2006 MERCEDES-BENZ SPRINTER Service Manual

roof jacking headlight aiming clock gas tank size charging

Page 2041 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (4) With the A/C compressor clutch engaged, duct
temperature should not be less than 2É C (35É F) or
more than 12É C (54É F). The compressor clutch may
cycle, depending upon the ambient temperatur

(4) With the A/C compressor clutch engaged, duct
temperature should not be less than 2É C (35É F) or
more than 12É C (54É F). The compressor clutch may
cycle, depending upon the ambient temperature and
humidity. If the clutch cycles, use the readings
obtained before the clutch disengaged.
(5) If the A/C compressor clutch has not cycled off
and the duct temperature is less than 2É C (35É F),
check the evaporator temperature sensor and circuitby performing the ATC Function Test (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - ATC FUNCTION TEST).
(6) If the air outlet temperature fails to meet the
specifications, refer to the A/C System Diagnosis
chart.
A/C SYSTEM DIAGNOSIS
Condition Possible Causes Correction
Rapid A/C compressor clutch
cycling (ten or more cycles
per minute).Very low refrigerant system
charge.See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the refrig-
erant system.1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Faulty fuse. 2. Check the fuses in the Power distribution
block and junction block. Repair the shorted
circuit or component and replace the fuses, if
required. Refer to Group 8.
3. Faulty A/C compressor
clutch coil.3. See A/C Compressor Clutch Coil in this
group. Test the compressor clutch coil and
replace, if required.
4. Improperly installed or faulty
evaporator temperature sensor.4. See Evaporator Temperature Sensor in this
group. Test the sensor and replace, if re-
quired.
5. Faulty A/C pressure trans-
ducer.5. See A/C Pressure Transducer in this
group. Test the sensor and replace, if re-
quired.
6. Faulty engine Control Mod-
ule (ECM).6. Refer to Group 9 - Engine Electrical Diag-
nostics for testing of the ECM. Test the ECM
and replace, if required.
Normal pressures, but A/C
Performance Test air temper-
atures at center panel outlet
are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level,
if required.
2. Blend door cable improperly
installed or faulty.2. See Mode Door Cables in this group. In-
spect the cable for proper operation and re-
place, if required.
3. Blend-air door(s) inoperative
or sealing improperly.3. See HVAC Housing in this group. Inspect
the blend-air door(s) for proper operation and
sealing. Repair if required.
24 - 4 HEATING & AIR CONDITIONINGVA

Page 2042 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Condition Possible Causes Correction
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this
gro

Condition Possible Causes Correction
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Refrigerant flow through the
A/C evaporator is restricted.2. See A/C Evaporator in this group. Replace
the restricted A/C evaporator, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Re-
place the A/C compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.1. A/C condenser air flow re-
stricted.1. Check the A/C condenser for damaged
fins, foreign objects obstructing air flow
through the condenser fins, and missing or
improperly installed air seals. Clean, repair, or
replace components as required.
2. Refrigerant flow through the
receiver/drier is restricted.2. See Receiver/Drier in this group. Replace
the restricted receiver/drier, if required.
3. Inoperative radiator cooling
fan.3. Test the radiator cooling fan and replace, if
required. Refer to Group 7 - Cooling.
4. Refrigerant system over-
charged.4. See Refrigerant System Charge in this
group. Recover the refrigerant from the refrig-
erant system. Charge the refrigerant system
to the proper level, if required.
5. Air in the refrigerant system. 5. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
6. Engine overheating. 6. Test the engine cooling system and repair,
if required. Refer to Group 7 - Cooling.
The low side pressure is too
high, and the high side pres-
sure is too low.1. Accessory drive belt slip-
ping.1. Inspect the accessory drive belt condition
and tension. Repair as required. Refer to
Group 7 - Cooling.
2. Faulty A/C expansion valve. 2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Re-
place the A/C compressor, if required.
The low side pressure is too
low, and the high side pres-
sure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid Line, Suction Line and Dis-
charge Line in this group. Inspect the refriger-
ant lines for kinks, tight bends or improper
routing. Correct the routing or replace the re-
frigerant line, if required.
2. Restricted refrigerant flow
through the A/C expansion
valve.2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Restricted refrigerant flow
through the A/C condenser.3. See A/C Condenser in this group. Replace
the restricted A/C condenser, if required.
HEATER PERFORMANCE TEST
Before performing the following tests, perform the
ATC Function Test using the DRBIIItand refer to
Cooling for the procedures to check the radiator cool-
ant level, serpentine drive belt tension, radiator air
flow and the radiator fan operation.
MAXIMUM HEATER OUTPUT
Engine coolant is provided to the heater core
through a heater valve and heater hose. With the
engine idling at normal operating temperature, set
the heater-A/C controls as follows:
²Temperature control in the full hot position
VAHEATING & AIR CONDITIONING 24 - 5

