129 Climate Vacum Control

83-520 Testing vacuum system, automatic heater control, automatic air conditioning temperature
control, automatic air conditioning control up to 05/96
Operation no. of the operation texts and work units

or standard texts and flat rates
A. Testing vacuum valve block and vacuum reservoir for leakage

B. Testing switch-over valve strip (Y11) for leakage
C. Testing automatic heater control vacuum system for leakage (up to 10/93)
D. Testing air conditioning - automatic temperature control vacuum system for leakage
E. Testing automatic air conditioning control vacuum system for leakage
Permissible leakage
Permissible leakage per vacuum circuit 30 mbar/min

(without vacuum reservoir) at vacuum of 400 mbar
Permissible leakage of vacuum valve block 50 mbar in 10 min
at vacuum of 300 mbar
Permissible leakage of other individual components 20 mbar/min
at vacuum of 300 mbar
Special tool
Parts for testing
1 dummy plug 000 987 11 45

3 plug connectors 129 805 04 44
1 vacuum line 129 800 09 15
Copyright DaimlerChrysler AG 02.04.2012 CD-Ausgabe G/09/05 . This WIS print-out will not be recorded by Page 1
Modification services.
Vacuum schematic for automatic heater control up to 10/93
Y11 Valve strip, 15-fold (multiplex) 43 Vacuum element for main air flap, left
2 Switchover valve for main air flaps (flap "open")
3 Switchover valve for recirculating air flap 44 Vacuum element for main air flap, right
4 Switchover valve for defroster nozzle flaps (flap "open")
(small stroke) 46 Vacuum element for side nozzle, left
5 Switchover valve for defroster nozzle flaps (flap "open")
(large stroke) 47 Vacuum element for center nozzle (flap "closed")
8 Switchover valve for footwell flaps (large stroke) 48 Vacuum element for side nozzle, right
9 Switchover valve for footwell flaps (small stroke) (flap "open")
10/11 Switchover valve for side nozzle, left hbl light blue
12/13 Switchover valve for side nozzle, right drt dark red
14/15 Switchover valve for center nozzle ge yellow
36 Vacuum valve block mgn medium green
38 Vacuum element for defroster nozzle flaps gr grey
(flaps "open") rt red
39 Vacuum element for footwell flaps ws white
(flaps "closed") sw black
42 Vacuum element for recirculating air flap dgn dark green
("fresh air" flap)
Vacuum schematic, air conditioner - automatic temperature control/automatic air
conditioning control
Y11 Valve strip, 15-fold (multiplex) 42 Vacuum element for recirculating air flap
1 Switchover valve for main air flaps (large stroke) ("fresh air" flap)
2 Switchover valve for main air flaps (small stroke) 43 Vacuum element for main air flap, left
3 Switchover valve for recirculating air flap (flap "open")
4 Switchover valve for defroster nozzle flaps 44 Vacuum element for main air flap, right
(small stroke) (flap "open")
5 Switchover valve for defroster nozzle flaps 45 Vacuum element for tempering flaps
(large stroke) (flap "closed")
6 Switchover valve for air scoop flap 46 Vacuum element for side nozzle, left
7 Switchover valve for tempering flap (flap "open")
8 Switchover valve for footwell flaps (large stroke) 47 Vacuum element for center nozzle (flap "closed")
9 Switchover valve for footwell flaps (small stroke) 48 Vacuum element for side nozzle, right
10/11 Switchover valve for side nozzle, left (flap "open")
12/13 Switchover valve for side nozzle, right hbl light blue
14/15 Switchover valve for center nozzle drt dark red
36 Vacuum valve block ge yellow
38 Vacuum element for defroster nozzle flaps mgn medium green
(flaps "open") gr grey
39 Vacuum element for footwell flaps rt red
(flaps "closed") ws white
41 Vacuum element for air scoop flaps sw black
(flap "closed") dgn dark green
Vacuum schematic, air conditioning - automatic temperature control/automatic air
conditioning control, throttles installed to prevent switchover valve strip from vibrating
up to vehicle ident. end No. 1F 007429.
2 Throttles installed in profile rubber hose (1).

3 Throttles installed in profile rubber hose (2)
A. Testing vacuum valve block and vacuum reservoir for leakage
a "Air conditioner" check valve
b "Transmission" check valve
Connection schematic for vacuum valve block
No. Color from

1 white Central supply pump
2 medium green-yellow Switchover valve strip "0"
3 red-grey Air conditioner supply reservoir
4 black-grey Supply reservoir (selection program 2)
5 black-grey El. switchover valve (selection program 2)
6 violet LWR
7 Connection not used
8 grey Intake manifold
1 Disconnect vacuum valve block (36)
(1 screw).
2 Pry off remaining lines up to grey line (connection

