smartcarofamerica.com/threads/short-in-ac-compressor-how-to-replace-chafed-wire-bad-heater.163722/

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Forum thread: Short in AC compressor, how to replace? (chafed wire/bad heater) | Smart Car of America Forum

smartcarofamerica.com/threads/short-in-ac-compressor-how-to-replace-chafed-wire-bad-heater.163722/ · p. 1 · Applies to: 451

Source: smartcarofamerica.com Topic: Chafed wiring harness, AC compressor diagnosis, PTC heater fault Models discussed: 451 Solution status: unclear

Problem: Smart fortwo ED (451) displaying 'HV System Workshop' and 'Restart not possible' messages, initially suspected to be a faulty AC compressor but later diagnosed as a chafed wire harness in the engine compartment. Subsequently, PTC heater malfunction with error code U145641 (Implausible data received from PTC).

Solution: Initial AC issue was resolved by identifying and repairing a chafed blue/white wire from the compressor harness on the right side of the engine compartment using solder and heat shrink. For the PTC heater issue, the user obtained a J2534 Xentry Passthru kit from China (TopOBD on Aliexpress) to properly diagnose and clear remaining codes. Xentry DAS diagnostic software identified potential bad CAN bus connections to the PTC heater as a possible cause rather than the heater itself. User ordered a replacement heater from a junkyard and was advised to check wiring connections. Final resolution remained unresolved at thread end, with user investigating chafed wires and CAN bus connections before heater replacement.

Key facts: - Initial 'HV System Workshop' error was caused by a chafed blue/white wire in the engine compartment harness, not a faulty AC compressor - Soldering and heat shrinking the broken wire connection resolved the AC issue completely - PTC heater error code U145641 persisted after AC repair; suspected causes include bad CAN bus connection, chafed wiring, or faulty PTC heater unit - J2534 Xentry Passthru kit (C3/C4 equivalent from China) successfully cleared most codes except U145641 - PTC fuse (10A Red, labeled R5) located in fuse box on driver's side under dash - Temperature door actuator was confirmed functional through AP200 scanner observation and manual inspection - TopOBD Aliexpress vendor provided Xentry Passthru kit with remote setup assistance for approximately $50