure and suction hole
in downward direction and letting the oil run out
through pressure and suction hole for approx.
10 minutes. Accelerate draining of the oil by
rotating drive shaft (coupling) several times.
3 Drain oil from new refrigerant compressor as

described under item 2.
4 Check how much oil has run out of original

refrigerant compressor and out of pipe line.
5 Fill similar quantity of fresh oil into new

refrigerant compressor through suction hole, plus
an additional 10 cc for new receiver-drier.
6 When reconditioning refrigerant compressor

(e.g. front shaft seal) renew receiver-drier and add
an additional 20 cc of fresh oil into compressor.
83.11-520/2
EXIT
83-522 Removal and installation of refrigerant compressor
A. Delco refrigerant compressor engine 102
Oil capacity, fresh oil, in refrigerant compressor 170 cc
Tightening torques Nm
Screws M 12 refrigerant compressor on carrier 60+10
Screw pipe line on refrigerant compressor 50 * 3
cardiagn.com
Hose line from evaporator to pipe line 7/8”
Hose line from pipe line to condenser 7/8”
Special tools
, \
116569143100
. /
Conventional tools
Double open-end wrench l/2” x 9/l 6”, 5/8” x 3/4”, 7/8” x 15/l 6”, 1” x 1 l/8”
Socket 14 mm, 3/8” square
Assembly tester with 3 filling hoses e.g. Christof Fischer

or evacuating and filling equipment for air conditioning system Augsburger Str. 289, D-7000 Stuttgart 60
Note
If the refrigerant compressor must be renewed or reconditioned, fill in oil according to job No. 83-520.
If the refrigerant compressor is renewed owing to inside damage (e.g. blocking or damage on valve plates), addi-
tionally renew pipe line on compressor, expansion valve and receiver-drier. In addition, check function and
direction of rotation of auxiliary fan (clockwise) by means of 20 bar and 100 ‘C switch.
83.11-522/l
EXIT
Removal
Mask both front fenders.
Disconnect battery.
Remove engine compartment panelling, below.
Remove alternator.
Drain air conditioning system.
Pull plug from electromagnetic clutch.
Loosen screw (3).
Loosen tensioning screw (7) and remove V-belt

(2).
cardiagn.com
9 Unscrew screws (6) on holder (8).
10 Unscrew screws (5) on holder of pipe line.
83.11-52212
EXIT
11 Unscrew screw (arrow) left and right on torsion

bar and pull torsion bar in downward direction.
12 Unscrew screw (15) from pipeline.
13 Unscrew screws (9 to 11 and 14) on carrier for

14 Remove refrigerant compressor (11) with
cardiagn.com
carrier (12) in downward direction.
103 - 2OQ5012
15 Unscrew nuts (17) and screw (3) on holder (8).
183 - 25440
16 Unscrew screws (13 and 16) and remove refri-

gerant compressor from carrier (12).
17 If the refrigerant compressor is renewed, refer

to section “Testing oi I level in refrigerant compres-
sor” (83-520).
13
18 When working orI electromagnetic clutch or on

shaft seal, close connections on refrigerant compres-
sor with pressure-testing plate.
25439
83.1142213
EXIT
Installation
19 Check O-rings on refrigerant compressor and

renew, if required.
20 Screw carrier (12) to refrigerant compressor by

means of screws (13 and 16).
21 Mount holder (8) on carrier with screw (3) and

nuts (17).
cardiagn.com
183 - 25440
22 Install refrigerant compressor with carrier from

below and mount to engine block by means of
screws (9 to 11 and 14).
23 Mount pipe line with screw (15).
1 8 3 - 2095812
24 Mount torsion bar, top, with screws (arrow).
83.11-52214
EXIT
25 Mount holder (8) with screws (6).
26 Mount V-belt (2) and tension with tensioning

screw (4).
27 Tighten screw (3).
cardiagn.com
28 Screw screws (5) to holder for pipe line.
29 Insert plug on electromagnetic clutch.
30 Install alternator.
31 Renew receiver-drier (83-530).
32 Connect battery.
33 Evacuate air conditioning system and refill.
34 Install engine compartment panelling, below.
Attention!
When filling oil into refrigerant compressor, handle
like a new refrigerant compressor, i.e. during initial
operation of engine, run for min. 4 minutes at idle
speed only.
35 Check air conditioning system for function and

