Mercedes-Benz Sprinter / Dodge Sprinter. Manual - part 527

(3) Remove clamp from the fuel line at the fuel

tank connection and separate the line from the tank.

(4) Remove any retaining clips and remove the

fuel line from vehicle.

INSTALLATION

WARNING: Do not operate the diesel supplemental
cabin heater in an enclosed area such as a garage
that does not have exhaust ventilation facilities.
Always vent the cabin heater exhaust when operat-
ing the cabin heater. Allow the diesel supplemental
cabin heater to cool before performing any service
procedures to the cabin heater. Verify that all diesel
supplemental cabin heater fuel lines are securely
fastened to their respective components before per-
forming any service procedures to the cabin heater.
Failure to follow these warnings may result in pos-
sible personal injury or death.

NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle’s fuel tank before performing this
procedure. Add fuel, if necessary.

(1) Install the cabin heater fuel supply line into

vehicle and fuel line retainers.

(2) Install the fuel line connection at the fuel tank

and tighten the connection securely.

(3) Install the fuel line at the dosing pump and

tighten the connection securely.

(4) Lower the vehicle.

NOTE: Failure to prime the dosing pump after drain-
ing the supplemental cabin fuel line will prevent
cabin heater activation during the first attempt to
start the cabin heater. This will also set a diagnostic
trouble code (DTC) in the cabin heater control’s
memory. Do not perform the Dosing Pump Priming
procedure if an attempt was made to start the cabin
heater without priming the dosing pump first. This
will put excess fuel in the cabin heater and cause
smoke to emit from the cabin heater exhaust pipe
when cabin heater activation occurs.

(5) Connect the DRBIII

t scan tool to the diagnos-

tic link connector.

(6) Turn the ignition to the ON position.

NOTE: Do not activate the dosing pump prime more
than one time. This will put excess fuel in the sup-
plemental cabin heater and cause smoke to emit
from the cabin heater exhaust pipe when cabin
heater activation occurs.

NOTE: A clicking noise heard coming from the dos-
ing pump indicates that the pump is operational.

Fig. 3 Cabin Heater Dosing Pump Fuel Line

1 - FUEL LINE
2 - RETAINING CLAMP

3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE

CABIN HEATER

24 - 109

(7) With the DRBIII

t scan tool in Cabin Heater,

select System Tests and Dosing Pump Prime. Allow
the dosing pump to run for the full 45 second cycle
time. When the 45 second cycle is complete, press
Page Back on the DRBIII

t scan tool key pad to exit

the Dosing Pump Prime. The Dosing Pump Priming
procedure is now complete.

HEATER UNIT

REMOVAL

HEATER UNIT

(1) Raise and support the vehicle. Take note of the

location of the flexible section of the cabin heater
exhaust tube.

(2) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).

(3) Carefully open one hose to the underbody tube

assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the cabin heater and the
hose and tube assemblies.

(4) Remove the second hose from the underbody

hose and tube assembly.

(5) Loosen the hose and tube assembly from the

toe-board crossmember at two locations.

(6) Disconnect the electrical connector from the

body harness near the toe-board crossmember and
rail.

(7) Remove the wiring harness from the toe-board

crossmember (Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN

HEATER/HEATER

UNIT

REMOVAL - WIRE HARNESS).

(8) Open the fuel filler cap. Disconnect the rubber

fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.

NOTE: Utilize an approved fuel storage container to
catch any residual fuel.

(9) Loosen the two fasteners at the rail. Take care

to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.

(10) Remove the flexible section of the cabin

heater exhaust tube from the exhaust tube by loos-
ening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).

(11) Remove seat hex nut at the heater mounting

flange to crossmember.

(12) Loosen the remaining fasteners which mount

the exhaust tube assembly to the vehicle.

(a) Install a suitable support device under the

cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the

crossmembers.

(14) Remove the loosened fasteners that support

the cabin heater while supporting the weight of the
heater.

(15) Swing the cabin heater mounting bracket

from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.

