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Home >> Mercedes Benz >> 2012 >> S600 >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Climate Control - 221 Chassis - 2 Of 3 >> Testing & Repair >> Remove/install expansion valve - AR83.30-P-5520SX

Remove/install expansion valve - AR83.30-P-5520SX

MODEL 216.3, 221.0/1 

MODIFICATION NOTES

20.11.13 Work procedure changed and special tools for electrical vacuum pump and LTC adaptation added. Operation steps 14 to 16 AR20.00-P-1142-04A
26.9.14 coolant mixing ratio   BF20.00-P-1001-04A
Fig 1: Identifying Expansion Valve Remove/Install Components - Shown On Model 221
G10113017Courtesy of MERCEDES-BENZ USA

Shown on model 221 

DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
NOTES Notes on coolant   AH20.00-N-2080-01A
REMOVINGINSTALLING Remove/install     
1 Drain air conditioning system INSTALLATION IMPORTANT Evacuate air conditioning system, refill it and check it for proper operation and leaktightness. AR83.30-P-1760SX 
2 Release pressure in cooling system IMPORTANT To do this, carefully open expansion reservoir cover and close again.  
3 Remove cover above brake booster If necessary  
4 Detach air/water channel (2) from the partition wall, press upward and fix in place    
5 Unclip cable tie (3) and expose electrical wiring harness    
6 Disconnect washer fluid line at expansion valve (1) and set aside    
7 Cover working area at hot water hoses (5) with rags    
8 Clamp off hot water hoses (5) using a suitable tool and detach from connection lines to heat exchanger    
9 Seal connection lines to heat exchanger    
10 Detach refrigerant line to high-voltage battery from expansion valve (1) Model 221.095/195
INSTALLATION IMPORTANT Replace sealing ring of refrigerant line and moisten with compressor oil.		  
11 Disconnect low-pressure line (8) and close INSTALLATION IMPORTANT Replace the sealing ring of the low-pressure line (8) and moisten with compressor oil.  
TORQUE SPECIFICATION Nut, low-pressure line to high-pressure line *BA83.30-P-1001-01K 
12 Disconnect high pressure line (10) and close INSTALLATION IMPORTANT Replace the sealing ring of the high-pressure line (10) and moisten with compressor oil.  
TORQUE SPECIFICATION Nut, high-pressure line to expansion valve *BA83.30-P-1002-01K 
13 Remove screws (11), remove expansion valve (1) and close connection lines (13) INSTALLATION NOTES
Screw in the screws/bolts (11) alternately in order to prevent the expansion valve (1) from canting.
The expansion valve (1) will otherwise be damaged.
INSTALLATION IMPORTANT Replace the sealing rings (12) and moisten with compressor oil. Moisten thread of bolts (11) with compressor oil.		  
TORQUE SPECIFICATION Bolt, expansion valve to retaining plate *BA83.30-P-1003-01K 
14 Install in the reverse order    
15 Pour in coolant and bleed cooling system   AR20.00-P-1142-04A
NOTES Notes on coolant level   AH20.00-P-1142-01V
REFER TO CAPACITIES & SPECIFICATIONS Anticorrosion/antifreeze agents (Sheet 325.0)   Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
REFER TO CAPACITIES & SPECIFICATIONS Coolant specifications   Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
    FLUID SPECIFICATION Coolant mixing ratio *BF20.00-P-1001-04A 
    FLUID SPECIFICATION *BF20.00-P-1001-02BA 
    MODEL 221 with ENGINE 276  
    FLUID SPECIFICATION *BF20.00-P-1001-02U 
    MODEL 216, 221 with ENGINE 156
MODEL 216, 221 with ENGINE 273
MODEL 221 with ENGINE 272		  
    FLUID SPECIFICATION *BF20.00-P-1001-02Y 
    MODEL 221 with ENGINE 629  
    FLUID SPECIFICATION *BF20.00-P-1001-02W 
    MODEL 221 with ENGINE 642  
    FLUID SPECIFICATION *BF20.00-P-1001-02AA 
    MODEL 221 with ENGINE 651  
    FLUID SPECIFICATION *BF20.00-P-1001-02Q 
    MODEL 216, 221 with ENGINE 275.953
MODEL 216, 221 with ENGINE 275.982		  
    FLUID SPECIFICATION *BF20.00-P-1001-02EA 
    MODEL 216 with ENGINE 278
MODEL 221 with ENGINE 278		  
    SPECIAL TOOL NTKL Adaption Fig 4
    SPECIAL TOOL Electric vacuum pump Fig 3
    SPECIAL TOOL Test cap Fig 2
    SPECIAL TOOL Cooler vacuum filling device Fig 5
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
16 Perform an engine test run and check cooling system for leaktightness MODEL 216 with ENGINE 156, 157, 273, 275, 278
MODEL 221 with ENGINE 156, 157, 272, 273, 275, 276, 278, 642, 651		 AR20.00-P-1010SX
MODEL 221 with ENGINE 629
IMPORTANT Perform visual inspection.		 AR20.00-P-1010SXD
AIR CONDITIONING