leaks (83-036).
83.11-52215
EXIT
B. Nippondenso refrigerant compressor engine 601
Oil capacity in new refrigerant compressor in cc 120
M8x40
Screw, carrier to crankcase M 8 x 6. 23 2 2.3
Screw, compressor to carrier M 8 x 95 23 * 2.3
Suction or pressure hoses on refrigerant compressor 23 t 2.3
cardiagn.com
Spare part
Closing plate for refrigerant compressor 601 131 00 21
Conventional tools
Open-end wrench
Socket 10 mm, 13 mm (3/8” square)
Note
Bores and screws with metric threads, hose connections as before with inch threads.
If the refrigerant compressor must be renewed or reconditioned, fill in oil according to job No. 83-520.
If the refrigerant compressor is renewed owing to inside damage (e.g. blocking or damage on valve plates), addi-
tionally renew pipe line on compressor, expansion valve and receiver-drier. In addition, check function and
direction of rotation of auxiliary fan (clockwise) by means of 20 bar and 100 ‘C switch.
83.11-52216
EXIT
Removal
Mask both front fenders.
Remove air cleaner and air scoop.
4 Slacken V-belt and remove. For this purpose,

unscrew flange nut (90). Insert a mandrel into
spring tensioning lever (91) and push against force
of draw spring (92), while pulling back screw (93).
Load spring tensioning lever and remove V-belt.
cardiagn.com
5 Pull plug from refrigerant compressor.
6 Disconnect hose line (94) from refrigerant com-

pressor, unscrewing screw (95) for this purpose.
Then mount connections to refrigerant compressor
with closing plate (refer to special tools) and avail-
able screw (95).
7 Unscrew four screws (arrow) on refrigerant

compressor and remove refrigerant compressor
in upward direction.
Installation
Attention!
New refrigerant compressors are filled with
refrigerant. Slowly drain refrigerant at service
valve prior to installing new refrigerant com-
pressor.
8 Correct oil level (83-520).

EXIT
9 If refrigerant compressor is not renewed,

check O-rings at connections and renew, if
required.
10 Screw refrigerant compressor to carrier

(arrows).
11 Connect hose line (94) to refrigerant com-

pressor.
12 Insert plug on refrigera nt compressor.
13 Mount V-belt. Push spt -ing tensioning lever

(91) back with a mandrel, s‘lip screw (93) through
spring tensioning lever and screw on nut (90).
cardiagn.com
14 Install air scoop and air cleaner.
16 Evacuate air conditioning system and refill.
17 Check air conditioning system for function

and leaks (83-036).
EXIT
83-524 Reconditioning refrigerant compressor
Data
Designation Delco radial 4-cylinder
Max. speed rpm (l/min) 7000
Power input at max. compressor speed kW (HP) approx. 6.3 (8.5)
Cylinder capacity 164 cc
cardiagn.com
Oil capacity, fresh oil, in refrigerant compressor 170 cc
Screws (8) pulley clutch body 11
Screw M 10 x 30 pipe line to refrigerant compressor 50 + 3
Nut (1) to drive shaft 13
Screws (5 and 6) M 12 refrigerant compressor to carrier 60+10
Hose line (14) from evaporator to pipe line 7/8” 29-37
Hose line (15) from pipe line to condenser 3/4” 24-28
Special tools
116589044000
\ J
83.11-524/l
EXIT
000589883300 115589023502
1 00058921 6100
\
000589656300
/
109589002500
Conventional tools
Socket 14 mm, 3/W’ square e.g. Hazet, D-5630 Remscheid
e.g. Hazet, D-5630 Remscheid

Slip gauge (set)
Order No. 2147

Langbeck pliers 72 J (internal lock)
Order No. 1846a-1
cardiagn.com
Pliers for locking ring A 2 (outside lock)
Order No. 1846 c-2
Double open-end wrench l/2” x 9/l 6”, 5/8” x 3/4”, 7/8” x 15/l 6”, 1” x 1 l/8”
Self-made tool
Remover for O-ring
a) Renewing shaft seal of refrigerant compressor
Removal
1 Drain air conditioning system.
3 Remove spring plate (83-526).
4 Remove locking ring (10) for shaft seal.
83.11-52412
EXIT
5 Remove slip ring (12) by means of remover and

installer.
183-15023
6 Remove shaft seal (13) by means of remover and

installer. Keep pushing against tool, turn tool to the
right to contact lug of shaft seal with detents on
tool. Remove complete shaft seal from shaft by
straight pulling.
cardiagn.com
183-15024
7 Remove O-ring (11) from inside bore in housing

cover. A wire, bent to a hook, can be used for this
purpose.
14-
1 Nut on drive shaft 9 Magnetic coil

2 Spring plate 10 Locking ring
3 Coupling member 11 O-ring
5 Locking ring 12 Slip ring
6 Bearing for coupling member 13 Shaft seal
7 Pulley 14 Drive shaft
8 Screw with lock 20 Housing cover
6 7
1 1833-8144
9
83.1 l-52413
EXIT
Installation
8 Check whether parts of the old shaft seal are still

in bore of housing cover. Clean bore prior to insert-
ing new seal.
9 Dip new sealing parts into clean cold-f lowing oil.

Insert O-ring (11) into groove of housing cover.
10 Insert shaft seal (13) into tool and slip on shaft.

