A/C - No Cool Air Output
Date: January 20, 2009Order No.: S-B-83.55/126
Supersedes:
Group: 83
SUBJECT:
Model 164.122/822
Model 211.022
Model 251.122
No Cooling Output / Refrigerant Compressor Malfunctioning
If you receive customer reports in the above model vehicles of a rattling noise with deactivated AC or no AC cooling output, this could be caused by the oil cap leaking or oil loss at the engine air intake duct from the air filter to the turbocharger damaging the guide pulley rubber dampener elements which can lead to breakage of the torque limiter of the guide pulley. The refrigerant compressor shaft can rotate freely and the internal components of the refrigerant compressor are not damaged. To remedy, follow the steps below.
Note:
The above condition could be an indicator that components in the entire belt drive of the engine are often contaminated with oil.
Note:
On accident vehicles with frontal damage and damaged refrigerant compressor belt pulley, the entire refrigerant compressor must be replaced, however, this is not a warrantable condition.
For all claims, before replacing, always determine the exact quantity of refrigerant in the refrigeration circuit. An indication of the exact quantity with the returned part is an important element in localizing the cause and preventing the fault in development and production. When returning parts, please state the quantity along with the fitter's findings in order for the claim to be accepted under warranty.
1. Disassemble malfunctioning belt pulley.
a) Relieve stress on belt.
b) Remove belt from belt pulley on refrigerant compressor. Refer to WIS document AR83.55-P-7685D. Use counter holder for drive plate, Special Tool Number W112 589 07 4000
2. Check rotation of refrigerant compressor shaft / replace belt pulley on refrigerant compressor
a) Carefully turn compressor shaft after disassembling belt pulley with a suitable 7 mm hexagon socket or 7 mm hexagon socket wrench.
b) If the shaft of the refrigerant compressor rotates freely and the removed belt pulley has traces of oil on it (Figure 1 and 2), install new belt pulley. Refer to WIS document AR83.55-P-7685D).
Note:
The belt pulley is replaced with the refrigerant compressor still in the vehicle. It is not necessary to open or evacuate the refrigeration circuit in order to access the refrigerant compressor, the vehicle must be raised. Repair work on all affected model series is carried out from underneath. The engine must be cold. Do not exert any tensile force on the refrigerant compressor shaft in the axial direction doing so can damage the compressor neck resulting in a non-warrantable condition.
c) If the shaft of the refrigerant compressor cannot be freely rotated with the suitable 7 mm hexagon tool or is sluggish, replace entire refrigerant compressor.
3. Check alternator freewheel for easy movement (if installed on the engine in question)
a) If the alternator freewheel is not blocked, install belt and continue with step 4.
b) If the alternator freewheel is blocked, replace defective part and continue with step 4.
4. Rectify cause of engine oil loss to prevent further consequential damage.
a) One possible cause, refer to DTB S-B-09.20/29 (or latest version).
b) If there is no attempt to rectify the oil loss, then future claims for subsequent conditions will be subject to debit.
Note:
Important notes on warranty processing
Before replacing parts, make absolutely certain that the belt pulley and not the entire refrigerant compressor is causing the noise problem. Avoid replacing the entire refrigerant compressor if only the belt pulley is defective for both noise and performance complaints.
When components of the air conditioning system are replaced and then returned for warranty inspection, a control unit log must be included with the component from now on. DAS versions 09/2005 and higher include the menu item "Control unit log" to facilitate printing. Without the required paperwork, any claims submitted will potentially be subject to a full debit.
This menu item automatically compiles the following data which can then be printed:
^ Control units
^ Vehicle data
^ Customer complaint (to be completed by workshop staff)
^ Fault memory freeze frame data from quick test
To ensure correct inspection of the component, it is important to complete the field "Customer complaint (remarks on damage)". This must include a meaningful fitter's findings report and any other information available. If the refrigerant compressor was replaced, it is absolutely essential to state the quantity of refrigerant extracted.
Special Tools
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on January 20, 2009. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In Case of Warranty, use the table above.