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TEMPMATIC Climate Control Modifications (83/26)

Publication date: 1988-05-01
Reference number: 83/26

TEMPMATIC CLIMATE CONTROL MODIFICATIONS

TEMPMATIC CLIMATE CONTROL MODIFICATIONS

TECHNICAL SERVICE BULLETIN

Reference Number(s): 83/26, Date of Issue:  May 1988

TEMPMATIC CLIMATE CONTROL MODIFICATIONS - MODEL 201.024/028 - M.Y. 1985 TO M.Y. 1988 (NOVEMBER 1987 PRODUCTION)

Model(s): 1985-1988 Mercedes-Benz 190 E

Group: 83 - Climate Control System, Automatic/Tempmatic A/C

Bulletin No.: MBNA 83/26

Date: May 1988

SERVICE INFORMATION

The air conditioning system has undergone improvements which enhance the performance and reliability. Refrigerant pressures and temperatures are being reduced by optimizing the airflow through the A/C condenser. This is accomplished by the installation of specific shields around the perimeter of the condenser/radiator and earlier engagement of the auxiliary fan. Additionally, a two-piece A/C hose assembly has been developed to better withstand high underhood temperatures. These improvements are incorporated in the current 190E 2.3 and can be applied to previous 190E 2.3.

It is very important that the procedure outlined in the attached W.I. #226 is adhered to and followed through completely. Do not perform the modification in a piecemeal fashion (i.e. the A/C hose modification during one visit and the radiator/condenser shielding modification the following visit). To ensure that the desired A/C system improvements are obtained, the entire modification is to be completed at one time.

This procedure applies to all M.Y. 1985, 1986, 1987 and 1988 190E 2.3 vehicles up to chassis end number F-441505.

This procedure does not apply to M.Y. 1984 190E 2.3, all 190D 2.2 and 2.5, all 190E 2.3-16 and all 190E 2.6.

The table below will assist you in determining which tasks are to be performed an a vehicle as per model year.

CLIMATE CONTROL MODIFICATIONS

Task To Be Performed M.Y 1985 M.Y 1986 M.Y 1987 M.Y 1988 (1)
A. Replace A/C hose assembly yes yes yes yes
B. Replace receiver-drier after inspection as needed as needed as needed as needed
C. Replace refrigerant high pressure switch, auxiliary fan (S32) yes yes yes yes
D. Replace refrigerant low pressure switch (S31) yes yes (2) no no
E. Install radiator shielding yes yes yes yes
F. Replace evaporator temperature sensor (B10/6) (S.I. MEN 83/57 ) as needed (3) as needed (3) as needed (3) no
G. Install encapsulation panel (S.I. MBNA 83/20a with W.I. #194) as needed (4) as needed (4) no no
H. Install wiring harness and relay for integrating auxiliary and engine fan control (S.I. MBNA 83/13a with W.I. #177) as needed no no no
I. Evacuate/charge A/C system & check for leaks yes yes yes yes
(1) = up to F-441505
(2) = up to F-242785
(3) = if necessary, up to F-372972
(4) = if necessary, up to F-270375

WARRANTY CLAIM INFORMATION

If some of the modification work (F,G,H) has already been performed at an earlier date, do not repeat those modifications and again claim them under this procedure. Claims submitted as such will be rejected.

Submit one warranty claim for modification work done as per the attached W.I. #226 per each vehicle. Additional warranty claims may only be submitted for necessary work that falls outside the scope of the attached W.I. #226.

PARTS RETURN INFORMATION

All parts replaced/exchanged under this W.I., as well as additional work that may be necessary, may be scrapped; except for those items listed below.

PARTS TO BE RETURNED

Part Name Part Number
Compressor 003 131 95 01
Condenser 000 830 14 70 05
Condenser 201 830 17 70 05

The above items are not part of this A/C service program. If these items are replaced for any reason they must be held until their return is requested, along with the corresponding receiver-drier from that vehicle.

Failure to adhere to the above conditions may void the warranty claim.