Keep turning tool to the right until shaft seal engages
in shaft. Only then turn the tool to the left for dis-
engagement on lugs of shaft seal and remove.
11 Introduce slip ring (12) into bore by means of

tool until ring touches shaft seal. Make sure that the
O-ring (11) is not pushed out of groove.
Attention!
Sealing surface of slip ring (12) must be protected
cardiagn.com
against any kind of damage, e.g. scratches.
12 Introduce locking ring (10) with flat side facing

downwards until the locking ring rests on slip ring.
Then push against locking ring with lock pliers or a
screwdriver until locking ring snaps into groove.
13 Install spring plate (83-526).
b) Checki w refrigerant compressor for external

leaks
Note: When working on shaft seal it wi II be of

advantage to drain all the cold-flowing oil from
refrigerant compressor. Determine drained quantity
of cold-flowing oil and fill same quantity of fresh
oil into refrigerant compressor. For details refer to
Checking oil level in refrigerant compressor
(83-520).
83.11-52414
EXIT
14 Check installed sealing rings (2) on refrigerant

compressor (1) for condition, renew if required
and provide with cold-f lowing oil.
1 Refrigerant compressor
2 Sealing ring
3 Suction connection
4 Pressure connection
15 Screw pressure-testing plate (3) with available

hex. screw to refrigerant compressor (1).
16 Connect inner connection of pressure-testing

plate with hose line (4) of service unit.
cardiagn.com
pressor. A bottle or filling cylinder pressure of
above 4 bar gauge pressure is required.

sor, rotate compressor shaft in direction of rota-
tion manually several times.
19 Check refrigerant compressor with leak tester

for leaks.
20 Close valve on service unit or on filling cylinder

again and remove hose line from pressure-testing
plate.
21 Remove pressure-testing plate again, but only

directly before attachment of pipe line.
22 For details concerning oil filling capacity of

refrigerant compressor refer to “Checking oil
level in refrigerant compressor” (83-520).
24 Install refrigerant compressor (refer to

83-522).
25 Evacuate air conditioning system and fill

again, also check for function (83-036).
83.1 l-524/5
EXIT
B. Nippondenso refrigerant compressor engine 601
Data, test values
Designation 10 P 15 G, 5 double piston swash plate compressor
Displacement cc 153
Nominal output kcal/h 5200 at 14.7 bar
Power input kW 3.1
Max. rpm 1 /min 8000
Nominal rpm l/min 7000

~~
Oil filling capacity (fresh oil) cc 120
cardiagn.com
Screw carrier to cylinder head M 10 x 30 30 * 3.0
Screw compressor to holder M 8 x 90 20 * 2.5
Nut M 8 to compressor shaft 16 * 1.0

-
Special tools
126 589 01 40 00
1126 589 06 33 00 126 589 07 33 00
126 589 01 59 00 126 589 02 59 00
Spare part
Closing plate for refrigerant compressor 601 131 00 21
Conventional tools
Pliers for locking ring J 3 (inner) e.g. Hazet, D-5630 Remscheid
83.11-524/6
EXIT
Slip gauge (set) e.g. Hazet, D-5630 Remscheid
Socket 12 mm, 13 mm (3/8” square) e.g. Hazet, D-5630 Remscheid
Double open-end wrench 12 x 14,17 x 19,24 x 26 e.g. Hazet, D-5630 Remscheid
Note
Renewing shaft seal of refrigerant compressor
Removal
cardiagn.com
3 Remove spring plate (83-526).
4 Push out dust seal (arrow) with a screwdriver.
718
5 Plug key puller on compressor shaft and rotate

by half a turn.
Attention!
Pay attention to inclination of refrigerant compres-
sor to prevent loss of oil.
6 Pull out key and remove.
7 Remove locking ring by means of circlip pliers

(J 3).
8 Apply cold-flowing oil to inner bore of refri-

gerant compressor.
8X11 -52417
EXIT
9 Insert sealing plate-assembly tool against shaft

and push holding ring (arrow) down up to mark.
Pull out sealing plate and remove from tool.
cardiagn.com
10 Introduce assembly tool for shaft seal against
shaft, push in, turn to the right and remove shaft
seal.
Installation
Attention!
The crankshaft seal on coupling side of refrigerant
compressor is available as a complete unit only and
must also be installed as such. Never install new and
used parts together.
Newly installed shaft sealing sets need not be
removed again immediately owing to a slight leak.
The carbon ring is lapped together with the inside of
the sealing plate. Its fit is getting better during
running-in time of shaft seal.
83.11-52418
EXIT
11 Fasten shaft seal on assembly tool and moisten

12 Insert shaft seal and loosen special tool by

turning to the left.
1 Dust seal
2 Locking ring
3 Sealing plate
4 O-ring
5 Shaft seal
6 Head part, front
13 Fasten sealing plate to assembly tool (Fig.) and

lubricate with cold-flowing oil.
14 Insert sealing plate and mount locking ring.
Attention!
cardiagn.com
Tapered surface of locking rings must be front end.
15 Mount key and push in (arrows).
16 Push in dust seal (arrows).
17 Install spring plate (83-526).
i718
83.11-52419
EXIT

pressor at service valve (arrow). A bottle or filling
cylinder pressure of above 4 bar gauge pressure is
required.

