oil 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 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

front cover of the compressor. Be certain that the
snap ring is properly fully and properly seated in the
groove.
(6) If the original clutch plate and clutch pulley
are to be reused, reinstall the original shim(s) on the
compressor shaft against the shoulder. If a new
clutch plate and/or clutch pulley are being used,
install a trial stack of shims 1.0 mm (0.040 in.) thick
on the compressor shaft against the shoulder.
(7) Install the clutch plate onto the compressor
shaft.
(8) Install and tighten the compressor shaft bolt. If
necessary, a band-type oil filter wrench or a strap
wrench can be placed around the clutch plate to aid
in bolt tightening. Tighten the bolt to 17.5 N´m (155
in. lbs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(9) If a new clutch plate and/or clutch pulley are
being installed, the air gap between the clutch plate
and clutch pulley must be checked (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
COMPRESSOR CLUTCH - STANDARD PROCE-
DURE).
(10) Install the retainer that secures the compres-
sor clutch coil lead to the top of the compressor.
(11) Reconnect the engine wire harness connector
to the clutch coil lead on the top of the compressor.
(12) Reinstall the serpentine accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).
(13) Reconnect the battery negative cable.
(14) If a new clutch plate and/or clutch pulley are
being installed, the new clutch components must be
burnished (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS/A/C COMPRESSOR CLUTCH
- STANDARD PROCEDURE).
A / C COMPRESSOR CLUTCH
COIL
DIAGNOSIS AND TESTING
A / C COMPRESSOR CLUTCH COIL
The air conditioning compressor clutch coil electri-
cal circuit is controlled by the ATC control module
which is integral to the heater-A/C control. Begin
testing of a suspected compressor clutch coil problem
by performing the ATC Function Test using the
DRBIIItscan tool.PRELIMINARY CHECKS
(1) If no diagnostic trouble codes (DTCs) are found
in the A/C-heater control or the powertrain control
module (PCM), go to Step 2. If any DTCs are found,
repair as required.
(2) If the A/C compressor clutch still will not
engage, verify the refrigerant charge level (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS). If the refrigerant charge level is
OK, go to TESTS. If the refrigerant charge level is
not OK, adjust the refrigerant charge as required.
TESTS
(1) Verify the battery state of charge (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY -
DIAGNOSIS AND TESTING).
(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the A/C-heater control in the A/C mode
and the blower motor at low speed, start the engine
and allow it to run at a normal idle speed.
(4) The A/C compressor clutch should engage
immediately, and the clutch coil supply voltage
should be within two volts of the battery voltage. If
the coil supply voltage is OK, go to Step 5. If the coil
supply voltage is not within two volts of battery volt-
age, test the clutch coil feed circuit for excessive volt-
age drop and repair as necessary.
(5) For the acceptable A/C clutch coil current draw
specifications refer to 24 - HEATING & AIR CONDI-
TIONING - SPECIFICATIONS. Specifications apply
for a work area temperature of 21É C (70É F). If volt-
age is more than 12.5 volts, add electrical loads by
turning on electrical accessories until voltage reads
below 12.5 volts.
(a) If the A/C clutch coil current reading is zero,
the coil is open and must be replaced.
(b) If the A/C clutch coil current reading is above
specifications, the coil is shorted and must be
replaced.
A / C HEATER CONTROL
DESCRIPTION
This ATC system uses a combination of electrical
and mechanical controls. These controls provide the
vehicle operator with a number of setting options to
help control the climate and comfort within the vehi-
cle.
The A/C-heater control is located on the instrument
panel inboard of the steering column and below the
24 - 12 CONTROLS-FRONTVA