WORK INSTRUCTIONS NO. 226 TEMPMATIC CLIMATE CONTROL MODIFICATIONS - MODEL 201.024/028 - M.Y. 1985 TO NOVEMBER 1987 PRODUCTION

Model(s): 1985-1988 Mercedes-Benz 190 E

Group: 83

Number: 226

Date: May 1988

NOTE: Read through entire W.I. before performing any work on vehicle.
SCOPE OF WORK

Task To Be Performed Up To Chassis End Number
A. Replace A/C hose assembly F-441505
B. Replace receiver-drier after inspection, if necessary All
C. Replace refrigerant high pressure switch, auxiliary fan (S32) All
D. Replace refrigerant low pressure switch (S31) F-242785
E. Install radiator shielding F-440573
F. Replace evaporator temperature sensor (B10/6) (see S.I. MBNA 83/57 ) F-372972 only vehicles not yet modified
G. Install encapsulation panel (see S.I. MBNA 83/20a with W.I. #194) F-270375 only vehicles not yet modified
H. Install wiring harness and relay for integrating auxiliary and engine fan control (see S.I. MBNA 83/13a with W.I. #177) M.Y. 1985 vehicles not yet modified
I. Evacuate/charge A/C system & check for leaks All

PROCEDURE A - REPLACE A/C HOSE ASSEMBLY

NOTE: The new A/C hose assembly is now a two piece design and is supplied as one unit for the purpose of this campaign. During manufacture the two parts were joined using a jig to determine the correct orientation, and were properly torqued. The hose assembly has been pressure tested as a complete unit. We recommend that the two parts not be separated during installation.
  1. Prior to performing any disassembly work, run the engine (ensure that vehicle is in Park/neutral and emergency brake is on) and operate the A/C system via the pushbuttons. Observe and note the appearance of the oil visible through the sight glass in the receiver-drier. This information is needed for procedure B.
  2. Drain freon from system. Release pressure slowly to conserve refrigerant system lubricating oil.
  3. Remove air filter housing, air intake duct and intake scoop.
  4. Loosen distributor cap and remove rotor. Release tension on Poly V-belt.
  5. Remove lower encapsulation panel.
  6. remove left and right sway bar attachment bolts from frame rails.
  7. Remove A/C compressor.
  8. Remove bracket (10) by loosening bolts (b, Fig. Fig 1 ).
  9. Remove bolt (a) for stabilizing bracket (Fig. Fig 1 ).
  10. Disconnect the low pressure side of the hose assembly from metal line (leading to expansion valve).
  11. Disconnect the high pressure side of the A/C hose assembly from the condenser. Remove support clamp below fitting, if so equipped.
  12. Disconnect stabilizing bracket (on the high pressure side pipe of the hose assembly) from rubber buffer mounted on the radiator support.
  13. Loosen fuel filler cap to release any pressure. Unscrew and close off the fuel lines (arrow) from fuel cooler. Immediately clean up any spilt fuel (Fig. Fig 2 ). Retighten fuel filler cap.
  14. Remove both bolts (a) from cylinder head (Fig. Fig 2 ).
  15. Remove A/C hose through the top of engine compartment.
  16. Guide new A/C hose assembly into place through top of engine compartment. Start the two bolts to the cylinder head, but do not tighten at this time.
  17. Install compressor, fasten A/C hose manifold to compressor and reattach bolt for stabilizing bracket (a, Fig. Fig 3 ). Tighten two bolts (a, Fig. Fig 2 ) to cylinder head (from step 16).
    NOTE: Always use new O-rings at the compressor/hose manifold Interface.
  18. Tighten and adjust Poly V-belt.
  19. Connect bracket (10, Fig. Fig 3 ).
  20. Fill 20ccm of oil into the low pressure connection of A/C hose assembly and reconnect to the metal line (leading to expansion valve).
    CAUTION: Additional refrigerant oil will be needed if additional components are replaced (i.e. receiver-drier, condenser, etc.). See service microfiche Tempmatic Model 201, job no. 83-520 for specific guidelines and oil fill quantities.
  21. Connect fuel lines to fuel cooler.
  22. Reinstall rotor and distributor cap.

PROCEDURE B - REPLACE RECEIVER DRIER, AFTER INSPECTION

Replace receiver-drier if:

  1. The refrigerant system was empty of freon as a result of a leak.
  2. The vehicle is older than 3 years.
  3. The oil visible through the sight glass of the receiver-drier appears contaminated (i.e. due to burnt oil).

