A/C - Ticking/Whistling Noises From Dash Area
Date: October 30, 2008Order No.: P-B-83.00/78b
Supersedes: P-B-83.00/78a dated Jan. 30, 2007
Group: 83
Revision History
SUBJECT:
Model 203.040/061/064/065/081/084/261/264/281/284/740/747/764 Up to Model Year 2004
Instructions for Stepper Motor Replacement
If you receive customer reports in the above model vehicles of a ticking noise coming from the area of the instrument panel, incorrect air distribution or whistling sounds from the vents, the cause could be malfunctioning stepper motors or damaged lever arms. Please perform the below instructions for replacing the following stepper motors and lever arms.
C-ACC, option code 581
M2/10 Left footwell flap stepper motor or lever arm
M2/19 Left fresh air flap stepper motor
M2/20 Right fresh air flap stepper motor
ACC, option code 580
M2/15 Left and right footwell flap stepper motor and lever arm
M2/21 Fresh air flap stepper motor
Diagnostic: Use SDS to confirm specific stepper motor malfunctions using the instructions below. Control units -> Air conditioning -> C-AAC, ACC -> Control unit adaptations -> Check adjustment range of positioning motors.
Any motors out of range will be shown operating in the red zone of the graphic display. There must be an out of range condition for the graphic display to appear.
If there is a ticking noise coming from the area of the instrument panel, it could be a damaged lever arm and it is not necessary to replace the footwell stepper motor. The cause of the noise may be the hex shaped drive shaft of the motor turning in a fractured lever. New updated levers are available separately in kit A203 830 00 33.
Procedure:
1. Remove the radio, refer to WIS document AR82.60-P-7502P.
2. Disassemble the center console enough to slide it back to disengage it from the bottom of the center dash, refer to WIS document AR68.20-P-2000P.
3. Remove the three screws and the right side panel from center dash; see (Figure 1). Remove by pulling straight back.
4. Remove right side air duct for rear AC panel and unclip left side duct. See (Figure 2, center dash reinforcement removed for picture).
5. Remove 4 remaining screws (7 total) for the center dash support reinforcement. To remove the reinforcement, release the two center lock tabs by inserting a large flat blade screwdriver in the right lock tab and turning it a quarter turn to release tab (Figure 3). Pull on reinforcement to release tab fully. Repeat for left lock tab. With center tabs released, pull reinforcement by the bottom right corner rearward and towards the passenger side. At the same time, clear the top center and left side locating pins (circled in Figure 1), by prying gently on the panels.
NOTE:
Use caution not to damage the center dash reinforcement A203 689 02 16 or surrounding dash panels.
6. Remove left side air duct (Figure 2).
7. Fold down foam insulation mat to expose stepper motors (Figure 4).
8. Remove the three screws to remove stepper motor (Figure 4), recommended tool 900 589 00 11 00, T-Handle Driver, Torx T20 X 200 mm.
9. If removing left footwell stepper motor M2/10, remove and inspect lever arm.
NOTE:
If the repair is for a ticking noise coming from the area of the instrument panel, it is not necessary to replace the footwell stepper motor. The cause of the noise may be the hex shaped drive shaft of the motor turning in a fractured lever. New updated levers are available separately in kit A203 830 00 33 (Figure 5).
10. Reassemble in reverse order.
11. Synchronize stepper motor.
Special Tools
Parts Information
NOTE:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on October 30, 2008. Please refer to Netstar -> Star TekInfo -> Star Time for the most current labor time allowance.
In Case of Warranty
Operation:
Short test, perform (54-1011)
Radio, R&R/replace, (82-7520)
Center dash support reinforcement, R&R (83-0000)
Step motor (M2/15) - footwell flap (auto. A/C control code 580), repl. (after test) (83-9140)
Step motor (M2/21) - ventilation flap (auto. A/C control code 580), repl. (after test) (83-9145)
Step motor (M2/10) - footwell flap (auto. climate control code 581) l/s, repl. (after test) (83-9171)
Step motor (M2/19) - ventilation flap (auto. climate control code 581) l/s, repl. (after test) (83-9176)
Step motor (M2/20) - ventilation flap (auto. climate control code 581) r/s, repl. (after test) (83-9177)
Synchronization - step motors (after repair), perform (only claimed once per RO) (83-9195)