8) with open-end wrench (7 mm).
3 Pull off grey line to valve block (connec-

tion 8) on intake manifold and attach test instrument.
4 Evacuate with test instrument and read off on

pressure gauge. If a pressure increase is indicated on
the pressure gauge, renew vacuum valve block (36)
or grey vacuum line.
Note
If no defects are noted, test check valves a and b in
vacuum valve block (36).
a "Air conditioning" check valve

b "Transmission" check valve
Valve a, connect test instrument to connection 1,

evacuate with test instrument and read off on
pressure gauge. If the pressure gauge indicates an
increase in pressure, renew vacuum valve block (36).
Valve b, connect test instrument to connection 4,

evacuate with test instrument and read off on
increase in pressure, renew vacuum valve block (36).
5 Connect red-grey vacuum line

(connection 3) on vacuum valve block (36) to test
instrument.
increase in pressure, test supply reservoir (1) for
leakage, renew if necessary or renew red-grey
vacuum line (2).
Arrangement, vacuum supply reservoir (1)

below right front fender
7 Connect all vacuum lines except for medium

green-yellow line (connection 2) to vacuum valve
block.
Preparing for tests B through E

-------------------------------
1 Connect medium green-yellow vacuum line
(connection 2) on vacuum valve block (36) to test
instrument.
2 Set temperature selection wheel/wheels to white

field.
Note
The test instrument must remain connected to the
medium green-yellow vacuum line during the entire
test.
If leakage is detected, first eliminate defect (plug)

before performing next test step.
B. Testing switch-over valve strip (Y11) for leakage
1 Switch off ignition.
2 Set center nozzle, left and right side nozzles,

knurled wheels to center position.

increase in pressure, renew switchover valve strip
(Y11) or medium green-yellow vacuum line.
C. Testing automatic heater control vacuum system for leakage up to 10/93
1 Switch on ignition.
2 Set knurled wheels for center and side nozzles to

center position.
1. Test center (47) and side nozzles (46 and 48) for leakage
1 Air quantity switch position
2 Air distribution switch position

increase in pressure, check lines to elements 46, 47
and 48 individually; for this purpose remove
switchover valve strip (repair instructions 83-138).
4 Renew defective element or elements or lines.
2. Testing main air flap elements (43 and 44) for leakage

increase in pressure, check elements 43 and 44
individually; for this purpose remove switchover valve
strip (repair instructions 83-138).
3. Testing recirculating air vacuum element (42) for leakage
3 Recirculating air switch pressed k

increase in pressure, renew vacuum element (42) or
line.
4. Testing vacuum element for footwell flaps (39) with large stroke
for leakage

increase in pressure, renew vacuum element for
footwell flaps (39) with large stroke or line.
5. Testing vacuum element for footwell flaps (39) with small stroke
for leakage

footwell flaps (39) or line.
6. Testing vacuum element for defroster nozzle (38) with large stroke for leakage

defroster nozzle (38) or line.
7. Testing vacuum element for defroster nozzle (38) for leakage

line.
D. Testing air conditioning - automatic temperature control vacuum system for leakage

center position.
Vacuum schematic, air conditioner - automatic temperature control/automatic air

conditioning control
Y11 Valve strip, 15-fold 42 Vacuum element for recirculating air flap
1 Switchover valve for main air flap (large stroke) ("fresh air" flap)
2 Switchover valve for main air flap (small stroke) 43 Vacuum element for main air flap, left
(small stroke) 44 Vacuum element for main air flap, right (flap "open")
4 Switchover valve for defroster nozzle flaps 45 Vacuum element for tempering flaps (flap "closed")
(small stroke) 46 Vacuum element for side nozzle, left (flap "open")
5 Switchover valve for defroster nozzle flaps 47 Vacuum element for center nozzle (flap "closed")
(large stroke) 48 Vacuum element for side nozzle, right
6 Switchover valve for air scoop flap (flap "open")
7 Switchover valve for tempering flap hbl light blue
8 Switchover valve for footwell flaps (large stroke) drt dark red
9 Switchover valve for footwell flaps (small stroke) ge yellow
10/11 Switchover valve for side nozzle, left mgn medium green
12/13 Switchover valve for side nozzle, right gr grey
14/15 Switchover valve for center nozzle rt red
36 Vacuum valve block ws white
38 Vacuum element for defroster nozzle flaps sw black
(flaps "open") dgn dark green
39 Vacuum element for footwell flaps
(flaps "closed")
41 Vacuum element for air scoop flaps (flap "closed")
Vacuum schematic, air conditioning - automatic temperature control/automatic air

conditioning control, throttles installed to prevent switchover valve strip from vibrating
up to vehicle ident. end No. 1F 007429
Vacuum schematic, retrofitted air conditioning system
1 12 profile rubber hose 30 mm
1. Testing center nozzle (47), side nozzles (46, 48), air scoop flap (41) and tempering flap
(45) for leakage

increase in pressure, check lines to vacuum elements
41, 45, 46, 47 and 48 individually; for this purpose
remove switchover valve strip (repair instructions 83-
138).
2. Testing main air flap elements (43 and 44) for leakage

increase in pressure, check lines to elements 43 and
44 individually.
3 Recirculating air switch pressed k

line.
4. Testing vacuum element for footwell flaps (39) with large stroke for leakage

footwell flaps (39) with large stroke or line.
5. Testing vacuum element for footwell flaps (39) with small stroke
for leakage

