Part 3
Installation InstructionsAir Conditioner - R134a 83.1
C. Installation of condenser, expansion tank, refrigerant lines and auxiliary fan
NOTE: Protect hose lines and connections of evaporator, condenser and receiver/drier against moisture and dirt. Do not remove safety caps until just before connecting. Coat the threads and sealing surfaces with refrigerant oil each time prior to connecting. Hold the connections in place when tightening.
1 Attach pressure switch (S32/1) to line.
2 Install pressure line in engine compartment on the right and fasten with clamp.
NOTE: In order to fasten the clamp remove the cover in the wheel house and detach the reservoir of the washer unit.
3 Attach pressure switch (S31/2) to receiver.
4 Fasten receiver with bracket and clamp to the provided studs and connect line.
5 Attach auxiliary fan (9) using the rubber buffer (10) and also using a bracket for the mounting at the top.
6 Attach condenser (16) in front of radiator.
NOTE: Use shims (17).
7 Attach radiator with condenser.
8 Install group of pipes (G).
NOTE: The group of pipes with the M 602/603 is held with the rear upper bolt of the A/C compressor (arrow).
M 102/103
M 602/603
9 Attach pressure line of pipe assembly to condenser.
NOTE: Coat all lines prior to assembly with refrigerant oil.
M 102/103
10 Install pressure line (19) from condenser to receiver.
11 Install intake line (6) from fire wall to group of pipes and tighten with bolt (7).
NOTE:
- For routing the intake line (6) release the vent lines (2), heater hose (3) and heat baffle (5) and unclip the electric line to the oxygen sensor.
- On the M 103 the line 3a must also be removed due to space reasons.
M 102/103
12 Screw on intake line (8).
NOTE: Coat thread with refrigerant oil.
M 102/103
13 Install intake line (8) from group of pipes to fire wall (arrow).
NOTE: Coat thread with refrigerant oil.
M 602/603
14 Tighten pressure line on condenser inlet and fasten on the side on the front end.
M 602/603
15 Connect pressure line to condenser outlet.
M 602/603
D. Install auxiliary cable harness
1 Draw auxiliary cable harness through the rubber sleeve in the fire wall and connect ground cable (1).
2 Rout auxiliary cable harness along the main cable harness and fasten with cable clips .
3 Attach ground cable to wheel house.
4 Connect plug connections on the pressure switches.
5 Install relays K9, K7 and K9/1 and connect to cable harness.
6 Install control unit of A/C compressor (N6) using the adapter frame (1) and connect.
7 Connect plug connection for TD signal (X1OO).
NOTE: Remove bridge. Connect aux. cable harness to TD signal.
8 Install fuses F19 and F23 and connect corresponding to wiring diagram section F.
9 Connect terminal block X5/1.
Terminal 30 2, 5 red
Terminal 15 1 black
10 Connect terminal block, terminal 58d (X6/4) and ground (W12).
11 Disconnect blue cable from chamber 1 and connect to the auxiliary cable harness. Insert plug of auxiliary cable harness in chamber no. 1.
NOTE: Chamber number is printed on housing.
12 Route electric cables for components on the left side of the vehicle through the rubber sleeve into the engine compartment and fasten.
13 Unscrew screw plug, screw in temperature switch (S25/1) with sealing ring and tighten to 20 Nm.
14 Connect electrical cable.
M 102
M 103
15 Change coolant outlet socket (L).
16 Remove inlet union on overflow hose and secure hose at fitting with clamp.
17 Screw in temperature switch (S25/1) with sealing ring and tighten to 20 Nm.
M 602/603
18 Connect electrical connections to receiver/drier.
18 Connect 3-pin connection on A/C compressor.
20 Connect plug connection on auxiliary fan.
E. Install external series resistor
1 In vehicles without series resistor, make a hole for the external series resistor in the wall of the circulating air unit, as shown in the diagram.
2 Install external series resistor.
3 Route auxiliary cable harness "external series resistor" (4-core) through the sleeve next to the expansion valve, from the series resistor along the existing cables to the blower switch.
4 Connect plug connector (x6) to the series resistor. Insert the red cable on the blower switch in allocation "3" and the black cable (1 mm2) in allocation "5".
5 Insert the blue cable (bl) of the auxiliary cable harness "vehicle" on the blower switch in allocation "1" and provide intermediate contact (air conditioner plug connection) with the blue cable of the auxiliary cable harness "external series resistor".
6 Insert yellow cable (coming from blower) on the blower switch in allocation "9". Assemble blower switch.
7 Connect black cable(2.5 mm2) from auxiliary cable harness "external series resistor" to the plug connection of the black cable (coming from the blower).
a from series resistor
b Plug connection, air conditioner
c from blower
d Plug connection of blower
1 Connector pin assignment
3 Connector pin assignment
5 Connector pin assignment
9 Connector pin assignment
Vehicles with external series resistor installed as standard
1 Insert yellow cable (coming from blower) on the blower switch into allocation "9".
2 Insert blue cable of the auxiliary cable harness "vehicle" on the blower switch into the allocation "1" and provide intermediate contact (plug connection of air conditioner) with the existing blue cable. Assemble blower switch.
3 Provide plug connection between the two black cables (2.5 mm2).
F. Cable harness, air conditioner 230/300 GE
F. Cable harness, air conditioner 250/300 GD
F. Cable harness for external series resistor
G. Schematic wiring diagram for air conditioner 230/300 GE
G. Schematic wiring diagram, air conditioner 250/300 GD
H. Relay assignment diagram
Accessories plate
1 Front end interval relay
2 Rear end interval relay
3 Kick-down relay
4 A/C compressor control unit M 102/103 M 602/603
5 Central locking control unit
6 Fuel pump relay M 102/103
Control unit ELR M 603
7 Resistance trimming plug CIS-E
8 Terminal block
9 Overvoltage protection
10 Bracket for plug connection TD
11 Fusebox
Device plate, dash panel
1 Relay, headlight washer system
2 Relay, day driving light
3 Relay, window lifter
4 Turn signal relay
5 Relay for heated rear window
6 -
7 Disconnecting relay I, ABS
8 -
9 -
10 Time relay, differential locks
11 Relay, blower, auxiliary heating
12 Relay, circulation pump, auxiliary heating system
13 Relay I, auxiliary fan, air conditioner
14 Relay II, temperature regulator, air conditioner
15 Disconnecting relay II, ABS
16 -
A Relay, lock RA
B Relay, lock, interaxle differential, transfer case
C Relay, lock, FA
D Control unit CIS-E 3
E Control unit, ABS
F Antenna relay
I. Sets of parts
1 Part set for conversion to higher-capacity alternator
comprising:
1 Alternator 008 154 02 D2
1 Air intake cover 103 154 01 04
1 Line 463 540 15 09
1 Bracket 603 154 00 45
1 Clamp 103 995 00 35
1 Air intake hose 103 154 01 86
4 Nut M5 N 000934 005008
4 Washers N 000137 005203
1 Clamp 50/70 N 916026 050000
1 Washer and Screw assembly M6 N 912021 006001
1 Spring wastier N 000137 008107
1 Nut N 000934 008010