PROCEDURE C - REPLACE REFRIGERANT HIGH PRESSURE SWITCH AUXILIARY FAN (S32)

Install new 16 bar pressure switch in place of 20 bar pressure switch (S32) located on the receiver-drier (Fig. Fig 4 ).

PROCEDURE D - REPLACE REFRIGERANT LOW PRESSURE SWITCH (S31)

Install 2/30 bar refrigerant low/high pressure switch on the receiver-drier in place of the 2 bar low pressure switch (S31) on vehicles up to chassis end number F-242785, (Fig. Fig 4 ).

PROCEDURE E - INSTALL RADIATOR SHIELDING

  1. Remove engine fan.
  2. Remove fan shroud.
  3. Remove two clamps on top of radiator, lift and gently push radiator back towards engine as far as possible.
  4. Remove 2 clamps on top of condenser.
  5. Place seal (10) on carrier (11) so that approximately 15mm hangs over each end (Fig. Fig 5 ).
  6. Gently lift condenser and attach carrier (11) to bottom of condenser, via the two positioning pins. Reinstall condenser (Fig. Fig 6 ).
    NOTE: The above step is best performed by two technicians. One holding the condenser from the top while the other attaches the carrier. It is not necessary to remove the second hose/pipe fitting on the condenser.
  7. Lubricate condenser shields with silicone spray and insert left shield (14) between the two rows of U-tubes on the left side of the condenser and right shield (15) between the U-tubes on the right side of condenser (Figs. Fig 6 and Fig 7 ). Ensure that the shields are completely inserted and seated against the condenser side walls.
    NOTE: The auxiliary fan wiring harness may need to be re-routed on some vehicles.
  8. Connect the high pressure side of the A/C hose to condenser. Secure pipe to rubber buffer and to condenser frame with clamp where possible.
  9. Remove left and right shield on radiator (if so equipped) and install new, longer shields (1 and 2, Figs. Fig 7 and Fig 8 ).
  10. Connect three shields to bottom of radiator (5 and 6, Fig. Fig 8 ).
  11. Connect shield (16) to top of radiator (Figs. Fig 7 and Fig 8 ).
  12. Place bottom of radiator in proper position and secure top with clamps, ensuring that the right radiator shield (1) installs as shown (arrow, Fig. Fig 9 ).
  13. Secure top of condenser with clamps.
  14. Install fan shroud.
  15. Install engine fan.
  16. Install foam blocks (10 and 11) at top of radiator (Fig. Fig 10 ).

    10 = P/N 201 628 18 98

    11 = P/N 201 628 17 98

    both parts are included in kit

  17. Mount left plastic shield (8) next to left headlamp with 2 rivets supplied with kit (arrow, Fig. Fig 11 ).
    NOTE: For M.Y. 1985 & 1986 vehicles (without aerodynamic headlamps) install headlamp shield part number 201 628 13 07 and 201 628 14 07. The initial kits will only contain shields for M.Y. 1987 and M.Y. 1988 vehicles (with aerodynamic headlamps). Shields part number 201 628 09 07 and 201 628 10 07 must be modified for M.Y. 1985 & 1986 vehicles according to Fig. Fig 14 .
  18. Mount right plastic shield (9) next to right headlamp with 2 rivets supplied with kit (arrow, Fig. Fig 12 ).
  19. Install air intake scoop, intake duct and air filter housing.

PROCEDURE F - REPLACE EVAPORATOR TEMPERATURE SENSOR (B10/6)

On vehicles produced up to F-372972, verify if new version evaporator temperature sensor (B10/6) is installed (see S.I. 83/57 , July 1987). If not, install as per procedure in aforementioned S.I. (Fig. Fig 13 ).

PROCEDURE G - INSTALL ENCAPSULATION PANEL

On vehicles produced up to 201.024-1F-270375, verify if splash guards have been installed. If not, install modified encapsulation panel and splash guards as per S.I. MBNA 83/20a , with W.I. #194, November 1986.

On model 201.028 and any previously modified 201.024, reinstall encapsulation panel and splash guards. Secure sway bar using existing bolts; clean bolt threads and head and apply Loctite to bolt threads before resecuring sway bar.