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MERCEDES-BENZ SPRINTER 2006 Service Manual ²Mode control in the floor heat position
²Blower motor control in the highest speed posi-
tion
Using a test thermometer, check the temperature
of the air being discharged at the floor outlets. Com-p

²Mode control in the floor heat position
²Blower motor control in the highest speed posi-
tion
Using a test thermometer, check the temperature
of the air being discharged at the floor outlets. Com-pare the test thermometer reading to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE CHART
Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahreheit Celsius Fahreheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
If the floor outlet air temperature is insufficient,
check for a faulty heater valve (perform ATC Func-
tion Test) and verify that the cooling system is oper-
ating to specifications (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS AND TESTING).
Both of the heater hoses should be HOT to the touch
(the coolant return heater hose should be slightly
cooler than the supply hose. If the coolant return
hose is much cooler than the supply hose, locate and
repair the engine coolant flow obstruction in the
heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²Inoperative or stuck heater water valve.
²Plugged heater core.
If proper coolant flow is verified, and heater floor
outlet air temperature is insufficient, a mechanical
problem may exist.
POSSIBLE LOCATIONS OR CAUSE OF INSUFFI-
CIENT HEAT
²An obstructed cowl air intake.
²Obstructed heater system outlets.
²Heater water valve not functioning properly.
TEMPERATURE CONTROL
If outlet air temperature cannot be adjusted with
the A/C-heater temperature control, one of the follow-
ing could require service:
²Faulty A/C-heater control switch.
²Faulty temperature sensor.²Faulty A/C-heater control cable or actuator.
²Faulty A/C-heater control module.
ATC FUNCTION TEST
The automatic temperature control (ATC) system
can perform an self-test, which can be activated by
the DRBIIItscan tool to confirm that the A/C system
is performing satisfactorily. This test provides a
quick confirmation of heating and A/C system perfor-
mance to the service technician. Refer to Body Diag-
nostic Procedures for the appropriate diagnostic
information.
SPECIFICATIONS
HEATING-A/CSYSTEM
FRONT A/C SYSTEM
Item Description Notes
A/C Compres-
sorDenso 7SBU16C ND-8 PAG oil
Freeze-up Con-
trolEvaporator tem-
perature sensorHVAC hous-
ing mounted -
input to A/C-
heater control
- operating
range of -10É
C (14É F) to
40É C (104É
F)
24 - 6 HEATING & AIR CONDITIONINGVA

Page 2044 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Item Description Notes
Low psi Control A/C Pressure
TransducerLiquid line
mounted -
input to PCM
- operating
range of 200
kPa (29 psi)
to 2799 kPa
(406 psi)
High psi Con-
trolHigh Pressure
Relief Valv

Page 2045 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION..........................8
OPERATION............................9
STANDARD PROCEDURE
A/C COMPRESSOR CLUTCH AIR GAP......9

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH
DESCRIPTION..........................8
OPERATION............................9
STANDARD PROCEDURE
A/C COMPRESSOR CLUTCH AIR GAP......9
A/C COMPRESSOR CLUTCH BREAK-IN.....9
REMOVAL.............................9
INSPECTION..........................11
INSTALLATION.........................11
A/C COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH COIL........12
A/C HEATER CONTROL
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................13
INSTALLATION.........................13
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................14
OPERATION...........................14
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER..........14
REMOVAL.............................15
INSTALLATION.........................15
AIR OUTLET TEMPERATURE SENSOR
DESCRIPTION.........................16
OPERATION...........................16
REMOVAL.............................16
INSTALLATION.........................16
AMBIENT TEMPERATURE SENSOR
DESCRIPTION.........................17
OPERATION...........................17REMOVAL.............................17
INSTALLATION.........................17
BLOWER MOTOR RESISTOR
DESCRIPTION.........................17
OPERATION...........................18
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR............18
REMOVAL.............................18
INSTALLATION.........................18
BLOWER MOTOR SWITCH
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH..............19
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................19
OPERATION...........................19
REMOVAL.............................20
INSTALLATION.........................20
IN-CAR TEMPERATURE SENSOR
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING
IN-CAR TEMPERATURE SENSOR.........21
MODE DOOR CABLES
REMOVAL.............................21
INSTALLATION.........................21
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
A / C COMPRESSOR CLUTCH
DESCRIPTION
The A/C compressor clutch assembly consists of a
stationary electromagnetic field coil, a hub bearing
and pulley assembly, and a clutch plate (Fig. 1). The
field coil and the hub bearing and pulley assembly
are each retained on the nose of the compressor front
housing with snap rings. The clutch plate is splined
to the compressor shaft and secured with a bolt.
The compressor clutch plate and pulley and the
clutch field coil are available for service replace-
ment.
24 - 8 CONTROLS-FRONTVA