6. Testing vacuum element for defroster nozzle (38) with large stroke for leakage

defroster nozzle (38) or line.
7. Testing vacuum element for defroster nozzle (38) with small stroke
for leakage

lines.
E. Testing automatic air conditioning control vacuum system for leakage

center position.
Vacuum schematic, automatic climate control
Y11 Valve strip, 15-fold 42 Vacuum element for recirculating air flap
1 Switchover valve for main air flap (large stroke) ("fresh air" flap)
2 Switchover valve for main air flap (small stroke) 43 Vacuum element for main air flap, left
4 Switchover valve for defroster nozzle flaps 44 Vacuum element for main air flap, right
(small stroke) (flap "open")
5 Switchover valve for defroster nozzle flaps 45 Vacuum element for tempering flaps
(large stroke) (flap "closed")
6 Switchover valve for air scoop flap 46 Vacuum element for side nozzle, left
7 Switchover valve for tempering flap (flap "open")
8 Switchover valve for footwell flaps (large stroke) 47 Vacuum element for center nozzle (flap "closed")
9 Switchover valve for footwell flaps (small stroke) 48 Vacuum element for side nozzle, right
10/11 Switchover valve for side nozzle, left (flap "open")
12/13 Switchover valve for side nozzle, right hbl light blue
14/15 Switchover valve for center nozzle drt dark red
36 Vacuum valve block ge yellow
38 Vacuum element for defroster nozzle flaps mgn medium green
(flaps "open") gr grey
39 Vacuum element for footwell flaps rt red
(flaps "closed") ws white
41 Vacuum element for air scoop flaps sw black
(flap "closed") dgn dark green
Vacuum schematic, automatic climate control, throttles introduced to prevent

switchover valve strip vibration
up to vehicle ident. end no. 1F 007429
1. Testing center nozzle (47), side nozzles (46, 48), air scoop flap (41) and tempering flap
(45) for leakage
1 Air quantity button Io pressed
2 Air distribution button M pressed
3 Press Blue button, center nozzle.

pressure gauge. If pressure gauge indicates an
increase in pressure, test vacuum elements 41, 45,
46, 47 and 48 individually; for this purpose remove
switchover valve strip (Y11) (83-138).
5 Renew defective vacuum element or elements or

line or lines.
2. Testing main air flap elements 43 and 44 for leakage
1 Air quantity button m pressed

increase in pressure, test vacuum elements 43 and
44 individually.
1 Air quantity button d o pressed
2 Air distribution button M pressed
3 Recirculating air button k pressed

line.
4. Testing footwell flap vacuum element (39) for leakage
2 Air distribution button N pressed

5. Testing vacuum element for defroster nozzle (38) for leakage
2 Air distribution t pressed
lines.

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83-520 Testing vacuum system, automatic heater control, automatic air conditioning temperature

control, automatic air conditioning control up to 05/96

Operation no. of the operation texts and work units

A. Testing vacuum valve block and vacuum reservoir for leakage

Permissible leakage per vacuum circuit 30 mbar/min

Parts for testing

1 dummy plug 000 987 11 45

2 Throttles installed in profile rubber hose (1).

A. Testing vacuum valve block and vacuum reservoir for leakage

Connection schematic for vacuum valve block

No. Color from

2 Pry off remaining lines up to grey line (connection

3 Pull off grey line to valve block (connec-

4 Evacuate with test instrument and read off on

a "Air conditioning" check valve

Valve a, connect test instrument to connection 1,

Valve b, connect test instrument to connection 4,

5 Connect red-grey vacuum line

Arrangement, vacuum supply reservoir (1)

7 Connect all vacuum lines except for medium

Preparing for tests B through E

2 Set temperature selection wheel/wheels to white

If leakage is detected, first eliminate defect (plug)

B. Testing switch-over valve strip (Y11) for leakage

2 Set center nozzle, left and right side nozzles,

3 Evacuate with test instrument and read off on

C. Testing automatic heater control vacuum system for leakage up to 10/93

2 Set knurled wheels for center and side nozzles to

3 Evacuate with test instrument and read off on

4 Renew defective element or elements or lines.

3 Evacuate with test instrument and read off on

4 Renew defective element or elements or lines.

3. Testing recirculating air vacuum element (42) for leakage

3 Recirculating air switch pressed k

4 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

7. Testing vacuum element for defroster nozzle (38) for leakage

3 Evacuate with test instrument and read off on

2 Set knurled wheels for center and side nozzles to

Vacuum schematic, air conditioner - automatic temperature control/automatic air

Vacuum schematic, air conditioning - automatic temperature control/automatic air

Vacuum schematic, retrofitted air conditioning system

1 12 profile rubber hose 30 mm

1 Air quantity switch position

3 Evacuate with test instrument and read off on

4 Renew defective element or elements or lines.

3 Evacuate with test instrument and read off on

4 Renew defective element or elements or lines.

3. Testing recirculating air vacuum element (42) for leakage

3 Recirculating air switch pressed k

4 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

3 Evacuate with test instrument and read off on

E. Testing automatic air conditioning control vacuum system for leakage