sor rotate compressor shaft several times manually
in direction of rotation.
20 Test refrigerant compressor with leak tester for

leaks.
21 Close valve on service unit or on filling cylinder

again and remove hose line on service valve. 183-26800/1
24 Correct oil quantity (83-520), while adding an

additional 10 cc of fresh oil into compressor.
cardiagn.com
25 Leak test and evacuate.
26 Evacuate air conditioning system and refill,

also check for function (83-036).
83.11-524/10
EXIT
83-526 Removal and installation of electromagnetic clutch
Data, test values
Electromagnetic clutch 12 V Delco 4.9 inch
cold 3.9
Power input in amps at 13.5 V
warm 3.4
Screws (8) pulley-clutch body 11
Screw M 10 x 30 pipe line on refrigerant compressor 50 * 3

--~
cardiagn.com
Nut (1) on drive shaft 13
Screws (5 and 6) M 12 refrigerant compressor on carrier 60+10
Hose line (14) from evaporator to pipe line 7/8” 29-37
Hose line (15) from pipe line to condenser 7/8” 29-37
Special tools
1165691431CNJ
116589056300 115589023502
83.11-526/l
EXIT
Conventional tools
Socket 14 mm, 3/8” square e.g. Hazet, D-5630 Remscheid

Slip gauge (set)
Order No. 2147

Langbeck pliers 72 A (inner lock)
Order No. 1846 a-l

Pliers for locking ring J 2 (outer lock)
Order No. 1846 c-2
Self -made tool
Remover for O-ring
Note
cardiagn.com
Removal and installation of spring plate, of coupling member with pulley and magnetic coil, as well as of shaft
seal can be performed only with refrigerant compressor removed.
The coupling member with bearing, the pulley and the magnetic coil are together one assembly group. If a part
of this assembly group must be renewed, remove entire group (refer to 83-526, section b).
a) Spring plate
Removal
3 Close openings by means of pressure-testing

plate. Then fasten holding device on refrigerant
compressor and clamp into vise.
83.11-526/2
EXIT
4 Loosen refrigerant compressor from holding

device and fasten again with drive shaft in upward
direction.
5 Prevent turning of spring plate (2) with holding

wrench, unscrew nut from shaft, using socket
14 mm for this purpose.
cardiagn.com
6 Screw remover into hub, hold tool with wrench
and tighten central screw.
7 Remove key from shaft.
Installation
8 Clean friction surface of spring plate and of

coupling member.
9 Insert key (4) into groove of hub with approx.

5 mm projection.
83.11-52613
EXIT
10 Place spring plate on shaft in such a manner

that key and key groove are in alignment.
11 Place spacer on spring plate. Insert installer

through spacer and screw installation tool on shaft
end.
12 Hold hex. head of tool in place and screw in

center screw, until a clearance of approx. 0.5-l mm
is obtained between the friction surfaces of the
spring plate and the coupling member.
13 Remove installer and spacer.
14 Screw new nut on shaft (smaller diameter of

nut in direction of shaft shoulder) and tighten.
Check clearance once again.
cardiagn.com
1 Nut on drive shaft

2 Spring plate
3 Coupling member
5 Locking ring
6 Bearing for coupling member
7 Pulley
8 Screw with lock
9 Magnetic coil
10 Locking ring
11 O-ring
12 Slip ring
13 Shaft seal
14 Drive shaft
20 Housing cover
b) Removal and installation of coupling member

with pulley, magnetic coil and bearing
Removal
17 Remove spring plate (83-526, section a, item 1

to 7).
18 Remove lock (5). Mark location of magnetic

coil terminals.
83.1 l-52614
EXIT
19 Insert guide piece over shaft on head part of

20 Pull off assembly group with puller.
21 Bend away locks on hex. head screws and

remove the 6 screws (8) with locks.
cardiagn.com
22 Remove pulley from coupling member and
take magnetic coil out of pulley.
Note: If bearing (6) of magnetic body (3) must be

renewed, perform items 22 to 24.
Removal of bearing
23 Place coupling member (3) on wooden support

and press out bearing (6). Removal of bearing does
not require elimination of notches.
83.11-626/5
EXIT
Installation of bearing
24 Align new bearing (6) accurately on bore and

then press in.
15010
25 Punch-mark bearing at three points 120’ away

from each other as a safety measure. Do not punch
too deeply, since this may distort outer race of
bearing. Do not use old notches again!
cardiagn.com
Installation
26 Insert magnetic coil (9) into pulley (7).
J83-15011
27 Slip coupling member (3) into pulley (7) and

screw on provisionally with new locks and screws
(8). Provide threads of screws with Loctite.
183 -15012
83.11-526/6
EXIT
28 Place complete assembly group on front housing

