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83 Climate Control System

General, Technical Data

• 00-005 - Instructions for Use of Service Manual
• 00-010 - Model and System identification
• 00-015 - Vehicle identification number location  

Section 1 - Heating and Ventilation

• 83-020 - Control of heating system
• 83-100 - Removal and installation of heater box
• 83-110 - Removal and installation of heat exchanger
• 83-114 - Checking vacuum element on heater tap and vacuum switches on control unit for leaks
• 83-120 - Removal and installation of heater blower
• 83-140 - Removal and installation of ornamental grille on air inlet  

Section 1 - Air Conditioning I

• 83-500 - General description and operation of air conditioning system
• 83-502 - Refrigerant circuit
• 83-504 - Safety measures
• 83-506 - Repair instructions for air conditioning system
• 83-508 - Electrical function of air conditioning system (USA)
• 83-510 - Function test of air conditioning system
• 83-512 - Leak test and evacuation
• 83-514 - Refilling or replenishing air conditioning system
• 83-516 - Draining of air conditioning system
• 83-518 - Cleaning of air conditioning system
• 83-520 - Checking oil level in refrigerant compressor
• 83-522 - Removal and installation of refrigerant compressor
• 83-524 - Reconditioning of refrigerant compressor
• 83-525 - Checking Delco-refrigerant compressor for outside leaks
• 83-526 - Removal and installation of electromagnetic clutch
• 83-528 - Removal and installation of condenser
• 83-530 - Removal and installation of receiver dehydrator
• 83-531 - Checking, removing and installing pressure switch in receiver dehydrator
• 83-532 - Checking, removing and installing temperature switch in receiver dehydrator
• 83-534 - Removal and installation of expansion valve
• 83-538 - Removal and installation of evaporator
• 83-542 - Removal, installation & checking of temperature vacuum switch or switch for AC system & ETR switch
• 83-544 - Removal & installation of vacuum element or recirculating air flap, LH steering up to 8/81 & RH steering
• 83-545 - Checking vacuum element & temperature vacuum switch for leaks, LH steering up to 8/81 & RH steering
• 83-546 - Removal and installation of auxiliary fan  

Section 2 - Air Conditioning II

• 83-600.1 - Operation of automatic climate control system and tester
  • Select page... A. General Page 1 B. Control Unit 2 C. In-car and ambient temperature sensor 6 D. Amplifier 7 E. Regulating valve 8 F. Electrical and vacuum system for controlling entire installation 8
• 83-600.2 - Operation of automatic climate control system and tester (continued)
  • Select page... F. Electrical and vacuum system for controlling entire installation (cont'd) Page 8 G. Temperature control 17 H. Tester 21
• 83-601 - Quick test without tester, remedies
• 83-602 - Preparation for test, connection of tester
• 83-603 - Function test of total system and remedies (with tester)
  • Select page... A. Test program and remedies (USA starting model year 1977) Page 1 B. Testing of sensor chain and temperature dial with tester 7
• 83-604 - Vacuum function diagrams
• 83-605 - Electric wiring diagrams (standard)
  • Select page... 1. Blower control (regulating valve in position "P 2") Page 1 2. Blower control, position "park" and "AUTO-LO" (regulating valve in position "P 2") 3 3. Blower control, stage 5 "LO" (regulating valve in position 5) 5 4. Control for switchover valves 28 and 29 (switch 3 for refrigerant compressor at "ON") 6 5. Blower control, stage 4 "LO" (regulating valve in position 4) 7 6. Blower control, stage 3 "HI" (regulating valve in position 5) 8 7. Blower control, stage 2 "BI-LEVEL" (regulating valve in position 5) 9 8. Refrigerant compressor control at "BI-LEVEL" (switch 3 for refrigerant compressor at "ON") 10 9. Blower control, stage 2 "BI-LEVEL" (heat), (regulating valve in position 4) 12 10. Blower control, stage 4 "DEF" (regulating valve in position 4) 13 11. Blower control, stage 1 "LO" (regulating valve in position 1) 14 12. Blower control, stage 2 "LO" (regulating valve in position 2) 15 13. Blower control, stage 3 "LO" (regulating valve in position 3) 16 14. Blower control, stage 1 "HI" and "BI-LEVEL" (regulating valve in position 3 "heating" to position 3 "cooling") 17 15. Regulating valve control (ignition off, regulating valve in position "P 2") 18 16. Blower control, stage 2 "HI" (regulating valve in position 4) 19
• 83-606 - Amplifier and park test
• 83-607 - Output test
• 83-608 - Testing quality of control
• 83-609 - Testing ambient, in-car temperature sensor and potentiometer (temperature dial) without tester
• 83-610 - Testing feedback potentiometer in regulating valve
• 83-611 - Balancing of sensor chain
• 83-612 - Testing temperature switch in regulating valve
• 83-613 - Testing vacuum lines for leaks
• 83-614 - Preparation for vacuum test
• 83-615 - Testing check valve, vacuum reservoir, temperature switch and vent lines of regulating valve
• 83-620 - Testing vacuum circuit I and II
• 83-621 - Testing pushbutton switch
• 83-622 - Testing vacuum circuit III and IV
• 83-624 - Testing vacuum circuit V and VI
• 83-626 - Testing vacuum circuit VII and VIII with vacuum element (43 and 44)
• 83-628 - Testing vacuum switch for refrigerant compressor or vacuum switch (main switch) & switchover valves
• 83-630 - Removal and installation of heating water pump
• 83-631 - Reconditioning of heating water pump
• 83-632 - Removal and installation of regulating valve and temperature switch
• 83-635 - Removal, installation and disassembly of control unit
• 83-640 - Removal and installation of in-car temperature sensor
• 83-645 - Removal and installation of ambient temperature sensor
• 83-650 - Removal and installation of ETR-switch
• 83-655 - Removal and installation of vacuum switch for refrigerant compressor (at "BI-LEVEL" only)
• 83-660 - Removal and installation of switchover valves
• 83-665 - Removal and installation of vacuum elements
• 83-670 - Removal and installation of vacuum switch for refrigerant compressor or vacuum switch (main switch)
• 83-675 - Removal and installation of amplifier
• 83-680 - Removal and installation of double contact relay
• 83-690 - Removal and installation of temperature switch for heating water pump
• 83-700 - Removal and installation of blower pre-resistors
• 83-710 - Removal and installation of vacuum lines  