Page 2046 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically

OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is
part of the pulley.
The compressor clutch engagement is controlled by
several components:
²A/C switch on the A/C-heater control panel
²Evaporator temperature sensor
²A/C pressure transducer
²Air temperature sensor
²CAN bus messages
The compressor clutch is de-energized under any of
the following conditions:
²Blocked compressor (thermal fuse in the pulley)
²Low pressure in the system
²Low evaporator temperature
²Hard acceleration (WOT)
²High coolant temperatures
STANDARD PROCEDURE
A / C COMPRESSOR CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between specifications
(Refer to 24 - HEATING & AIR CONDITIONING -
SPECIFICATIONS), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
A / C COMPRESSOR CLUTCH BREAK - IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control in the
Recirculation Mode, the A/C button in the on posi-
tion, the blower motor switch in the highest speed
position, and the engine speed at 1500 to 2000 rpm.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher compressor
clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil
wire harness connector on the top of the compressor.
(4) Remove the retainer securing the compressor
clutch coil lead on the top of the compressor.
(5) Remove the bolt that secures the compressor
clutch to the compressor shaft (Fig. 2). If necessary, a
band-type oil filter wrench or strap wrench can be
placed around the clutch plate to aid in bolt
removal.
Fig. 1 A/C Compressor Clutch
1 - BOLT
2 - CLUTCH PLATE
3 - PULLEY AND BEARING
4 - FIELD COIL
5 - SNAP RING
6 - SNAP RING
7 - SHIM (2)
VACONTROLS-FRONT 24 - 9

Page 2047 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (6) Tap the clutch plate lightly with a plastic mal-
let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3).Be certain not t

Page 2048 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSPECTION
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the fac-
tory using a burnishing operation. No a

INSPECTION
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the fac-
tory using a burnishing operation. No attempt should
be made to separately replace the compressor clutch
pulley or clutch plate. The clutch coil may be serviced
separately.
(1) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for wear. The clutch pulley
and clutch plate should be replaced if there is exces-
sive wear or scoring.
(2) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for oil contamination. If the
friction surfaces are oily, the clutch pulley and clutch
plate should be replaced. Also inspect the shaft and
nose area of the compressor for oil. Remove the felt
packing from around the compressor shaft in the
compressor front cover. If the felt is saturated with
oil, the compressor front shaft seal is leaking and the
compressor will also have to be replaced.
(3) Check the clutch pulley bearing for roughness
or excessive leakage of grease. Replace the clutch
pulley and clutch plate if the bearing is faulty.
INSTALLATION
(1) Align the dowel pin on the back of the clutch
field coil with the hole in the compressor front cover,
and position the clutch coil onto the compressor. Be
certain that the cluch coil wire harness leads are
properly oriented and routed so that they are notpinched between the compressor front cover and the
clutch coil.
NOTE: A new snap ring must be used to secure the
clutch coil to the compressor. The bevel side of the
snap ring must face outward.
(2) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring that
secures the clutch coil to the front cover of the com-
pressor. The bevel side of the snap ring must be fac-
ing outward and both snap ring eyelets must be
oriented to the right or left of the clutch coil dowel
pin on the compressor. Be certain that the snap ring
is fully and properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the compressor front
cover.
(3) Install and tighten the screw that secures the
clutch coil wire harness connector bracket and
ground clip to the top of the compressor housing.
(4) Install the pulley onto the front of the compres-
sor. If necessary, place a block of wood on the friction
surface and tap gently with a hammer (Fig. 6).
CAUTION: Do not mar the friction surfaces of the
pulley.
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
Fig. 5 Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
Fig. 6 Pulley Assembly Install
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
VACONTROLS-FRONT 24 - 11

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