cover. Before pressing on completely, make sure
that the terminals of the magnetic coil are in correct
position in relation to refrigerant compressor and
that the three projections on back of magnetic coil
are in alignment with the three depressions in
housing cover.
983-15021
29 Insert locking ring (5) for assembly group.
30 Clean friction surface of spring plate and of

coupling member.
cardiagn.com
31 Rotate pulley with coupling member to check
pulley for alignment. Slightly readjust pulley, if
required.
32 Tighten screws (8) of pulley - coupling

member. Secure screw heads in the same manner as
the screws were secured prior to removal.
183 -15012
83.11-526/7
EXIT
B. Nippondenso refrigerant compressor (engine 601)
Data, test values
Designation Electromagnetic clutch 12 V
cold 4.2
Power input In amps at 13.5 V
warm 3.75
Screw carrier to crankcase M 8 x 60 and M 8 x 40 23 ? 2.3
Screw compressor to carrier M 8 x 95 23 * 2.3
Nut M 8 to compressor shaft 16 4 1.0
Special tools
cardiagn.com
126589063300 126 5890643 00
Conventional tools
Pliers for locking ring A 2 (outer) e.g. Hazet, D-5630 Remscheid
Slip gauge (set) e.g. Hazet, D-5630 Remscheid
Socket 12 mm, 13 mm (3/8” square) e.g. Hazet, D-5630 Remscheid
Double open-end wrench 12 x 14,17 x 19,24 x 26 e.g. Hazet, D-5630 Remscheid
Self -made tool
Bearing mandrel (rotating part),

not required for assembly with
hand lever press
Note
83.11-62618
EXIT
a) Spring plate
Removal
1 Remove fan and fan cover.
2 Slacken V-belt and remove, as follows:

Unscrew collar nut (90). Place a mandrel into spring
tensioning lever (91) and pull back against force of
draw spring (92).
Release spring tensioning lever and remove V-belt.
3 Position holding rod for spring plate and unscrew

nut (arrow).
cardiagn.com
4 Screw puller (arrow) into spring plate and pull
off spring plate.
Installation
5 Plug spring plate on compressor shaft and tighten

with nut.
6 Check gap dimension with valve gauge and cor-

rect with spacing washer, if required.
7 Install V-belt.
8 Install fan cover and fan.

(83-036).
83.1 l-52619
EXIT
b) V-belt pulley
Removal
1 Remove spring plate (refer to section a).
2 Remove locking ring in front of V-belt pulley

(arrow) and knock off V-belt pulley with plastic
hammer.
3 Renew antifriction bearing according to con-

dition. Remove locking ring from antifriction
bearing (arrow).
cardiagn.com
4 Force out antifriction bearing with special tools
(arrows).
5 Force in new antifriction bearing with special

tools.
Installation
Attention!
If the same pulley is installed again, clean friction
surface of pulley. In the event of damage on friction
surface (e.g. caused by overheating) renew pulley
together with spring plate.
83.11-526/10
............................................. ....... ......................... EXIT
6 Mount V-belt pulley and install locking ring.
7 Mount spacing washer and spring plate on com-

pressor shaft. Tighten nut (arrow).
8 Check gap dimension with valve gauge or correct

with spacing washer, if required.

(83-036).
c) Magnetic coil
Data
Nominal value approx. warm 3.75 A
cardiagn.com
cold 4.2 A
For testing magnetic coil, refer to 83-040.
Removal
1 Remove spring plate and V-belt pulley (refer to

section a and b).
2 Pull plug from refrigerant compressor.
3 Unscrew both screws (arrow) from plug housing,

open plug housing and remove line (blue).
4 Disconnect grounding cable of magnetic coil

from refrigerant compressor.
5 Remove locking ring of magnetic coil and

remove coi I.
EXIT
Installation
Attention!
Tapered surface of locking rings must be front end.
6 Mount magnetic coil (pay attention to fitted pin)

and install locking ring (arrow).
7 Install V-belt pulley (refer to section b).
8 Slip spacing washer on compressor shaft and
cardiagn.com
mount spring plate (refer to section a).
9 Test air conditioning system for function

(83-040).
83.11-526112
EXIT
83-528 Removal and installation of condenser
Data
Version Aluminum pipe and aluminum fins
Hose line (101) to condenser 29-37

