All Passenger And Light Truck Models; Defective Refrigeration Circuit/Refrigerant Compressor (LI83.55-P-046799)

Publication date: 2009-05-14
Reference number: LI83.55-P-046799
Supersedes refnos: 83.55/118

ALL PASSENGER AND LIGHT TRUCK MODELS; DEFECTIVE REFRIGERATION CIRCUIT/REFRIGERANT COMPRESSOR

TECHNICAL SERVICE BULLETIN

Reference Number(s): LI83.55-P-046799 Version 1 (S-B-83.55/118, March 10, 2009), Date of Issue: May 14, 2009

Mercedes-Benz:	All Passenger and Light Truck Models
Design Group:	83.55 A/C compressor
Reason For Change:

COMPLAINT

Defective Refrigeration Circuit / Refrigerant Compressor

CAUSE

Locked refrigerant compressor, a broken torque limiter on the refrigerant compressor, the refrigeration circuit blocked or an electrical defect in the refrigerant compressor.

REMEDY

NOTE: This document is intended as a supplement to the SDS function test "Refrigerant circuit test". Only perform repair and replacement work on the refrigerant circuit if the SDS refrigerant circuit test was unsuccessful and you have received appropriate instructions in the SDS function test.

PREREQUISITES

Before parts can be replaced, the exact quantity of the refrigerant in the refrigeration circuit must be determined by evacuating the system. When returning parts be sure to indicate the exact amount of refrigerant in the circuit and any other findings by the technician. If the filling capacity is not indicated, warranty claims may be rejected.
If the fill level of the refrigerant circuit is too low, parts should only be replaced if the torque limiter is broken.
If the fill level of the refrigerant circuit is too low and the torque limiter is damaged, the leak test (Test 6 "Leak in refrigeration circuit") must be performed using the "Technology Guide -Vehicle Climate Control" located in SDS SDMedia first and then the system must be refilled and checked. If the amount of refrigerant in the circuit is less than 80% of the normal level, it is too low. Inadequate fill levels may be the cause of the air conditioning shutting down or malfunctioning.

REMEDY A - BROKEN TORQUE LIMITER

Ensure the alternator freewheel (when applicable) is not damaged and that the belt pulley of the refrigerant compressor rotates in the belt drive.
If the alternator freewheel is blocked, replace the alternator freewheel. For refrigerant compressors with a replaceable belt pulley, replace the belt pulley only, otherwise replace the refrigerant compressor. Refer to EPCNet for applicable part number.
If the alternator freewheel is not blocked and black refrigerant/oil is evacuated from the system, replace the AC compressor. Refer to EPCNet for applicable part number.

REMEDY B - BLOCKAGE IN THE REFRIGERATION CIRCUIT

Identify through SDS function test "Refrigeration circuit test" that the refrigerant circuit has not been underfilled or overfilled.
Inspect along the AC lines to check for blockage at the points with marked temperature differences.
Identify and replace the blocked components in the refrigeration circuit. Refer to EPCNet for applicable part number.

REMEDY C - ELECTRICAL DEFECT IN REFRIGERANT COMPRESSOR

Identify through SDS function test "Refrigeration circuit test" that the refrigerant circuit has not been underfilled or overfilled.
After ruling out a short circuit in the actuation and ground wiring, replace the refrigerant compressor only. Refer to EPCNet for applicable part number.

NOTE:

Always empty the oil from the new refrigerant compressor before installing.
When completely refilling the system, ensure the quantity of oil and refrigerant is correct (refer to WIS document BF83.00-Z-9999AZ). Take into consideration whether individual components or the entire refrigerant circuit are to be replaced.
Always perform a leak test on the system after changing the refrigerant circuit but before filling it with refrigerant.

NOTE: The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on March 10, 2009. Please refer to Netstar → Star TekInfo → Star Time for the most current labor time allowance.

