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| G-AMG G-Class DIY Host Date registered: May 2006 Location: South Texas Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350  | Photo DIY- W463 A/C Vent Flap Actuator Repair Greets. I guess I should consider myself blessed we have had as few "Failures" on this truck in it's 100,000 miles... The latest was a new, disturbing "Light Banging" noise eminating from the Center Dashboard area on Start-Up. Later, when I selected the Foot Vents setting, it sounded like something Restricting airflow with a Wheezing noise. As a rough guess, it sounded like a Broken Actuator arm; Motor; or Linkage. Pulling out my handy-dandy STAR showed Fault Code B15A8, which is a "Sticking or Frozen" Left/Right Footwell Flap Actuator, which goes along perfectly with my Hypothesis. To my complete surprise, and *DISAPPOINTMENT* searching the EPC for parts, and getting a little On-Line Info??? Guess what?? Our High-End G-Wagens have a *C-Class* Airconditioning System!! (W203 which is ca. 2001-2007) According to my Dealer-Lead Tech friend **EVERY** C-Class has Failure of these Actuators or Arms. The Following is the WIS procedure for R/R. I don't recall hearing others with this problem, but hopefully it may help someone in the future. G (1.jpg) (2.jpg) (3.jpg) (4.jpg) (5.jpg) (6.jpg) (7.jpg) (8.jpg) (9.jpg) (10.jpg) (11.jpg) (12.jpg) (13.jpg) (14.jpg) (15.jpg) (16.jpg) (17.jpg) Attachments ----------------  1.jpg (41KB - 18 downloads) 2.jpg (102KB - 12 downloads) 3.jpg (87KB - 14 downloads) 4.jpg (130KB - 17 downloads) 5.jpg (74KB - 21 downloads) 6.jpg (84KB - 18 downloads) 7.jpg (129KB - 20 downloads) 8.jpg (145KB - 17 downloads) 9.jpg (112KB - 24 downloads) 10.jpg (105KB - 18 downloads) 11.jpg (114KB - 18 downloads) 12.jpg (117KB - 16 downloads) 13.jpg (120KB - 13 downloads) 14.jpg (99KB - 15 downloads) 15.jpg (99KB - 21 downloads) 16.jpg (68KB - 19 downloads) 17.jpg (108KB - 16 downloads) | |
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| G-AMG G-Class DIY Host Date registered: May 2006 Location: South Texas Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350 | ||
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| louwdj Veteran Date registered: Feb 2007 Location: Johannesburg South Africa Vehicle(s): 89 W460 230GE 5 door; 82 W123 230e; 99 W210 E240 Posts: 139  | ||
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| gerryvz Extreme Veteran Date registered: Apr 2014 Location: Annapolis, MD Vehicle(s): 1994 G320, 1989 560SEC, 1994 E500 (W124) Posts: 336  | ||
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| nadd Expert Date registered: Apr 2006 Location: UAE, Dubai Vehicle(s): G500 2016 LHD, numerous Chevys Posts: 1285 | RE: Photo DIY- W463 A/C Vent Flap Actuator Repair G-AMG - 7/8/2014 4:17 AM To my complete surprise, and *DISAPPOINTMENT* searching the EPC for parts, and getting a little On-Line Info??? Guess what?? Our High-End G-Wagens have a *C-Class* Airconditioning System!! (W203 which is ca. 2001-2007) According to my Dealer-Lead Tech friend **EVERY** C-Class has Failure of these Actuators or Arms. I don't recall hearing others with this problem, but hopefully it may help someone in the future. G It's like we work in parallel across the pond! I did this last month on the ML320, and sadly these very same motors and system are used on most MLs (W163), and a quick search online reveals the joys C-class owners have with them. Once you get the revised motors/levers things seem to go much better. The motors all have the same part number but seem to be made by different companies (Denso, Behr, etc) and I had a number of faults that could only be accessed by removing the top and lower dash, thankfully much easier on the W163 than the early 463. Great photos as always (bar the one  )(AC flap motor W163.jpg) (W163 dash off.jpg) Attachments ---------------- AC flap motor W163.jpg (89KB - 17 downloads) W163 dash off.jpg (72KB - 14 downloads) | |
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hipine Date registered: Jul 2006 Location: US, CO, Bailey Vehicle(s): 460 1980 280GE w. 617A  | RE: Photo DIY- W463 A/C Vent Flap Actuator Repair So whereas they start the assembly line build of a 460 G with the heater core and build the truck around it, from your pictures it looks like the W163 assembly line starts with the flap motor.  Nice work both of you and thanks for sharing. Your blazing the trail on stuff like this is key to giving others confidence to self-maintain and is doing a great service in the interest of keeping G's on the road. -Dave G. | |
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| G-AMG G-Class DIY Host Date registered: May 2006 Location: South Texas Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350 | ||
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| fernweh Date registered: Apr 2006 Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa  | Re: Photo DIY- W463 A/C Vent Flap Actuator Repair Thanks Patrick for this DIY, I might have to dig in there myself..... I never noticed the "only screw" in picture 7.jpg The trim in my G500, is held in place by the four clips, two of them seem to fall into the abyss, regardless what you do..... Is that screw used only in the AMG models? To keep the trim in place while accelerating G55 style? Please advise Karl | |
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| 94rover Veteran Date registered: Oct 2010 Location: 39.2036° N, 76.8569° W Vehicle(s): 02 G500 Posts: 240 | ||
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| 4x4abc Date registered: Apr 2006 Location: La Paz, Baja California, Mexico Vehicle(s): 02 G500 | ||
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| G-AMG G-Class DIY Host Date registered: May 2006 Location: South Texas Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350 | Re: Photo DIY- W463 A/C Vent Flap Actuator Repair fernweh - 7/8/2014 10:08 AM Thanks Patrick for this DIY, I might have to dig in there myself..... I never noticed the "only screw" in picture 7.jpg The trim in my G500, is held in place by the four clips, two of them seem to fall into the abyss, regardless what you do..... Is that screw used only in the AMG models? To keep the trim in place while accelerating G55 style? Please advise Karl In WIS, it looks like the procedure (remove the one screw) applied to "Most W463" models... There were a zillion listed. | |
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| fernweh Date registered: Apr 2006 Location: Calabasas, CA - Centenario, BCS - Luebeck, Germany Vehicle(s): Few Mercedes-Benz, a Toyota Amphibious and a Vespa | Re: Photo DIY- W463 A/C Vent Flap Actuator Repair Hmmm.... with the four clips on the trim piece, I would not been able to pull it down, before pulling it aft. I need to get in there to verify.....  Karl | |
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| thebigblue Date registered: Jan 2012 Location: Vehicle(s):  | ||
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| nadd Expert Date registered: Apr 2006 Location: UAE, Dubai Vehicle(s): G500 2016 LHD, numerous Chevys Posts: 1285 | Re: Photo DIY- W463 A/C Vent Flap Actuator Repair What prompted my action was discovering a number of similar error codes (defrost flap motor, centre vent flap motor, hot/cold blend flap, etc!) so I was convinced it was worth digging in to. Fortunately the motors all seemed fine, but sometimes the levers only come with a motor attached And it can be a bit tricky finding the right lever on the EPC. When the system works it is great however, the cooling of the post '02 Gs is so much better than the '00 model (at least the one we have). | |
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| G-AMG G-Class DIY Host Date registered: May 2006 Location: South Texas Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350 | ||
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| s2kysk Member Date registered: Aug 2009 Location: PNW Vehicle(s): 04' G500 Black/Gray, 00' 528it BMW, 86' 911 turbo Posts: 40  | ||
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