Mercedes-Benz Sprinter / Dodge Sprinter. Manual - part 517

• The upper bolt at the front of the compressor.

• The lower bolt at the front of the compressor.

• The bolt at the rear of the compressor.
(2) If equipped with an add-on rear A/C system,

install the lower A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION - DENSO 10S17).

(3) Lower the vehicle.
(4) Remove the tape or plugs from the opened suc-

tion line fitting and the discharge line fitting and the
compressor ports.

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

refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.

(6) Connect the A/C suction and discharge lines to

the A/C compressor.

(7) Install the bolts that secure the A/C suction

and discharge lines to the A/C compressor. Tighten
the bolts to 23 N·m (17 ft. lbs.).

(8) Connect the wire harness connector to the A/C

compressor clutch coil.

(9) Install the accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

INSTALLATION).

(10) Replace the receiver/drier if the A/C compres-

sor is being replaced due to an internal failure (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER/DRIER - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - INSTALLATION).

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

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

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

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

DENSO 10S17 A / C COMPRESSOR

NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.

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

(1) Position the A/C compressor in the engine com-

partment and loosely install the three compressor

retaining bolts. Tighten the bolts using the following
sequence to 20 N·m (14 ft. lbs.).

• The upper bolt at the front of the compressor.

• The lower bolt at the front of the compressor.

• The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened

underbody suction and discharge line fittings and
compressor ports.

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

(4) Connect the underbody suction and discharge

lines to the A/C compressor.

(5) Install the bolts that secure the underbody suc-

tion and discharge lines to the A/C compressor.
Tighten the bolts to 21 N·m (15 ft. lbs.).

(6) Connect the wire harness connector to the A/C

compressor clutch coil.

(7) Install the accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/BELTS-DRIVE

INSTALLATION).

(8) Lower the vehicle.
(9) Replace the receiver/drier if the A/C compressor

is being replaced due to an internal failure (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
CEIVER/DRIER - INSTALLATION).

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

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

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

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

A / C CONDENSER

DESCRIPTION

The condenser is located in the air flow in front of

the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.

OPERATION

When the refrigerant gas gives up its heat, it con-

denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that

PLUMBING

24 - 69

there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.

The condenser cannot be repaired and, if faulty or

damaged, it must be replaced.

REMOVAL

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) 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 front fascia.
(4) Remove the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - REMOVAL).

(5) Remove the headlamps from their mounts.
(6) Remove the radiator crossmember (Refer to 23

- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).

(7) Disconnect the A/C discharge and liquid lines

from the A/C condenser and remove and discard the
O-ring seals (Fig. 6).

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

line fitting and the condenser ports.

(9) Disconnect the wire harness connector from the

auxiliary fan.

(10) Remove the auxiliary fan and upper bracket

assembly.

(11) Remove

the

auxiliary

fan

lower

bracket

retainers and bracket.

(12) Remove the four condenser retaining screws.
(13) Carefully remove the condenser from the vehi-

cle.

INSTALLATION

NOTE: If the A/C condenser 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) Carefully position the A/C condenser into the

engine compartment.

(2) Install the four screws that secure the A/C con-

denser. Tighten the screws to 2 N·m (17 in. lbs.).

(3) Install the lower auxiliary fan bracket and

retaining nuts. Tighten the nuts to 5 N·m (45 in.
lbs.).

(4) Install the auxiliary fan and upper bracket

assembly. Tighten the screws to 5 N·m (45 in. lbs.).

(5) Connect the wire harness connector to the aux-

iliary fan.

(6) Remove the tape or plug from the condenser

ports and the opened refrigerant line fittings.

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

refrigerant oil and install it on the refrigerant line
fittings.

(8) Connect the A/C discharge and liquid lines to

the A/C condenser.

