Mercedes-Benz Sprinter / Dodge Sprinter. Service manual - part 519

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) Remove the heater housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).

(2) Disassemble the HVAC housing to access the

heater core (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).

(3) Lift the heater core out of the lower half of the

HVACr housing (Fig. 15).

(4) If necessary, remove the three heater core tube

retaining bolts and the heater core tube assembly
from the heater core.

(5) Remove the heater core tube seals and discard

as required.

INSTALLATION

(1) If the heater core tube assembly was removed

from the heater core, lubricate two new rubber
O-ring seals with clean engine coolant and install
them onto the heater core fitting.

(2) If required, connect the heater core tube

assembly to the heater core and install the three
retaining bolts. Tighten the bolts to 5 N·m (45 in.
lbs.).

(3) Install the heater core into the bottom half of

the HVAC housing.

(4) Assemble the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).

NOTE: If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/RE-
VERSE FLUSHING).

(5) Install the HVAC housing (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).

LIQUID LINE

REMOVAL

NOTE: The A/C liquid line is serviced in two sec-
tions. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure sensor
on the fitting for the receiver/drier. The rear section
connects between the receiver/drier and the A/C
expansion valve.

FRONT SECTION

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Disconnect and isolate they negative batter

cable.

(3) Remove the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - REMOVAL).

Fig. 15 HVAC Housing

1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)

PLUMBING

24 - 77

(4) Remove the nut that secures the A/C liquid line

to the A/C condenser.

(5) Disconnect the A/C liquid line to the A/C con-

denser and remove and discard the O-ring seal.

(6) Install plug in, or tape over the opened liquid

line fitting and the condenser outlet port.

(7) Remove the routing clip retaining nut and dis-

engage the routing clip retainer on top of the left
frame rail from the front section of the liquid line.

(8) Remove the A/C pressure sensor from the front

liquid line fitting (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C

PRESSURE

TRANSDUCER - REMOVAL).

(9) Remove the bolt that secures the front section

of the liquid line to the top of the receiver/drier (Fig.
16).

(10) Disconnect the front section of the liquid line

from the receiver/drier and remove and discard the
O-ring seal.

(11) Install plug in, or tape over the opened liquid

line fitting and the receiver/drier inlet port.

(12) Remove the front section of the A/C liquid line

from the engine compartment.

REAR SECTION

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE - REFRIGERANT SYSTEM RECOV-
ERY).

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - REMOVAL).

(4) Remove the nut that secures the A/C suction

and liquid lines to the stud on the A/C expansion
valve (Fig. 17).

(5) Disconnect the A/C suction and liquid lines

from the A/C expansion valve and remove and dis-
card the O-ring seals.

(6) Disengage the routing clip retainer from the

rear section of the A/C liquid line.

(7) Remove the bolt that secures the rear section

of the liquid line to the top of the receiver/drier (Fig.
16).

(8) Disconnect the rear section of the liquid line

from the receiver/drier.

(9) Remove the seal from the liquid line fitting

outlet port and discard.

(10) Install plugs in, or tape over the opened liquid

and suction line fittings, both receiver/drier ports and
both expansion valve ports.

(11) Remove the rear section of the liquid line from

the engine compartment.

Fig. 16 Receiver-Drier

1 - RECEIVER/DRIER
2 - A/C LIQUID LINE (REAR SECTION)
3 - A/C PRESSURE TRANSDUCER
4 - A/C LIQUID LINE (FRONT SECTION)
5 - CLAMP

Fig. 17 A/C Expansion Valve

1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE
4 - BOLT (2)
5 - A/C SUCTION LINE
6 - NUT
7 - A/C LIQUID LINE
8 - O-RING SEAL (2)

24 - 78

PLUMBING

INSTALLATION

NOTE: The A/C liquid line is serviced in two sec-
tions. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure trans-
ducer on the fitting for the receiver/drier. The rear
section connects between the receiver/drier and the
A/C expansion valve.

FRONT SECTION

(1) Position the front section of the A/C liquid line

into the engine compartment.

(2) Remove the tape or plugs from the liquid line

fitting and the receiver/drier inlet port.

(3) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the liquid line fitting.

(4) Connect the front section of the liquid line to

the receiver/drier.

(5) Install the bolt that secures the liquid line fit-

ting to the receiver/drier. Tighten the bolt to 7 N·m
(62 in. lbs.).

(6) Position the front section of the liquid line into

the routing clip and install the routing clip onto the
body stud on the left frame rail.

(7) Install the routing clip retaining nut. Tighten

the nut to 5 N·m (45 in. lbs.).

