Dodge Sprinter. Manual - part 347

FRONT A / C SYSTEM

• LOW PRESSURE GAUGE HOSE—The low

pressure hose (Blue with Black stripe) attaches to
the suction line service port. This port is located on
the suction line near the dash panel.

• HIGH PRESSURE GAUGE HOSE—The high

pressure hose (Red with Black stripe) attaches to the
discharge line service port. This port is located on the
liquid line between the condenser and the reciver-
drier.

• RECOVERY/RECYCLING/EVACUATION/

CHARGING HOSE—The center manifold hose (Yel-
low, or White, with Black stripe) is used to recover,
evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold
gauge set are opened, the refrigerant in the system
will escape through this hose.

REAR A / C SYSTEM

• LOW PRESSURE GAUGE HOSE—The low

pressure hose (Blue with Black stripe) attaches to
the suction line service port. This port is located
within the rear A/C evaporator housing near the left
side of the evaporator, below the high-pressure ser-
vice port.

• HIGH PRESSURE GAUGE HOSE—The high

pressure hose (Red with Black stripe) attaches to the
liquid line service port. This port is located within
the rear A/C evaporator housing near the left side of
the evaporator, above the low-pressure service port.

• RECOVERY/RECYCLING/EVACUATION/

REFRIGERANT SYSTEM RECOVERY

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.

A R-134a refrigerant recovery/recycling/charging

station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.

REFRIGERANT SYSTEM EVACUATE

If the refrigerant system has been open to the

atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:

(1) Connect a R-134a refrigerant recovery/recy-

cling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.

(2) Open the low and high side valves and start

the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.

(a) If the refrigerant system fails to reach the

specified vacuum, the system has a leak that must
be corrected. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING

DIAGNOSIS

AND

TESTING - REFRIGERANT SYSTEM LEAKS)

(b) If the refrigerant system maintains the spec-

ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-

ing station vacuum pump.

(4) The refrigerant system is now ready to be

charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)

REFRIGERANT SYSTEM CHARGE

24 - 64

PLUMBING

CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrig-
erant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more infor-
mation.

After the refrigerant system has been tested for

leaks and evacuated, a refrigerant charge can be
injected into the system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS - CHARGE CAPACITY)

A R-134a refrigerant recovery/recycling/charging

station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.

PARTIAL CHARGE METHOD

The partial charge method is used to add a partial

charge to a refrigerant system that is low on refrig-
erant. To perform this procedure the evaporator inlet
and outlet tube temperatures are measured. The
temperature difference is measured with a tempera-
ture meter with one or two clamp-on thermocouple
probes. The difference between the evaporator inlet
and outlet tube temperatures will determine the
amount of refrigerant needed.

Before adding a partial refrigerant charge, check

for refrigerant system leaks. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - DIAGNOSIS
AND TESTING - REFRIGERANT SYSTEM LEAKS)
If a leak is found, make the necessary repairs before
attempting a full or partial refrigerant charge.

(1) Attach a manifold gauge set to the refrigerant

system service ports.

(2) Attach the two clamp-on thermocouple probes

to the inlet and outlet tubes of the evaporator coil.

• If a single thermocouple probe is used, attach

the probe to the evaporator inlet tube just before the
collar of the refrigerant line connector fitting. The
probe must make contact with the bottom surface of
the evaporator inlet tube.

• If dual thermocouple probes are used, attach

probe 1 to the evaporator inlet tube, and probe 2 to
the evaporator outlet tube. Attach both probes to the
evaporator tubes just before the collar of the refrig-

erant line connector fittings. The probes must make
contact with the bottom surfaces of the evaporator
inlet and outlet tubes.

(3) Open all of the windows or doors of the passen-

ger compartment.

(4) Set the A/C button on the A/C Heater controls

to the on position, the temperature control knob in
the full cool position, select Recirculation Mode, and
place the blower motor switch in the highest speed
position.

(5) Start the engine and hold the engine idle speed

at 1,000 rpm. Allow the engine to warm up to normal
operating temperature.

(6) The compressor clutch may cycle, depending

upon ambient temperature, humidity, and the refrig-
erant system charge level.

(7) Hold the engine idle speed at 1,000 rpm.
(8) Allow three to five minutes for the refrigerant

system to stabilize, then record the temperatures of
the evaporator inlet and outlet tubes.

• If a single probe is used, record the temperature

of the evaporator inlet tube. Then remove the probe
from the inlet tube and attach it to the evaporator
outlet tube just before the collar of the refrigerant
line connector fitting. The probe must make contact
with the bottom surface of the evaporator outlet tube.
Allow the thermocouple and meter time to stabilize,
then record the temperature of the evaporator outlet
tube. Subtract the inlet tube temperature reading
from the outlet tube temperature reading.

• If dual probes are used, record the temperatures

of both the evaporator inlet and outlet tubes. Then
subtract the inlet tube temperature reading from the
outlet tube temperature reading.

(9) If the measured temperature differential is

higher than 22° C to 26° C (40° F to 47° F), add 0.4
kilograms (14 ounces) of refrigerant.

(10) Allow three to five minutes for the refrigerant

system to stabilize, then take a second set of thermo-
couple measurements. Record the temperature differ-
ence to determine if an additional charge is required.

(11) Record the compressor discharge pressure. If

the reading is higher than the pressure shown in the
Compressor Discharge Pressure Chart, the system
could be overcharged. If the reading is equal to, or
lower, than the pressure shown in the chart, continue
with this procedure.