Number Designation MODEL 221 MODEL 216
BA83.30-P-1001-01K Nut, low-pressure line to high-pressure line Nm 8 8
AIR CONDITIONING

Number Designation MODEL 221 MODEL 216
BA83.30-P-1002-01K Nut, high-pressure line to expansion valve Nm 8 8
AIR CONDITIONING

Number Designation MODEL 221 MODEL 216
BA83.30-P-1003-01K Bolt, expansion valve to retaining plate Nm 5 5
COOLING SYSTEM

Number Designation ENGINE 651 in MODEL 221
BF20.00-P-1001-02AA Cooling system Workshop replacement quantity Main circuit Liter ≈6, 0
Low temperature circuit Liter -
Antifreeze/water Up to -37_°C % 50/50
As of -38_°C % 55/45
Specifications for Operating Fluids Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLING SYSTEM

Number Designation ENGINE 276 in MODEL 221
BF20.00-P-1001-02BA Cooling system Workshop replacement quantity Main circuit Liter ≈10, 2
Low temperature circuit Liter -
Antifreeze/water Up to -37_°C % 50/50
As of -38_°C % 55/45
Specifications for Operating Fluids Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLING SYSTEM

Number Designation ENGINE 278 in MODEL 216 ENGINE 278 in MODEL 221
BF20.00-P-1001-02EA Cooling system Workshop replacement quantity Main circuit Liter ≈13, 7 ≈13, 7
Low-temperature circuit Liter - -
Antifreeze/water up to -37°C % 50/50 50/50
As of -38 °C % 55/45 55/45
Specification Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1 Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1 Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1 Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLING SYSTEM

Number Designation ENGINE 275.953 in MODEL 216, 221 ENGINE 275.982 in MODEL 216, 221
BF20.00-P-1001-02Q Cooling system Total filling capacity Main circuit Liter ≈8, 8 ≈11, 8
Low temperature circuit Liter ≈1, 5 ≈2, 1
Filling capacity for corrosion and antifreeze down to -37 °C Main circuit Liter ≈4, 4 ≈5, 9
Low temperature circuit Liter ≈0, 75 ≈1
Specification Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1 Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1 Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLING SYSTEM

Number Designation ENGINE 156 in MODEL 216, 221 ENGINE 272 in MODEL 221 ENGINE 272.985 in MODEL 219
BF20.00-P-1001-02U Cooling system Workshop replacement quantity Main circuit Liter 10, 0 8, 0
Low temperature circuit Liter - -
Antifreeze/water Up to -37_°C 50/50 50/50
As of -38_°C 55/45 55/45
Specifications for Operating Fluids Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1 Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1 Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1 -
COOLING SYSTEM

Number Designation ENGINE 273 in MODEL 216, 221
BF20.00-P-1001-02U Cooling system Workshop replacement quantity Main circuit Liter 8, 5
Low temperature circuit Liter -
Antifreeze/water Up to -37_°C 50/50
As of -38_°C 55/45
Specifications for Operating Fluids Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specifications for Operating Fluids -
COOLING SYSTEM

Number Designation ENGINE 642 in MODEL 203, 209, 211, 219, 221
BF20.00-P-1001-02W Cooling system Workshop replacement quantity Liter ≈7, 5
Antifreeze/water Up to -37 °C % 50/50
As of -38 °C % 55/45
Specification Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Premixed coolant (Specification 326.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLING SYSTEM

Number Designation ENGINE 629 in MODEL 221
BF20.00-P-1001-02Y Cooling system Total filling capacity ≈ Liter 9
Antifreeze/water up to -37°C 50/50
Antifreeze/water up to -45°C 55/45
Specification Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Specification Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1
COOLANT MIXING RATIO

Number Designation ENGINE ALL
BF20.00-P-1001-04A Coolant mixing ratio Antifreeze/water up to -37°C 50/50
Antifreeze/water up to -45°C 55/45
Specification Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
Fig 2: Identifying Test Cap (210 589 00 91 00)
G09981975Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Electric Vacuum Pump (285 589 02 21 00)
G10126591Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying NTKL Adaption (285 589 01 21 00)
G10126592Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Cooler Vacuum Filling Device (285 589 00 21 00)
G09981978Courtesy of MERCEDES-BENZ USA
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