(8) Remove the tape or plugs from the condenser

outlet port and the liquid line fitting.

(9) Lubricate a new O-ring seal with clean refrig-

erant oil and install it on the liquid line fitting.

(10) Connect the liquid line fitting to the con-

denser outlet port on the right side of the condenser.

(11) Install the nut that secures the liquid line fit-

ting to the condenser. Tighten the nut to 17 N·m (12
ft. lbs.).

(12) Reinstall the A/C pressure transducer (Refer

to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C PRESSURE TRANSDUCER - INSTAL-
LATION).

(13) Install the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - INSTALLATION).

(14) Reconnect the battery negative cable.
(15) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM EVACUATE).

(16) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM CHARGE).

REAR SECTION

(1) Position the rear section of the A/C liquid line

into the engine compartment.

(2) Remove the tape or plugs from the liquid and

suction line fittings, the receiver/drier outlet port and
both expansion valve ports.

(3) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them onto the suction and
liquid line fittings for the expansion valve.

(4) Connect the liquid line and suction line fittings

to the A/C expansion valve.

(5) Install the nut that secures the suction line

and liquid line fittings to the stud on the A/C expan-
sion valve. Tighten the nut to 10 N·m (89 in. lbs.).

(6) Lubricate new rubber O-ring seal with clean

refrigerant oil and install it on the liquid line fitting.

(7) Connect the liquid line fitting to the receiver/

drier outlet port.

(8) Install the bolt that secures the liquid line fit-

ting to the receiver/drier. Tighten the bolt to 7 N·m
(62 in. lbs.).

(9) Install the routing clip retainer to the rear sec-

tion of the liquid line.

(10) Install the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - INSTALLATION).

(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM EVACUATE).

(13) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM CHARGE).

RECEIVER / DRIER

DESCRIPTION

The receiver/drier is mounted in a bracket secured

to the left front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the A/C liquid line between
the condenser outlet and the evaporator inlet.

The receiver/drier cannot be repaired. If the receiv-

er/drier is faulty or damaged, or if the refrigerant
system has been contaminated or left open to the
atmosphere for an indeterminable period or if the
compressor has failed, it must be replaced.

OPERATION

The receiver/drier performs a filtering action to

prevent foreign material in the refrigerant from con-
taminating the A/C expansion valve. Refrigerant
enters the receiver/drier as a high-pressure, low tem-
perature liquid. Desiccant inside the receiver/drier
absorbs any moisture which may have entered and
become trapped within the refrigerant system. In
addition, during periods of high demand operation of
the A/C system, the receiver/drier acts as a reservoir
to store surplus refrigerant.

PLUMBING

24 - 79

The receiver/drier cannot be repaired. If the receiv-

er/drier is faulty or damaged, or if an internal failure
of the A/C compressor has occurred, the receiver/drier
must be replaced.

REMOVAL

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Remove the bolts that secure the front and rear

sections of the A/C liquid line to the top of the receiv-
er/drier (Fig. 18).

(3) Disconnect the liquid line fittings from the

receiver/drier and remove and discard the O-ring
seals.

(4) Install a plug in, or tape over the opened liquid

line fittings and the receiver/drier ports.

(5) Loosen the clamp that secures the receiver/

drier to the mounting bracket.

(6) Remove the receiver/drier from the engine com-

partment.

INSTALLATION

NOTE: If the receiver/drier is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.

(1) Position the receiver/drier onto the mounting

bracket on the front left strut tower.

(2) Tighten the clamp that secures the receiver/

drier to the mounting bracket.

(3) Remove the tape or plugs from the liquid line

fittings and the receiver/drier ports.

(4) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them on the liquid line fit-
tings.

(5) Connect the front and rear sections of the liq-

uid line to the receiver/drier.

(6) Install the bolts that secures the liquid line fit-

tings to the receiver/drier. Tighten the bolts to 7 N·m
(62 in. lbs.).

(7) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

(8) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

REFRIGERANT

DESCRIPTION

The refrigerant used in this air conditioning sys-

tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.

Even though R-134a does not contain chlorine, it

must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.

OPERATION

R-134a refrigerant is not compatible with R-12

refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.

R-134a refrigerant system service ports, service

tool couplers and refrigerant dispensing bottles have

Fig. 18 Receiver/Drier

1 - RECEIVER/DRIER
2 - A/C LIQUID LINE (REAR SECTION)
3 - A/C PRESSURE TRANSDUCER
4 - A/C LIQUID LINE (FRONT SECTION)
5 - CLAMP

24 - 80

PLUMBING

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