H. INSTALL WIRING HARNESS AND RELAY FOR INTEGRATING AUXILIARY AND ENGINE FAN CONTROL

On model 201.024, M.Y. 1985 only, verify connection of the engine fan to the auxiliary fan low speed circuit (see S.I. MBNA 83/13a with W.I. #177, August 1985). If modification was not performed, follow procedure in aforementioned S.I and W.I.

I. EVACUATE/CHARGE A/C SYSTEM & CHECK FOR LEAKS

  1. On vehicles up to chassis end number F-385822, replace label for fill quantity on radiator cross member.
  2. Evacuate system, and charge with 1000g of refrigerant R12. This should only be done using approved charging equipment (automatic is preferred) or the premeasured 1000g canister of freon which is available through our Parts Department. We must stress that it is of extreme importance to charge the system with the correct fill quantity of 1000g. Check for refrigerant leaks and fuel leaks at fuel cooler fittings.
  3. Operate the TCC system and check suction and discharge pressure as well as air temperature at center outlet in relation to the ambient temperature according to the temperature/pressure data for model 201.024 listed in S.I. MBNA 83/25 , October 1987.
    NOTE: The data is identical for model 201.028.
  4. Verify if engine and auxiliary fan cut-in simultaneously at approximately 16 bar. Also ensure correct rotation of auxiliary fan.
  5. For M.Y. 1985 through 1987 vehicles, ensure that a 25 amp solder tip fuse is installed for fuse position no. 1 (blower fuse). As of M.Y. 1988 production the 25 amp blower motor fuse was changed to a 30 amp blade fuse in an auxiliary fuse holder. Do not change these type fuses.

EQUIPMENT INFORMATION

EQUIPMENT INFORMATION

Equipment Name (1) Manufacturer/Model No.
Air conditioning evacuating and recharging system Sun Electric/SAK-500 (2) Draf/1250 (2) Kent-Moore/J23500-01 Draf/1381
(1) Available through the MB Standard Equipment Program.
(2) Preferred automatic models.

PARTS INFORMATION

PARTS INFORMATION - KIT #1 - VEHICLES AS OF M.Y. 1987

Fig. /Item Qty. Part Name Part Number
" 1 Kit #1 Vehicles as of M.Y. 1987 201 505 30 86 05
consists of: " " "
8/16 1 Shield, radiator, top 201 505 56 86
8/2 1 Shield, radiator, left 201 505 30 86
8/1 1 Shield, radiator, right 201 505 31 86
8/5 2 Shield, radiator, bottom, left & right 201 505 09 86
8/6 1 Shield, radiator, bottom middle 201 505 11 86
6/14 1 Shield, condenser, left 201 505 65 86
6/15 1 Shield, condenser, right 201 505 61 86
12/9 1 Shield, headlamp, left 201 628 10 07
11/8 1 Shield, headlamp, right 201 628 09 07
10/11 1 Foam block, radiator, top left 201 628 17 98
10/10 1 Foam block, radiator, top right 210 628 18 98
5 & 6/11 1 Metal carrier 201 835 00 22
5 & 6/10 1 Seal 210 835 12 98
" 4 Rivet 000 990 40 92
PARTS INFORMATION - KIT #1 - 1985 & 1986 VEHICLES

Fig. /Item Qty. Part Name Part Number
" 1 Kit #1 M.Y. 1985 & 1986 vehicles 201 505 30 86 06
" consists of: "
8/16 1 Shield, radiator, top 201 505 56 86
8/2 1 Shield, radiator, left 201 505 30 86
8/1 1 Shield, radiator, right 201 505 31 86
8/5 2 Shield, radiator, bottom, left & right 201 505 09 86
8/6 1 Shield, radiator, bottom middle 201 505 11 86
6/14 1 Shield, condenser, left 201 505 65 86
6/15 1 Shield, condenser, right 201 505 61 86
12/9 1 Shield, headlamp, left 201 628 14 07
11/8 1 Shield, headlamp, right 201 628 13 07
10/11 1 Foam block, radiator, top left 201 628 17 98
10/10 1 Foam block, radiator, top right 210 628 18 98
5 & 6/11 1 Metal carrier 201 835 00 22
5 & 6/10 1 Seal 210 835 12 98
" 4 Rivet 000 990 40 92
PARTS INFORMATION - KIT #2