A/C PRESSURE TRANSDUCER VOLTAGE
Voltage Possible Cause
0.0 1. No transducer supply voltage from ATC control module.
2. Shorted transducer circuit.
3. Faulty transducer.
0.150 to 0.450 1. Ambient temperature below 10É C (50É F).
2. Low refrigerant system pressure.
0.451 to 4.519 1. Normal refrigerant system pressure.
4.520 to 4.850 1. High refrigerant system pressure.
5.0 1. Open transducer circuit.
2. Faulty transducer.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 10).
(4) Using an open end wrench, remove the A/C
pressure transducer from the fitting on the liquid
line.
(5) Remove the O-ring seal from the A/C pressure
transducer and discard.
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the A/C pressure trans-
ducer.
(2) Using an open end wrench, install and tighten
the A/C pressure transducer into the fitting on the
liquid line. Tighten the transducer to 12 N´m (106 in.
lbs.).
(3) Reconnect the wire harness connector to the
transducer.
(4) Reconnect the battery negative cable.
(5) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
Fig. 10 A/C Pressure Transducer
1 - WIRE HARNESS CONNECTOR
2 - A/C PRESSURE TRANSDUCER
3 - O-RING SEAL
4 - LIQUID LINE FITTING
VACONTROLS-FRONT 24 - 15

AMBIENT TEMPERATURE SEN-
SOR
DESCRIPTION
The ambient air temperature sensor is a variable
resistor that monitors the air temperature outside of
the vehicle. The ambient air temperature sensor is
connected to the instrument cluster through a two-
wire harness lead and connector of the vehicle elec-
trical system (Fig. 13). The instrument cluster sends
out a message on the CAN bus to the ATC control
module which uses the sensor data to maintain opti-
mum cabin temperature levels.
The ambient air temperature sensor is mounted to
the front licence plate bracket by three integral
retaining tabs.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the instrument cluster. The resistance in
the sensor changes as temperature changes. Based
upon the resistance in the sensor, the instrument
cluster sends the ATC control module a specific volt-
age on the temperature sensor signal circuit, which
is programmed to correspond to a specific tempera-
ture.
The ambient temperature sensor is diagnosed
using the DRBIIItscan tool. Refer to Body Diagnos-
tic Procedures.
The ambient temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front license plate bracket (Refer
to 23 - BODY/EXTERIOR/LICENSE PLATE
BRACKET - REMOVAL).
(3) Disconnect the wire harness connector from the
ambient temperature sensor (Fig. 14).
(4) Disengage the sensor retaining tabs and
remove the ambient temperature sensor from the
front license plate bracket.
INSTALLATION
(1) Install the ambient temperature sensor onto
the front license plate bracket. Make sure the retain-
ing tabs are fully engaged.
(2) Connect the wire harness connector to the
ambient temperature sensor.
(3) Install the front license plate bracket (Refer to
23 - BODY/EXTERIOR/LICENSE PLATE BRACKET
- INSTALLATION).
(4) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
DESCRIPTION
This temperature control system uses a blower
motor resistor (Fig. 15). The blower motor resistor is
mounted to the top of ventilation housing located in
the engine compartment. The blower motor resistor
consists of a molded plastic mounting plate with an
integral retaining tab and wire connector receptacle.
Concealed behind the mounting plate are coiled resis-
tor wires contained within a ceramic heat sink.
Fig. 13 Ambient Air Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
3 - RETAINING TABS (3)
Fig. 14 Ambient Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - FRONT LICENSE PLATE BRACKET
VACONTROLS-FRONT 24 - 17