(16) Remove the cabin heater from the vehicle.

WIRE HARNESS

(1) Raise and support the vehicle while taking note

of the location of the flexible exhaust tube section.

(2) Disconnect the cabin heater wire harness con-

nector from the vehicle wiring harness.

(3) Disconnect the cabin heater wire harness con-

nector from the dosing pump.

(4) Disconnect the two cabin heater wire harness

connectors from the cabin heater controller.

(5) Remove two wiring harness retainers from the

underbody.

(6) Remove two wiring harness retainers from the

cabin heater shield.

(7) Carefully route the cabin heater wire harness

out the left side between the heater unit and the
heater shield.

INSTALLATION

HEATER UNIT

(1) Install the cabin heater mounting bracket

between the exhaust bracket and the rail mounting
location.

(2) Support the cabin heater and install the fasten-

ers that secure the cabin heater to the mounting
bracket.

(3) Install the three fasteners to the crossmem-

bers. Tighten the M6 fasteners to 7 N·m (62 in. lbs.).

24 - 110

CABIN HEATER

(4) Position the two spacer washers between the

body and the rubber grommets for the two mounting
points on the rail.

(5) Tighten the remaining M6 fasteners to 7 N·m

(62 in. lbs.) and the M8 fasteners to 23 N·m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.

(6) Install the seat hex nut at the heater mounting

flange to the crossmembers. Tighten the nut to 60
N·m (44 ft. lbs.)

(7) Install the flexible section of the cabin heater

exhaust tube to the exhaust tube. Tighten the M6
bolt of the clamp securley. Install the hose to the
exhaust tube.

(8) Tighten the two M8 fasteners at the rail to 23

N·m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.

(9) Install the wiring harness (Refer to 24 - HEAT-

ING

AIR

CONDITIONING/CABIN

HEATER/

HEATER

UNIT

INSTALLATION

WIRE

HARNESS).

(10) Tighten the hose and tube assembly to the

toe-board crossmember at two locations.

(11) Install the second hose to the underbody hose

and tube assembly.

(12) Connect the rubber fuel hose between the

body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.

(13) Remove the cabin heater support device from

under the vehicle.

(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).

(16) Verify function of the heater unit.

WIRE HARNESS

(1) Carefully route the cabin heater wire harness

from the left side between the heater unit and the
heater shield.

(2) Install the two wiring harness retainers to the

cabin heater shield.

(3) Route the wiring harness along the underside

of the vehicle and install the two wiring harness
retainers to the underbody.

(4) Connect the two cabin heater wire harness con-

nectors to the cabin heater controller.

(5) Connect the cabin heater wire harness to the

dosing pump.

(6) Connect the cabin heater wire harness connec-

tor to the vehicle wiring harness.

(7) Lower the vehicle.
(8) Verify function of the heater unit.

INLET HOSE

REMOVAL

NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.

(1) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - DRAINING
COOLING STSTEM).

(2) Remove clamps from the cabin heater tubes at

the lower heater port and the lower EGR connector
which are located under the hood.

(3) Remove the retaining clamp at the cabin

heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).

(4) Remove the clamp at the flexible tube to steel

tube connection (Fig. 4).

(5) Remove the two retaining screws and remove

pipe assembly (Fig. 5).

Fig. 4 Cabin Heater Flexible Air Intake Line

1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE

CABIN HEATER

24 - 111

INSTALLATION

(1) Install the air intake pipe assembly and install

the two retaining screws. Tighten the screws to 7
N·m (62 in. lbs.).

(2) Attach the steel tube to the flexible tube and

position

and

then

tighten

the

retaining

clamp

securely.

(3) Install the flexible tube to the cabin heater air

intake muffler and install and tighten the retaining
clamp securely.

(4) Install the cabin heater tubes to the lower

heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.

(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).

(7) Verify function of the heater unit.

Fig. 5 Cabin Heater Air Intake And Heater Pipe

Assembly

1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE

24 - 112

CABIN HEATER

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