Part 1
Installation InstructionsAir Conditioner - R134a 83.1
Type 463
For subsequent installation of an air conditioner the instrument panel and the middle console must be removed completely. For routing refrigerant lines it is not necessary to make any additional holes. The A/C compressor with clutch is attached to the engine, the condenser is attached in front of the radiator, the expansion tank is attached behind the radiator, on the right, and the heater/ventilation unit with radial fan is attached behind the fire wall. If the vehicle is not equipped with a heavy duty alternator, (80A) this must be subsequently installed.
NOTE: In vehicle which are not intended for use in tropical climates it is possible, for cost reasons, to continue with the previously used alternator.
In the 230 GE this is only possible when doing without the fording depth of 600 mm, as here the air intake cover with hose has to be removed for space reasons.
CAUTION: Always observe the general notes when carrying out installation jobs. For details, refer to the introductory Specification for Cross-Country Vehicle Model 463 Group 83 or corresponding car literature, Group 83.
The complete scope of work is divided into the following sections:
A. Installation of A/C compressor
B. Installation of heater/ventilation unit
C. Installation of condenser, expansion tank, refrigerant lines and auxiliary tan
D. Installation of auxiliary cable harness
E. Installation of external series resistor
F. Cable harness
G. Schematic wiring diagram
H. Relay connection diagram
I. Sets of parts
M 102/103
A. Installation of A/C compressor
1 Position fender protection covers left and right.
2 Disconnect battery at negative terminal.
3 Remove radiator cowl.
4 Remove front end cross member with hood catch.
5 Detach air filter.
NOTE: Air cleaner housing is secured with 3 nuts.
6 Detach underride guard.
7 Drain coolant.
NOTE: Open vent on top of radiator.
8 Remove upper and lower coolant hose from radiator.
9 Remove radiator.
10 Remove viscous fan coupling complete.
11 Remove poly-V-belt. For this purpose release bolt (25) and tensioning nut (24) in counterclockwise direction until the poly-V-belt can be removed. (Poly-V-belt is delete part).
12 Remove bracket for vent pipe of alternator.
13 Detach generator.
14 Remove pulley (1).
15 Remove bracket (2). (delete part)
NOTE: On M 103 the fan support (3) as well as the vibration damper (4) must also be removed.
M 103
16 Attach new support (A).
17 Attach bracket plate (B).
NOTE: Insert bolt (7) and tighten.
18 Attach deflection pulley (C).
19 Attach shook absorber for tensioning device with bolt (6).
M 102
M 102/103
A Support for compressor and alternator
B Bracket plate (support to crankcase)
H Bracket, top
I Fan support
3 Screw M8 x 80
4 Screw M8 x 30
8 Screw M8 x 80
9 Screw M8 x 70
12 Clamping sleeve
M 103
20 Attach alternator (E) with new air intake cover and horse.
NOTE:
- In vehicles not planned for use in tropical climates it is possible to install the either to used alternator again, in order to keep down costs.
- On the M 102 this is only possible if the fording depth of 600 mm is sacrificed, as in this case the air intake cover with hose must be removed due to space reasons.
21 Press on plastic cap (D).
22 Insert clamping sleeves (12).
23 Attach pulley for water pump.
24 Attach A/C compressor and lighten.
NOTE: Unscrew cap (14), let pressure escape slowly at the valve and screw cap back on.
25 Insert new poly-V-belt and tension.
Poly-V-belt 2245 mm by M 102
2345 33 by M 103
Ribbed V-belt - Arrangement M 102
1 Crankshaft
2 Tensioning roller
3 Alternator
4 Coolant pump - fan
5 Power steering pump
6 Deflection Roller
7 A/C compressor
Ribbed V-belt - Arrangement M 103
1 Crankshaft
2 Tensioning roller
3 Fan
4 Alternator
5 Deflection Roller
6 Coolant pump
7 Power steering pump
8 A/C compressor
26 Attach fan and tighten to 25 Nm.
27 Install auxiliary fan, receiver, refrigerant lines and condenser, refer to section C.
28 Install auxiliary cable harness, refer to section D.
29 Install air conditioner unit, refer to section B.
30 Install radiator with condenser.
31 Fill with coolant. Check cooling system for leaks.
32 Attach front end cross member with hood catch.
33 Attach radiator cowl.
34 evacuate air conditioning system, charge, check for function and leaks.
1 High pressure side.
2 Intake pressure side.
35 Attach air cleaner.
NOTE: The air cleaner housing is secured with 3 nuts.
36 Attach underride guard.
M 602/603
A. Installation of A/C compressor
1 Position fender protection covers left and right.
2 Disconnect battery at negative terminal.
3 Remove radiator cowl.
4 Remove front end cross member with hood catch.
5 Detach air filter.
NOTE: The air cleaner housing is secured with 3 clamps at the top and bottom respectively.
6 Detach underride guard.
7 Drain coolant.
NOTE: Open vent on top of radiator.
8 Remove upper and lower coolant hose from radiator.
9 Remove radiator.
10 Remove viscous fan coupling complete.
11 Unscrew nut (378), insert a lever into the hole on the spring compression lever (374) and apply a small amount of pressure in counterclockwise direction until the bolt (375) can be pushed back in the direction of the intake pipe.
12 Release tension spring (380) of pressure. For this purpose swing lever in clockwise direction.
13 Remove pulleys (1 and 2).
14 Detach vibration damper (3).
15 Attach new support (A) with clamping sleeves.
16 Attach bracket plate (B).
17 Attach bracket (I) for deflection pulley.
18 Attach vibration damper (3) and tighten to 320 Nm.
19 Attach pulley (1).
20 Attach bracket plate (H).
21 Attach A/C compressor and secure with 3 bolts.
NOTE: The rear upper bolt is simultaneously for securing the group of pipes.
22 Install new pulley (K).
23 Attach deflection pulleys (C and J).
24 Press on plastic cap (D).
25 Attach A/C compressor and tighten.
M 602/603
26 Position new poly-V-belt according to diagram, swing spring compression lever (374) with an assembly lever in counterclockwise direction and secure with bolt (375).
NOTE: Check correct seat of the poly-V-belt on the pulleys.
27 Attach fan and tighten to 25 Nm.
Ribbed V-belt 2120 mm
Ribbed V-belt- Arrangement
1 Crankshaft
2 Tensioning roller
3 Alternator
4 Coolant pump - fan
5 Power steering pump
6 A/C compressor
7 Deflection Roller
28 Install auxiliary fan, receiver, refrigerant lines, coolant outlet socket and condenser, refer to section C.
29 Install auxiliary cable harness, refer 10 section D.
30 Install air conditioner unit, refer to section B.
31 Install radiator with condenser.
32 Fill with coolant. Check cooling system for leaks.
33 Attach front end Cross member with hood catch.
34 Evacuate air conditioning system, charge, check for function and leaks.
35 Attach radiator cowl.
1 High pressure side.
2 Intake pressure side.
36 Attach air Cleaner.
NOTE: The air cleaner housing is secured with 3 clamps at the top and bottom respectively.
37 Attach underride guard.