CONTROLS - REAR
TABLE OF CONTENTS
page page
A/C CLUTCH RELAY
DESCRIPTION.........................24
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................26
A/C CONDENSER FAN RELAY
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................27
INSTALLATION.........................28
A/C CONTROL MODULE
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................29
INSTALLATION.........................30
A/C HIGH PRESSURE SWITCH
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................31
INSTALLATION.........................31
A/C LOW PRESSURE SWITCH
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL.............................32
INSTALLATION.........................33
BLOWER MOTOR RELAY
DESCRIPTION.........................33
OPERATION...........................33
REMOVAL.............................34
INSTALLATION.........................35
BLOWER MOTOR SWITCH
DESCRIPTION.........................35
OPERATION...........................35
DIAGNOSIS AND TESTING
REAR BLOWER MOTOR SWITCH.........36REMOVAL.............................36
INSTALLATION.........................37
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................37
OPERATION...........................37
REMOVAL.............................37
INSTALLATION.........................38
TEMPERATURE CONTROL
DESCRIPTION.........................38
OPERATION...........................38
DIAGNOSIS AND TESTING
REAR A/C TEMPERATURE CONTROL.....39
REMOVAL.............................39
INSTALLATION.........................40
TEMPERATURE SENSOR
DESCRIPTION.........................40
OPERATION...........................40
DIAGNOSIS AND TESTING
REAR TEMPERATURE SENSOR..........40
REMOVAL.............................40
INSTALLATION.........................41
SUPPRESSOR FILTER - REAR BLOWER
MOTOR
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................42
INSTALLATION.........................43
SUPPRESSOR FILTER - REAR CONDENSER
FA N
DESCRIPTION.........................43
OPERATION...........................44
REMOVAL.............................44
INSTALLATION.........................44
A / C CLUTCH RELAY
DESCRIPTION
The rear A/C clutch relay for the rear A/C system
is an International Standards Organization (ISO)-
type relay (Fig. 1). Relays conforming to the ISO
specifications have common physical dimensions, cur-
rent capacities, terminal functions and patterns. The
rear A/C clutch relay is an electromechanical device
that uses a low current input controlled by the rear
A/C control module to control the high current output
to the A/C clutch field coil for the rear A/C system.The rear A/C clutch relay is located in the relay
block in the rear A/C evaporator housing.
24 - 24 CONTROLS - REARVA

OPERATION
The ISO-standard rear A/C clutch relay is an elec-
tromechanical switch that uses a low current input
from the rear A/C control module to control the high
current output to the rear A/C clutch. The movable,
common feed relay contact is held against the fixed,
normally closed relay contact by spring pressure.
When the electromagnetic relay coil is energized, it
draws the movable common feed relay contact away
from the fixed, normally closed relay contact and,
holds it against the fixed, normally open relay con-
tact. This action allows high current to flow to the
A/C clutch field coil.
When the relay coil is de-energized, spring pres-
sure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromag-
netic interference that can be generated as the elec-
tromagnetic field of the relay coil collapses.
The rear A/C clutch relay terminals are connected
to the vehicle electrical system through a receptacle
in the relay block located in the rear A/C evaporator
housing.
The rear A/C clutch relay cannot be repaired and,
if faulty or damaged, it must be replaced. Refer to
the appropriate wiring information for diagnosis and
testing of the ISO-standard relay and for complete
HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evapo-
rator housing (Refer to 24 - HEATING & AIR CON-DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear A/C clutch relay from the relay
block (Fig. 2).
Fig. 1 Rear A/C Clutch Relay
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
VACONTROLS - REAR 24 - 25

INSTALLATION
(1) Position the rear A/C clutch relay into the
proper receptacle of the relay block located in the
rear A/C evaporator housing.
(2) Align the A/C clutch relay terminals with the
terminal cavities in the relay block receptacle and
push down firmly on the relay until the terminals
are fully seated.
(3) Install the rear air filter (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/AIR FILTER - INSTALLATION).
(4) Reconnect the negative battery cable.
A / C CONDENSER FAN RELAY
DESCRIPTION
The rear A/C condenser fan relay for the rear A/C
system is an International Standards Organization
(ISO)-type relay (Fig. 3). Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal functions and patterns.
The rear A/C condenser fan relay is an electrome-
chanical device that uses a low current input to con-
trol the high current output to the A/C condenser fan
for the rear heating-A/C system.
The rear A/C condenser fan relay is located in the
relay block in the rear A/C evaporator housing.
OPERATION
The ISO-standard rear A/C condenser fan relay is
an electromechanical switch that uses a low current
input from the rear A/C control module to control the
high current output to the rear A/C condenser cooling
fan. The movable, common feed relay contact is held
against the fixed, normally closed relay contact by
spring pressure. When the electromagnetic relay coil
Fig. 2 Rear A/C Clutch Relay
1 - REAR A/C EVAPORATOR HOUSING
2 - BLOWER MOTOR RELAY K204
3 - BLOWER MOTOR RELAY K2034 - BLOWER MOTOR RELAY K201
5 - REAR CONDENSER FAN RELAY K205
6 - REAR COMPRESSOR RELAY K206
Fig. 3 Rear A/C Condenser Fan Relay
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
24 - 26 CONTROLS - REARVA

