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2000 E320 No AC (broken clutch wire)

7.2K views 4 replies 3 participants last post by  mrboca  
#1 ·
2000 e320 4matic 124k miles. air conditioner seems to just stooped working without warning. After a while the EC switch no longer turns the led on/off, it just stayed on. The ac compressor does not engage.

ac fault code 419, 234, 411, 419, 241 were found from the self diagnostics, and Code 7 Refrigerant Pressure is 5. Hooked up a gauge on the low pressure side and it reads 95psi (75F), similar to the 85 psi on a 2006 sprinter, so I resisted putting in more R134a.

After a couple hours of reading all related ac issues, it seems testing the ac compressor clutch is the next step. I had to rely on photo of a replacement ac compressor to locate the clutch connector since the its not visible from above, or under the engine even with both under engine splash guard removed, as the chassis frame blocks the view from underneath.

Since there are no photos of the connector available, I had considered removing the power steering pump just to get to see the wiring connector of the ac compressor. There is a 20 min youtube video that show how to remove the power steering pump and reservoir. but I resisted doing it after I got the belt off as its more than I want to try.

From the various online photos and by feel of the connector that I can not see, I deduced from the compressor side the single wire connector just press into the slot on the ac compressor. So after quite a few tries, I managed to prey out the connecter, which seems to mate with broken blue wire next to it (see photo).

The white tab that holds the pin in placed can be removed to slide out the center pin. I soldered a piece of wire to the connector, and then soldered the wires together. The AC works now.

Since it took me almost 6 hours to find this easy fix, I thought others might benefit.
 

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#3 · (Edited)
Looks like that might be another case where manufacturer puts the wire inside the conduit, but don't connect conduit to the plug, therefore the wire has to support conduit weight.
With age the plastic insulation deteriorate and vibration will make wire fatigue
I had several problems with wire like that and now when I work on the engine, I put a dap of marine caulk on those wires.
 
#4 ·
I would guess its fatigue as well, as the ac compressor side has been working since new without any service, and not a trace of oil anywhere outside the compressor itself...

Other than replacing fan speed control resistor and a stuck plastic button of the temperature up control that had to be filed down in its early year, the factory ac had been working and holding the freon charge for 16 years...