Hose line (102) to condenser 15-18
Conventional tool
Inch wrench
cardiagn.com
Note
If the condenser is not reinstalled immediately,

blow through condenser with refrigerant R 12 or
nitrogen. Then close connections with plug. When
renewing condenser, fill 20 cc of new compressor
oil into condenser.
Removal
2 On model 201.024, drain coolant and remove

radiator.
3 On model 201.024, remove clamp (98) from

hose line (101).
83.11-528/l
EXIT
4 Unscrew hose lines (101 and 102) from conden-

ser (63).
5 On model 201 .122, remove clamps (1111, lift

radiator out of lower support and put radiator
aside in direction of engine.
6 Remove cable strap (arrow).
7 Unclip both clamps (99) on radiator support-

ing frame and lift out condenser (63) in upward
direction.
Condenser model 201.024
cardiagn.com
Condenser model 201.122
Installation
8 Insert condenser (63) into grommets on front

cross member. Continue installation in vice-versa
sequence, while moistening threads for hose lines
(101 and 102) with cold-flowing oil.
10 Evacuate air conditioning system and refill,

check for leaks and function (83-036).
83.1 l-528/2
EXIT
83-530 Removal and installation of receiver-drier
Data
Version Steel housing with sight-glass
Lets refrigerant blow off at 40 * 5 bar.

Pressure relief valve (a) Closes at max. 5 bar below opening
pressure
-
Pressure switch (19) in receiver-drier for auxiliary Cutout pressure: 15 * 0.5 bar
fan and electromagnetic clutch of engine fan Cut-in pressure: 20 f. 0.5 bar
Cutout pressure: 2 + 0.2 bar gauge pressure

Pressure switch (22) in receiver-drier
Cut-in pressure: max. 0.6 bar above
for refrigerant compressor
cutout pressure
- ~--
cardiagn.com
Tightening torque Nm
Hose lines to receiver-drier 15-18
Note
In the event of trouble on air conditioning system

as the result of leaks, contamination or icing-up,
when exchanging or reconditioning refrigerant com-
pressor, as well as on air conditioning systems
which are without refrigerant, a new receiver-drier
must be generally installed. In accordance with
extent of contamination, blow out air conditioning
system prior to installing new receiver-drier with
refrigerant R 12 or nitrogen.
Removal
2 Pull plug from pressure switches (22 and 19).
3 Unscrew both pressure switches from receiver-

drier.
83.11-530/l
EXIT
4 Unscrew hose lines (102 and 103 from receiver-

drier. Close connections blind.
5 Unscrew two screws on receiver-drier and lift out

receiver-drier.
Installation
6 Prior to installation of new receiver-drier, fill

10 cc of fresh compressor oil into lateral connection
(83-520).
cardiagn.com
7 For installation proceed vice versa, while moisten-
ing threads for hose lines (102 and 103) with cold-
flowing oil.
8 Evacuate air conditioning system and fill up

again, check for leaks and function (83-036).
83.11-530/2
EXIT
83-53 1 Checking or removing and installing pressure switch for refrigerant compressor in
receiverdrier
Data
Cutout pressure: 2 + 0.2 bar gauge pressure

Pressure switch (22) in receiver-drier Cut-in pressure: max. 0.6 bar above
cutout pressure
Pressure switch 20 + 4
Note
cardiagn.com
To remove pressure switch (22), drain refrigerant of
air conditioning system.
Testing pressure switch (22)
Test cut-in pressure (air conditioning system filled

with refrigerant).
1 Run engine and switch on air conditioning

system.
2 If the electromagnetic clutch of refrigerant com-

pressor is not attracting, test the two flat plugs on
pressure switch for voltage (do not pull plug from
pressure switch [ 221).
3 If the two plugs of pressure switch are con-

nected to voltage and the electromagnetic clutch
of refrigerant compressor is not attracting, there is
a fault on model 201.024 on coil of electromag-
netic clutch or on electric line between pressure
switch and magnetic coil. On model 201 .122 and
on model 201.024 starting model year 1985 there
may also be a fault on compressor cutout (for
checking, refer to 83-040).
4 If only flat plug of pressure switch is connected

to voltage, there is not enough refrigerant in air
conditioning system (refer to sight-glass, arrow) or
the pressure switch (22) is defective.
83.11-531/l
EXIT
5 To check refrigerant level, pull the two electric

plugs from pressure switch and connect to each
other (bypass). Run air conditioning system for
approx. 2-3 minutes at 1000 rpm, then shortly
after adding electromagnetic clutch, check whether
refrigerant flows free of bubbles past sight-glass of
receiver-drier.
6 The pressure switch is defective while quantity

of refrigerant is adequate (high pressure > 3 bar).
7 Switch off ignition.
Testing cutout pressure
8 Connect pressure gauge (service unit or pertinent

tool) to service valve (pressure end).
9 Pull both electric plugs from pressure switch and
cardiagn.com
connect ohmmeter to pressure switch.
10 Drain refrigerant, at approx. 2 2 0.2 bar gauge

pressure the cutout point of pressure switch must
be indicated by ohm meter (ohm meter to infinite).
Removing pressure switch
12 Pull off electric lines and unscrew pressure

switch (22) from receiver-drier.
13 Close connection on receiver-drier with plug.
Installing pressure switch
14 Moisten O-ring and threads of pressure switch