is energized, it draws the movable common feed relay
contact away from the fixed, normally closed relay
contact and, holds it against the fixed, normally open
relay contact. This action allows high current to flow
to the electric cooling fan motor.
When the relay coil is de-energized, spring pres-
sure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromag-
netic interference that can be generated as the elec-
tromagnetic field of the relay coil collapses.
The rear A/C condenser fan relay terminals are
connected to the vehicle electrical system through a
receptacle in the relay block located in the rear A/C
evaporator housing.
The rear A/C condenser fan relay cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for diagnosis and testing of the ISO-standard relay
and for complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evapo-
rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear A/C condenser fan relay from
the relay block (Fig. 4).
VACONTROLS - REAR 24 - 27

INSTALLATION
NOTE: Replacement of the PTFE thread sealing
tape is required anytime the rear A/C low pressure
switch is removed from the rear suction line line.
Failure to replace the sealing tape could result in a
rear refrigerant system leak.
(1) Remove the tape or plug from the rear suction
line fitting.
(2) Install PTFE thread sealing tape onto the rear
A/C low pressure switch and install the switch onto
the rear suction line. Tightened the A/C low pressure
switch to 10 N´m (88 in. lbs.).
(3) Connect the wiring harness connector to the
rear A/C low pressure switch.
(4) Install new insulating tape around the rear A/C
low pressure switch area.
(5) Reconnect the negative battery cable.
(6) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(7) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(8) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).
BLOWER MOTOR RELAY
DESCRIPTION
The three rear blower motor relays used for the
rear A/C system are International Standards Organi-
zation (ISO)-type relays (Fig. 11). Relays conforming
to the ISO specifications have common physical
dimensions, current capacities, terminal functions
and patterns. The rear blower motor relays are elec-
tromechanical devices that switches fused battery
current directly to the rear blower motors. The rear
blower motor relays are energized when the relay
coils are provided battery current by the rear blower
motor switch (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/BLOWER MOTOR
SWITCH - DESCRIPTION).
The rear blower motor relays are located in the
relay block in the rear A/C evaporator housing.
OPERATION
The three ISO-standard rear blower motor relays
are electromechanical switches that uses a low cur-
rent input from the rear blower motor switch to con-
trol the high current output to the rear blower
motors. The movable, common feed relay contact is
held against the fixed, normally closed relay contact
by spring pressure. When the electromagnetic relay
coil is energized, it draws the movable common feed
relay contact away from the fixed, normally closed
relay contact and, holds it against the fixed, normally
open relay contact. This action allows high current to
flow to the rear blower motors.
When the relay coil is de-energized, spring pres-
sure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
Fig. 10 Rear A/C Low Pressure Switch
1 - INSULATING TAPE
2 - REAR A/C EVAPORATOR HOUSING
3 - WIRE HARNESS CONNECTOR
4 - REAR A/C LOW PRESSURE SWITCH
5 - REAR SUCTION LINE FITTING
Fig. 11 Rear Blower Motor Relays
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
VACONTROLS - REAR 24 - 33

or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromag-
netic interference that can be generated as the elec-
tromagnetic field of the relay coil collapses.
The rear blower motor relay terminals are con-
nected to the vehicle electrical system through recep-
tacles in the relay block located in the rear A/C
evaporator housing.
The rear blower motor relays cannot be repaired
and, if faulty or damaged, they must be replaced.
Refer to the appropriate wiring information for diag-
nosis and testing of the ISO-standard relay and for
complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evapo-
rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear blower motor relays as neces-
sary from the relay block (Fig. 12).
24 - 34 CONTROLS - REARVA