Fig. 6 A/C Condenser

1 - SCREW (4)
2 - CONDENSER
3 - LIQUID REFRIGERANT LINE
4 - COMPRESSOR DISCHARGE LINE
5 - NUT (2)
6 - LOWER AUXILIARY FAN BRACKET
7 - NUT (2)
8 - WIRE HARNESS CONNECTOR
9 - AUXILIARY COOLING FAN
10 - SCREW (2)

24 - 70

PLUMBING

(9) Install the nuts that secure the A/C discharge

and liquid lines to the A/C condenser. Tighten the
nuts to 33 N·m (24 ft. lbs.).

(10) Install the radiator crossmember (Refer to 23

- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).

(11) Install the headlamps into their mounts.
(12) Install the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - INSTALLATION).

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

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

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

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

A / C DISCHARGE LINE

REMOVAL

(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 RECOVERY).

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

RIOR/GRILLE - REMOVAL).

(4) Remove the nut that secures the discharge line

fitting to the condenser on the left side of the con-
denser.

(5) Disconnect the discharge line fitting from the

condenser inlet port.

(6) Remove the seal from the discharge line fitting

and discard.

(7) Install plug in, or tape over the opened dis-

charge line fitting and the condenser inlet port.

(8) Remove the bolt that secures the discharge line

fitting to the top of the compressor (Fig. 7).

(9) Disconnect the discharge line fitting from the

compressor discharge port.

(10) Remove the seal from the discharge line fit-

ting and discard.

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

charge line fitting and the compressor discharge port.

(12) Disconnect the discharge line from the retain-

ing clip and remove the discharge line from the vehi-
cle.

INSTALLATION

Any kinks or sharp bends in the refrigerant plumb-

ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.

(1) Position the discharge line into the engine com-

partment.

(2) Remove the tape or plugs from the compressor

discharge port and the discharge line fitting.

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

refrigerant oil and install it on the discharge line fit-
ting.

(4) Connect the discharge line fitting to the com-

pressor discharge port on the top of the compressor.

(5) Install the bolt that secures the discharge line

fitting to the compressor. Tighten the bolt to 23 N·m
(17 ft. lbs.).

Fig. 7 A/C Compressor - Refrigerant Lines

1 - A/C COMPRESSOR
2 - O-RING SEAL
3 - A/C SUCTION LINE
4 - BOLT
5 - RETAINING CLIP
6 - BOLT
7 - A/C DISCHARGE LINE
8 - O-RING SEAL

PLUMBING

24 - 71

(6) Remove the tape or plugs from the condenser

inlet port and the discharge line fitting.

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

refrigerant oil and install it on the discharge line fit-
ting.

(8) Connect the discharge line fitting to the con-

denser inlet port.

(9) Install the nut that secures the discharge line

fitting to the condenser. Tighten the nut to 33 N·m
(24 ft. lbs.).

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

RIOR/GRILLE - INSTALLATION).

(11) Evacuate the refrigerant system. (Refer to 24 -

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

(12) Charge the refrigerant system. (Refer to 24 -

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

(13) Reconnect the negative battery cable.

A / C EVAPORATOR

DESCRIPTION

The A/C evaporator for the heating-A/C system is

located within the HVAC housing, behind the instru-
ment panel (Fig. 8). The A/C evaporator is positioned
within the HVAC housing so that all air entering the
housing must pass over the evaporator fins before it
is distributed through the heating-A/C system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the A/C compres-
sor is engaged and circulating refrigerant through
the A/C evaporator.

The A/C evaporator tubes are connected and sealed

to the A/C expansion valve by use of rubber O-rings
and a tapping block.

The A/C evaporator is serviced by removing and

disassembling the HVAC housing.

OPERATION

Refrigerant enters the evaporator from the expan-

sion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas
before it leaves the evaporator.

The evaporator 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. 8 Front A/C Evaporator

1 - A/C EVAPORATOR
2 - EVAPORATOR TUBES
3 - TAPPING BLOCK

24 - 72

PLUMBING

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