Qty. Part Name Part Number
1 Kit #2 201 520 60 23 05
--- consists of: ---
1 Encapsulation Panel 201 520 60 23
1 Splash guard, left 201 520 42 23
1 Splash guard, right 201 520 48 23
2 Fastening clip 001 994 98 45
6 Screws 201 990 11 36
1 Closing cover 116 987 07 44
INDIVIDUAL PARTS NEEDED FOR MODIFICATION

Qty. Part Name Part Number
1 A/C hose assembly 102 130 51 57 05
1 16 bar pressure switch 004 820 07 10 05
2 O-ring seal 011 997 63 48
1 Label (vehicles up to F-385822) 124 835 00 88
1 Freon, 1000g canister Q 4 83 0187
INDIVIDUAL PARTS AS NEEDED

Qty. Part Name Part Number
1 Relay, black top 001 542 53 19
1 Connector socket (female) 002 545 29 26 or 003 545 06 26
1 Receiver-Drier 201 830 00 83
1 2/30 bar pressure switch 124 820 59 10 05
1 Evaporator temperature sensor 201 830 06 72
1 25 amp solder tip fuse 001 545 75 34
1 A/C compressor (1) 003 131 95 01
1 Condenser (up to 1F-200388) (1) 000 830 14 70 05
1 Condenser (as of 1F-200389) (1) 201 830 17 70 05
(1) These items will not require replacement in most cases. If replacement is necessary see Parts Return Information section in S.I. MBNA 83/26.

TIME ALLOWANCE

TIME ALLOWANCE INFORMATION

Operation Number Description Time Model Indicator(s)
Task A 83-0801 Refrigerant line-tubing to condenser, Replace (system discharged) 2.4 hrs. 41/47
Task B 83-0740 Receiver-drier, R & R/ Replace if required 0.3 hrs. 41/47
Task C 83-0587 Auxiliary fan high pressure switch on receiver-drier, Replace (system discharged) 0.2 hrs. 41/47
Task D 83-0584 Pressure switch on receiver-drier, Replace 0.2 hrs. 41
Task E 02-0274 Radiator/condenser shielding, install 1.6 hrs. 41/47
Task F 02-0283 Temperature sensor evaporator (ETR), Check 0.3 hrs. 41/47
Task F 83-0146 Temperature sensor evaporator (ETR), R & R/Replace if required (after test) 0.9 hrs. 41/47
Task G 02-8349 Splash guards for A/C compressor, install 0.9 hrs. 41
Task H 02-8334 Additional wiring harness, integrated engine and auxiliary fan control, install 1.2 hrs. 41
Task I 83-0510 TCC system, evacuate/leak test and range (after work on system) 0.9 hrs. 41/47

DAMAGE CODE: 83940 37 - Tempmatic Climate Control, modify.

This damage code which pertains to the above modification only, is to be used once per car to file a claim for the entire volume of work applicable to a given car.

The volume of work to be done depends upon the serial number of the vehicle and its existing modification status which must be determined by inspection.

Fig 1: A/C Compressor Bracket & Retaining Bolts
G98B57118
Fig 2: Fuel Line Connections From Fuel Cooler
G98C57119
Fig 3: A/C Compressor Bracket Installation
G98B57118
Fig 4: Refrigerant High Pressure Switch Location
G98F57120
Fig 5: Seal Placement On Carrier
G98G57121
Fig 6: Condenser With Carrier & Left & Right Shields
G98H57122
Fig 7: Condenser Installation
G98I57123
Fig 8: Radiator With Shields Connected
G98J57124
Fig 9: Right Radiator Shield Installation
G98A57125
Fig 10: Foam Blocks Installed On Top Of Radiator
G98B57126
Fig 11: Left Plastic Headlamp Shield Installation
G98C57127
Fig 12: Right Plastic Headlamp Shield Installation
G98D57128
Fig 13: New Version Evaporator Temperature Sensor Location
G98E57129
Fig 14: Headlamp Shield Modification Templates
G98H57130
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