15 Screw pressure switch (22) into receiver-drier

and plug on electric lines.
16 Evacuate air conditioning system, fill again and

check for function and leaks (83-036).
83.11-53112
EXIT
83-532 Testing or removing and installing pressure switch for auxiliary fan in
receiver-drier
Data
Cutout pressure: 15*05bar

Pressure switch (19) in receiver-drier
Cut-in pressure: 20 * 0.5 bar
-
-
Pressure switch (19) 10*2
Note
To remove pressure switch (191, drain refrigerant of
cardiagn.com
air conditioning system.
Testing pressure switch (19)
Switch on ignition and connect the two plugs of

pressure switch (19) with each other (bypass).
If the auxiliary fan prior to condenser is not
switching on, the fault is outside pressure switch
(19) - refer t o circuit diagram 83-028.
Testing cut-in pressure (air conditioning system

filled with refrigerant).
1 Unscrew closing cap (1) from pressure line. Then

connect hose line of high-pressure gauge to service
valve. Make sure that the connecting nipple of hose
line has a pressure pin in center.

Engine 102 up to model year 84
83.1 l-53211
EXIT

Engine 601 and engine 102
starting model year 85
2 Englage temperature wheel (a) at “MI N”.
3 Swi tch on mode selection of pushbutton

switch (b) and mode selection @ of switch for
air con ditioning (c).
cardiagn.com
4 Set blower switch (15) to 4th blower stage.
5 Let engine run at idle until pressure of refri-

gerant has attained 18 + 0.5 bar (corresponds with
a pressure on pressure switch (19) of 20 k 0.5 bar),
let engine speed increase slowly, if required. If the
auxiliary fan is not switching on, the pressure
switch (19) is defective.
Testing cutout pressure
6 Run engine at idle speed until pressure of refri-

gerant has attained 12 2 0.5 bar (corresponds with
a pressure on pressure switch (19) of 15 2 0.5 bar),
pull a plug from pressure switch (221, if required.
If the auxiliary fan is not switching off, the pres-
sure switch (19) is defective.
83.1 l-53212
.............................................. ............................... ................................ ...... EXIT
Removing pressure switch (19)
6 Pull off electric lines and unscrew pressure

switch (19) from receiver-drier.
7 Close connection on receiver-drier with plug.
installing pressure switch
8 Moisten O-ring and threads of pressure switch

cardiagn.com
9 Screw pressure switch (19) into receiver-drier
and plug on electric lines.
10 Evacuate air conditioning system, fill again and

check for function (83-036).
EXIT
83-534 Removal and installation of expansion valve
Data
1
Version Thermostatic valve with outer pressure compensation
Screws M 5 expansion valve to evaporator 6-10
Screw M 6 hose lines to expansion valve 7-13
Conventional tools
Hex. socket wrench 3 and 4 mm
cardiagn.com
Note
--- b a
If expansion valve is heavily contaminated, renew
receiver-drier and expansion valve (83-530 and
83-534).
Injection valve (diagram)
a To evaporator
b From evaporator
c From receiver-drier
d
d To compressor
35 Expansion valve c
Removal
2 Remove cover on air inlet (83-140).
83.11-53411
EXIT
3 Unscrew screw (arrow) and pull lines out of

expansion valve.
4 Unscrew both screws (arrows) and remove

expansion valve (82).
5 Close connections with plugs.
cardiagn.com
Installation
6 Install in vice-versa sequence, while testing O-rings

on evaporator pipes, as well as on pipe lines, and
moisten with cold-flowing oil.
8 Evacuate air conditioning system, fill again, and

check for function and leaks (83-036).
83.1 l-534/2
EXIT
83-538 Removal and installation of evaporator
Data
Version Pipes and fins made of aluminum
Face/depth 6.0 dm2 /96 mm
Note
If expansion valve shows heavy contamination,

renew receiver-drier and expansion valve (83-530
and 534). When renewing evaporator, add 40 cc of
cardiagn.com
fresh compressor oil into evaporator.
Removal
2 Remove cover on air intake (83-l 40).
3 Loosen bulkhead (62), while pulling screws

(arrow) at left and right on bulkhead forward up
to engine for this purpose.
4 Remove expansion valve (82) (83-534).
83.11-53811
EXIT
5 Remove blower motor (8) (83-120).
6 Unscrew screws (arrow) and lift out lower part

of housing (106).
cardiagn.com
7 Pull temperature sensor (3) out of guide tube.
8 Unclip clamps (arrow) laterally left and right

from frame (107) and remove frame.
9 Lift evaporator (108) with pan (109) and con-

densate water drain hoses (110 and 110a) out of
evaporator housing.
. . . . . . . . . . . . . . . . . . . _. . . . .__.. . . . . . . . . . .
EXIT
Installation
10 Clean pan (109) inside while checking whether

condensate water drain hoses (110 and 110a) have
perfect passage.
11 insert evaporator (108) into pan (109).
183-25201/l
12 Insert evaporator with pan into evaporator

housing. Then mount rubber grommets (arrow) of
condensate water drain hoses (110 and 110a).
cardiagn.com
13 Flange frame (107) to evaporator housing and
fasten with clips (arrow).
14 Insert temperature sensor (3) into guide tube

up to stop.
15 Mount lower part of housing (106) by means

of screws (arrow).
16 Install blower motor (83-l 20).
83.1 I -53813
EXIT
17 Remove closing cap (108) of new evaporator

from evaporator pipes unscrewing both screws
(arrow) for this purpose.
18 Install expansion valve (83-543).
19 Mount bulkhead (62) and fasten with screws