Compressor Discharge Pressure Chart

Ambient Tempera-
ture

16°C

(60°F)

21°C

(70°F)

27°C

(80°F)

32°C

(90°F)

38°C

(100°F)

43°C

(110°F)

Compressor Dis-
charge Pressure

1378 kPa

(200 psi)

1516 kPa

(220 psi)

1723 kPa

(250psi)

1930 kPa

(280 psi)

2206 kPa

(320 psi)

2413 kPa

(350 psi)

PLUMBING

24 - 65

(12)

EXAMPLE: The ambient temperature is 21°

C (70° F). The evaporator inlet tube temperature is
12° C (54° F) and the evaporator outlet tube temper-
ature is 10° C (50° F). Subtract the inlet tube tem-
perature from the outlet tube temperature. The
difference is -2° C (-4° F). With a -2° C (-4° F) tem-
perature differential at 21° C (70° F) ambient tem-
perature, the system is fully charged.

(13) Add enough refrigerant to bring the refriger-

ant system up to a full charge.

(14) Remove the jumper wire from the low pres-

sure cycling clutch switch wire harness connector
and plug the connector back into the switch.

A / C COMPRESSOR

DESCRIPTION

The standard front A/C system uses a Denso

7SBU16C

seven

cylinder,

variable

displacement

swash plate-type A/C compressor (Fig. 2). This A/C
compressor has a volume control which is regulated
by an internal control valve and has both the suction
and discharge ports located at the rear of the com-
pressor.

The optional independant Konvekta rear A/C sys-

tem uses theDenso 10S17C ten cylinder, double-act-
ing swash plate-type A/C compressor (Fig. 3). This
A/C compressor has a fixed displacement of 170 cubic
centimeters (10.374 cubic inches), and has both the
suction and discharge ports located on the cylinder
head at the rear of the compressor.

A label identifying the use of R-134a refrigerant is

located on both A/C compressors.

OPERATION

The A/C compressor is driven by the engine

through an electric clutch, drive pulley and belt
arrangement. The A/C compressor is lubricated by
refrigerant oil that is circulated throughout the
refrigerant system with the refrigerant.

The A/C compressor draws in low-pressure refrig-

erant vapor from the A/C evaporator through its suc-
tion port. It then compresses the refrigerant into a
high-pressure, high-temperature refrigerant vapor,
which is then pumped to the A/C condenser through
the compressor discharge port.

The A/C compressor cannot be repaired and, if

faulty or damaged, it must be replaced. The compres-
sor clutch, pulley and bearing assembly, and clutch
field coil are available for service. If an internal fail-
ure of the A/C compressor has occurred, the receiver/
drier must also be replaced.

DIAGNOSIS AND TESTING

A / C COMPRESSOR NOISE

When investigating an air conditioning related

noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation can often be misleading.
For example: What sounds like a failed front bearing
or connecting rod, may be caused by loose bolts, nuts,

Fig. 2 Denso 7SBU16C A/C Compressor

1 - A/C COMPRESSOR (DENSO 7SBU16C)
2 - SUCTION AND DISCHARGE PORT
3 - INTERNAL CONTROL VALVE

Fig. 3 Denso 10S17C A/C Compressor

1 - A/C COMPRESSOR (DENSO 10S17C)
2 - SUCTION AND DISCHARGE PORT
3 - CYLINDER HEAD

24 - 66

PLUMBING

mounting brackets, or a loose compressor clutch
assembly.

Drive belts are speed sensitive. At different engine

speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.

(1) Select a quiet area for testing. Duplicate the

complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.

(2) Loosen all of the compressor mounting hard-

ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and pulley are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C

COMPRESSOR

CLUTCH - INSTALLATION)

(3) To duplicate a high-ambient temperature condi-

tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi).

(4) Check the refrigerant system plumbing for

incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAU-
TION

REFRIGERANT

HOSES/LINES/TUBES

PRECAUTIONS)

(5) If the noise is from opening and closing of the

high pressure relief valve, reclaim, evacuate, and
recharge the refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT

SYSTEM

EVACUATE)

(Refer

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE) If the high pressure relief valve still
does not seat properly, replace the a/c compressor.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C COMPRESSOR - REMOVAL)

(6) If the noise is from liquid slugging on the suc-

tion line, check the refrigerant oil level and the
refrigerant system charge. (Refer to 24 - HEATING
&

AIR

CONDITIONING/PLUMBING/REFRIGER-

ANT OIL - STANDARD PROCEDURE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
SPECIFICATIONS - CHARGE CAPACITY).

(7) If the noise continues, replace the compressor

and repeat Step 1.

REMOVAL

DENSO 7SBU16C A / C COMPRESSOR

NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres-
sor clutch, clutch coil or the engine.

NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.

(1) Disconnect and isolate the negative battery

cable.

(2) Recover the refrigerant from the refrigerant

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

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(3) Remove the serpentine drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/BELTS-DRIVE

REMOVAL).

(4) Disconnect the wire harness connector from the

A/C compressor clutch coil.

(5) Remove the bolts that secure the A/C suction

and discharge lines to the A/C compressor.

(6) Disconnect the A/C suction and discharge lines

from the A/C compressor and remove and discard the
O-ring seals (Fig. 4).

(7) Install plugs in, or tape over the opened refrig-

erant line fittings and the compressor ports.

(8) Raise the vehicle on a hoist.
(9) If equipped with an add-on rear A/C system,

remove the lower A/C compressor and position it out
of the way (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C

COMPRESSOR

REMOVAL - DENSO 10S17).

(10) Support the A/C compressor and remove the

compressor mounting bolts.

(11) Remove the A/C compressor from the engine

compartment.

PLUMBING

24 - 67

Content .. 345 346 347 348 ..