Section 3 - Automatic Climate Control III (starting MY 1982 up to MY 1986)

• 83.9-600 - Operation of automatic climate control
  • Select page... A. General Page 1 B. Control Unit 2 C. Temperature Sensor 6 D. Monovalve with check valve, electric recirculating pump and cold engine lock 7 E. Electronic switching unit for temperature and blower control with electric wiring diagram 8 F. Air path and control of air flaps vacuum function diagram 18
• 83.9-601 - Manual and optical function test of automatic climate control
• 83.9-602 - Preparation for testing, connecting adapter to volt/ohm measuring instrument
• 83.9-603 - Function test of total system and remedies (with adapter)
  • Select page... Testing voltage supply and connecting lines 1 and 6 Page 1 Testing in-car temperature sensor 2 Testing connecting lines 6 and 10 2 Testing temperature sensor for heat exchanger and connecting lines 6 and 9 3 Testing temperature dial and connecting lines 5 and 6 4 Electromagnetic clutch and connecting lines 2 and 6 5 Checking function selection "c" or "e", as well as connecting lines 1 and 3 5 Testing temperature dial and connecting lines 5 and 7 6 Testing control line recirculating air and connecting lines 1 and 12 7 Testing switchover valve for center nozzle flap and connecting lines 1 and 4 8 Testing function selection "c", connecting lines 6 and 11, as well as electronic switching unit for blower control 9 Testing monovalve, function selection "c" and connecting lines 1 and 8 10 Checking switchover valves for main air, center nozzle, defroster nozzle and legroom flaps 13 Checking cold engine lock (engine temperature below 33C) 17 Checking monovalve for leaks 18
• 83.9-604 - Vacuum function diagrams
• 83.9-607 - Output test
• 83.9-614 - Preparations for vacuum test
• 83.9-615 - Testing check valve and vacuum reservoir
• 83.9-620 - Testing vacuum circuits I to IV
• 83.9-625 - Removal and installation of monovalve
• 83.9-635 - Removal, installation and disassembly of control unit
• 83.9-645 - Removal and installation of temperature sensor for heat exchanger
• 83.9-660 - Removal, installation and testing of switchover valves
• 83.9-665 - Removal and installation of vacuum elements
  • Select page... A. Vacuum element for defroster nozzle flaps Page 1 B. Vacuum element for legroom flaps 2 C. Vacuum element for center nozzle flap (J)(USA) only 4
• 83.9-675 - Removal and installation of electronic switching unit for temperature control
• 83.9-676 - Removal and installation of electronic switching unit for blower control
• 83.9-678 - Removal, installation and checking of temperature switch for cold engine lock  

Supplements to Climate Control

• A - Changes as of Model Year 1984
• B - Automatic Climate Control starting Model Year 1986
• C - Changes as of Model Year 1987  

• See Group 24 for schematics

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