SYMPTOMS

Body / Air conditioning / Air conditioning / Insufficient cooling output /

WORK UNITS

Op. no.	Operation text	Time	Damage code	Note
54-1011	SHORT TEST, PERFORM	0.3 hrs.		AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF, CB, CC, CD, DA, DB, DC, DD, DE, EA, EB, EC, ED J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, R1, R2, R3, R4, R5, R6, R7, R8, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, X1, X2, X3, X4, XA, Y1, Y2, Y3, Y4, Z1, Z2, Z3, Z4, Z5, Z6
54-1012	TEST PROGRAM - AFTER SHORT TEST, PERFORM	0.5 hrs.		AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF, CB, CC, CD, DA, DB, DC, DD, DE, EA, EB, EC, ED J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, R1, R2, R3, R4, R5, R6, R7, R8, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, X1, X2, X3, X4, XA, Y1, Y2, Y3, Y4, Z1, Z2, Z3, Z4, Z5, Z6
83-0000	REFRIGERANT CIRCUIT TEST, PERFORM	0.2 hrs. *		AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF, CB, CC, CD, DA, DB, DC, DD, DE, EA, EB, EC, ED J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, R1, R2, R3, R4, R5, R6, R7, R8, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, X1, X2, X3, X4, XA, Y1, Y2, Y3, Y4, Z1, Z2, Z3, Z4, Z5, Z6 Only to be claimed if a cooling performance complaint is documented * Maximum time allowed with a separate time punch. Ensure that punches are labeled as NON time.
				Remedy A: Step 1
15-0000	BELT PULLEY FOR ALTERNATOR, CHECK	0.1 hrs. *	15111 H5	AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF, CB, CC, CD, DA, DB, DC, DD, DE, EA, EB, EC, ED J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, R1, R2, R3, R4, R5, R6, R7, R8, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, X1, X2, X3, X4, XA, Y1, Y2, Y3, Y4, Z1, Z2, Z3, Z4, Z5, Z6 15111 H5 (Alt freewheel) * Maximum time allowed with a separate time punch. Ensure that punches are labeled as NON time.
15-5715	BELT PULLEY FOR ALTERNATOR, REPLACE	0.3 hrs.		AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF, CB, CC, CD, DA, DB, DC, DD, DE, EA, EB, EC, ED J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, R1, R2, R3, R4, R5, R6, R7, R8, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, X1, X2, X3, X4, XA, Y1, Y2, Y3, Y4, Z1, Z2, Z3, Z4, Z5, Z6
				Step 2: If necessary
83-7624	CLUTCH PULLEY - FOR A/C COMPRESSOR, REPLACE (AFTER TEST)	0.0 hrs. *	83525 06	AA, AB, AC, AD, AE, DA, DB, DC, DD, DE J1, J2, J3, L1, L2, L3, L7, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, Q6, Q7, Q8, Q9, QA * Maximum time allowed with a separate time punch. Ensure that punches are labeled as NON time.
83-7624	CLUTCH PULLEY - FOR A/C COMPRESSOR, REPLACE (AFTER TEST)	0.6 hrs.	83525 06	CA, CB, CC, CD S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, XA, Y1, Y3 83525 06 (compressor clutch)
83-7624	CLUTCH PULLEY - FOR A/C COMPRESSOR, REPLACE (AFTER TEST)	0.7 hrs.	83525 06	P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9 83525 06 (compressor clutch)
83-7624	CLUTCH PULLEY - FOR A/C COMPRESSOR, REPLACE (AFTER TEST)	0.8 hrs.	83525 06	X1, X2, X3, X4, Y2 83525 06 (compressor clutch)
83-0000	REFRIGERANT CIRCUIT TEST, PERFORM	0.0 hrs. *		BA, BB, BC, BD, BE, BF EA, EB, EC, ED, R1, R2, R3, R4, R5, R6, R7, R8, Z1, Z2, Z3, Z4, Z5, Z6 * Maximum time allowed with a separate time punch. Ensure that punches are labeled as NON time.
				Step 3: If necessary
61-1071	ENGINE COMPARTMENT PANEL, BOTTOM - FRONT PART R & R	0.2 hrs.	83421 47	P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC X1, X2, X3, X4 83421 47 (compressor)