(arrow).
20 Install cover at air inlet (83-140).
cardiagn.com
22 Evacuate air conditioning system, fill again
and check for function and leaks (83-036).
EXIT
83-546 Removal and installation of auxiliary fan
Data
Power input at 13 V * 0.2 V 17.5 A
Fan speed at 13 V + 0.2 V 2300 rpm
Removal
1 Separate 2-pin connector (arrow).
cardiagn.com
2 Remove clamp (98) on model 201.024.
3 Disconnect both horns and remove strut (104).
4 Loosen radiator and condenser, removing clips

(99 and 111) for this purpose. Pull out radiator and
condenser at lower holder and put aside as far as
possible in direction of engine.
Attention!
Hoses of radiator and condenser remain connected.
83.11-546/l
EXIT
6 Loosen both cable straps (arrow) from con-

denser.
7 Unscrew screw (112) and remove holder (113).
8 Remove auxiliary fan to the right and then in

forward direction.
9 Unclip protective grille (114) from auxiliary

fan and remove lower holder.
Installation
10 Pull rubber mount from lower holder of

auxiliary fan and wind approx. 5 layers of insu-
lating tape around bolt (arrow). Then slip rubber
cardiagn.com
mount on holder.
Note: The insulating tape makes sure that the

rubber mount will not fall off when mounting
auxiliary fan.
11 Insert auxiliary fan and slip rubber mount

into holder on cross member (arrow).
13 Check auxiliary fan for function, switching

on ignition for this purpose and bridging both con-
nections of pressure switch (191, but do not
separate connections of pressure switch and harness.
14 Check direction of rotation of auxiliary fan.

Fan rotates clockwise. If direction of rotation is
wrong, interchange sockets in 2-pin connector
(arrow).

Tempmatic, Climate Control

Uploaded by

Copyright:

Available Formats

Tempmatic, Climate Control

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tempmatic, Climate Control

Uploaded by

Copyright:

Available Formats

EXIT

Tempmatic, climate control 83

83 Tempmatic climate control

83-020 Operation and components of Tempmatic climate control

Model 201 has a blend air heating system in combi-

For adaptation to weather conditions, a number of

The blower can be manually adjusted except for

A change from fresh air to recirculated air intake

5 Control unit consists of:

The “cooling” mode requires the pressing of button

The system operates only with the engine running.

B. Function of temperature control

The in-car temperature is controlled by blend air

The blend air flaps (arrow) mix unheated air with

The switchover valve (11.4) supplies the vacuum ele-

If there is a temperature difference between in-car

C. Pushbutton switch unit with electronic temperature control

T_he pushbutton switch unit consists of a temperature

A fuse (g) is located at the rear of the pushbutton

Temperature wheel (a)

The temperature wheel (a) provides stepless interior

Rotation of the temperature wheel changes the

Pushbutton switch (b) with function selection

The blower runs at max. speed in 4th stage at 100 %

The blower switch and the temperature wheel are

The functions of the air conditioning mode switch

Function (pushbutton) selection

The blower runs in the stage to which the blower

The recirculating air mode is also influenced by the

With the heater valve opened, the recirculating

All the air flow is directed to the windshield. Air

Similar to pushbutton selection @ except for air

Similar to pushbutton selection e except for air

Similar to pushbutton selection e except for air

Blower is switched off and the fresh air/recirculating

Recirculating pump is not running. Temperature

Note: If none of the selection pushbuttons is de-

Air conditioning mode switch (c) with pushbutton

Functioning of the air conditioning mode switch

This selection dehumidifies the fresh air, while also

The refrigerant compressor is constantly switched

If necessary, the temperature set on the temperature

Pushbutton selection @ (normal adjustment)

With this mode selection the refrigerant compressor

An additional requirement for engagement of the

Pushbutton selection @ (economy)

In this position, the refrigerant compressor is

Note: If none of the air condit ioning mode buttons

D. Temperature sensor and feedback

In-car temperature sensor

The in-car temperature sensor (1) is located in roof

An aspirator blower (141, which is connected to the

Ambient sensor and temperature sensor for air

The ambient sensor (2) is located on the top of the

Note: These temperature sensors have a negative

Feedback potentiometer for flap position

The feedback potentiometer for flap position (4) is

The quality of the temperature control depends on

Location of feedback potentiometer for flap position (4)