Content .. 348 349 350 351 ..

Dodge Sprinter. Manual - part 350

INSTALLATION

(1) Install the electric coolant pump and mounting

bracket onto the body studs.

(2) Install the two bracket retaining nuts. Tighten

the nuts to 5 N·m (45 in. lbs.).

(3) Using a twisting motion gently install both

hoses onto the electric coolant pump.

(4) Tighten both hose clamps securely.
(5) Connect the wire harness connector to the elec-

tric coolant pump.

(6) Reconnect the negative battery cable.
(7) Fill the engine cooling system (Refer to 7 -

COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE - COOLING SYSTEM FILL).

HEATER CORE

DESCRIPTION

The heater core is mounted into the HVAC hous-

ing, located behind the instrument panel (Fig. 14).
The heater core is a heat exchanger made of rows of
tubes and fins. The heater core tubes are attached to
the heater core by using O-ring seals and bolts.

The heater core is serviced by removing and disas-

sembling the HVAC housing.

OPERATION

Engine coolant is circulated through the heater

hoses to the heater core whenever the heater water
valve is cycled open by the ATC A/C-heater control.
As the coolant flows through the heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
heater water valve controls the heater output air
temperature by controlling the amount of heated
engine coolant flowing through the heater core. The
blower motor speed controls the volume of air flowing
through the HVAC housing.

The heater core cannot be repaired and, if faulty or

damaged, it must be replaced.

REMOVAL

WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental

restraint

system

before

attempting

any

steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.

Fig. 13 Electric Coolant Pump

1 - HEATER HOSE
2 - HOSE CLAMP (2)
3 - HEATER HOSE
4 - ELECTRIC COOLANT PUMP
5 - WIRE HARNESS CONNECTOR
6 - NUT (2)

Fig. 14 Front Heater Core

1 - HEATER CORE
2 - BOLT (3)
3 - HEATER CORE TUBES
4 - O-RING SEALS

24 - 76

PLUMBING

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

Content .. 348 349 350 351 ..