61-1071	ENGINE COMPARTMENT PANEL, BOTTOM - FRONT PART R & R	0.3 hrs.	83421 47	AA, AB, AC, AD AE BA, BB, BC, BD, BE, BF, CA, CB, CC, CD, DA, DB, DC, DD, DE, J1, J2, J3, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, Y1, Y2, Y3, Y4 83421 47 (compressor)
61-1105	ENGINE COMPARTMENT TRIM AT BOTTOM REMOVE/INSTALL	0.3 hrs.		EA, EB, EC, ED, Z1, Z2, Z3, Z4, Z5, Z6
61-1069	ENGINE COMPARTMENT PANELS, BOTTOM (ALL), R & R	0.7 hrs.		R1, R2, R3, R4, R5, R6, R7, R8
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	0.0 hrs. *		AE, CC, CD, DB, DC, DD, J1, J3, L1, L2, L3, L7, M4, M8, R3, R4, R6, R7, R8, S9, U2, U4, XA, Y2, Y4, Z3 * Maximum time allowed with a separate time punch. Ensure that punches are labeled as NON time.
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	0.8 hrs.		S1, S4
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	0.9 hrs.		EA, EC
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.0 hrs.		BA, BB, BE, P1, P2, P3, P4, Q2, Q4
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.1 hrs.		BD, BF, Z1, Z2, Z5
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.2 hrs.		BC, P5, U5
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.3 hrs.		AB, AC, CA, CB, TC, X1, X2, X3, X4, Z4, Z6
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.4 hrs.		Y1
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.5 hrs.		EB, ED, T7, U6, U8
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.6 hrs.		AA, DA, J2
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.7 hrs.		Q1, Q3, Q5
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.8 hrs.		M1, M2, M3, M5, P6, P7, P8, P9, S7, S8
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	1.9 hrs		T6
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	2.0 hrs.		T1, T4, U1
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	2.1 hrs.		M6, M7, T2, T3, T5, TA, TB, U3
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	2.2 hrs.		T8, U7, Y3
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	2.4 hrs.		S2, S3, S5, S6
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	3.1 hrs.		AD, DE
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	4.4 hrs.		R1, R2, R5
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	5.6 hrs.		M9
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)	5.8 hrs.		N1, N2, N3, N4, N5, N6
83-1762	A/C REFRIGERANT SYSTEM EVACUATE/ CHARGE	0.9 hrs.		CA, CB, CC, CD, EA, EB, EC, ED, N1, N2, N3, N4, N5, N6, Z2, Z3, Z4, Z5, Z6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, X1, X2, X3, X4, XA, Z1, Z2, Z3, Z4, Z5, Z6
				Remedy C
61-1071	ENGINE COMPARTMENT PANEL, BOTTOM - FRONT PART R & R	0.2 hrs.	83421 53	P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, X1, X2, X3, X4
61-1071	ENGINE COMPARTMENT PANEL, BOTTOM - FRONT PART R & R	0.3 hrs.	83421 53	AA, AB, AC, AD, AE, BA, BB, BC, BD, BE, BF CA, CB, CC, CD, DA, DB, DC, DD, DE, J1, J2, J3, M1, M2, M3, M4, M5, M6, M7, M8, M9, N1, N2, N3, N4, N5, N6, T1, T2, T3, T4, T5, T6, T7, T8, T9, TA, TB, TC, U1, U2, U3, U4, U5, U6, U7, U8, Y1, Y2, Y3, Y4
61-1105	ENGINE COMPARTMENT TRIM AT BOTTOM REMOVE/ INSTALL	0.3 hrs.		EA, EB, EC, ED, Z1, Z2, Z3, Z4, Z5, Z6
61-1069	ENGINE COMPARTMENT PANELS, BOTTOM (ALL), R & R	0.7 hrs.		R1, R2, R3, R4, R5, R6, R7, R8
83-7351	A/C COMPRESSOR, R & R (AFTER TEST)			see Remedy A, Step 3
83-1762	A/C REFRIGERANT SYSTEM EVACUATE/ CHARGE	0.9 hrs.		CA, CB, CC, CD, EA, EB, EC, ED, N1, N2, N3, N4, N5, N6, Z2, Z3, Z4, Z5, Z6, P1, P2, P3, P4, P5, P6, P7, P8, P9, Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, QA, S1, S2, S3, S4, S5, S6, S7, S8, S9, SA, SB, SC, X1, X2, X3, X4, XA, Z1, Z2, Z3, Z4, Z5, Z6 Evac & charge

WIS-REFERENCES

Document number	Title	Note	Allocation
BF83.00-Z-9999AZ	Capacities: Passenger cars: Climate control		Remedy