Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 523

INSTALLATION

CONDENSER TO RECEIVER / DRIER

(1) Remove the tape or plugs from the rear liquid

line fittings and receiver/drier and condenser ports.

(2) Lubricate new O-ring seals with clean refriger-

ant oil and install them onto the rear liquid line fit-
tings. Use only the specified O-ring seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.

(3) Connect the rear liquid line to the rear receiv-

er/drier. Tighten the nut to 35 N·m (26 ft. lbs.).

(4) Connect the rear liquid line to the rear A/C

condenser. Tighten the nut to 35 N·m (26 ft. lbs.).

(5) Install the retaining straps that secure the rear

A/C wire harness to the rear liquid line.

(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to

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

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

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

(9) Install the rear air filter (Refer to 24 - HEAT-

ING

&

AIR

CONDITIONING/DISTRIBUTION

-

REAR/AIR FILTER - INSTALLATION).

(10) Install the cover onto the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - INSTALLATION).

RESERVOIR TO EXPANSION VALVE

(1) Remove the tape or plugs from the rear liquid

line fittings and the reservoir and expansion valve
ports.

(2) Lubricate new O-ring seals with clean refriger-

ant oil and install them onto the rear liquid line fit-
tings. Use only the specified O-ring seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.

(3) Connect the rear liquid line to the rear A/C

expansion valve. Tighten the nut to 35 N·m (26 ft.
lbs.).

(4) Route the liquid line through the opening in

the roof and engage the grommet to the roof panel.

(5) Connect the rear liquid line to the rear refrig-

erant reservoir. Tighten the nut to 35 N·m (26 ft.
lbs.).

(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to

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

Fig. 32 Rear Liquid Line - Reservoir to Expansion Valve

1 - GROMMET
2 - LIQUID LINE (TO EXPANSION VALVE)

3 - REAR REFRIGERANT RESERVOIR
4 - REAR A/C EXPANSION VALVE

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PLUMBING

24 - 93

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

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

(9) Install the cover onto the rear A/C evaporator

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).

(10) Install the cover onto the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - INSTALLATION).

REAR RECEIVER / DRIER

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) Remove the air filter from the rear A/C evapo-

rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).

(3) Recover the refrigerant from the rear refriger-

ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).

(4) Remove the cover from the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - REMOVAL).

(5) Disconnect the rear refrigerant reservoir from

the rear receiver/drier and remove and discard the
O-ring seal (Fig. 33).

(6) Disconnect the liquid line from the rear receiv-

er/drier and remove and discard the O-ring seal.

(7) Remove the bolt and retaining bracket that

secures the rear receiver/drier to the rear A/C con-
denser housing and remove the receiver/drier.

(8) Install plugs into, or tape over the opened rear

liquid line fitting and reservoir and receiver/drier
ports.

INSTALLATION

NOTE: Be certain to add refrigerant oil if the rear
receiver/drier is being replaced. The refrigerant oil
must be drained from the old receiver/drier and
measured to determine the amount of refrigerant oil
to add to the new receiver/drier. Use only refriger-
ant oil of the type recommended for the rear A/C
compressor in the vehicle.

(1) If the rear receiver/drier is being replaced,

install the correct amount and type of refrigerant oil
into the new rear receiver/drier. Drain the old receiv-
er/drier and measure the refrigerant oil. Fill the new
receiver/drier with the same amount of new refriger-
ant oil that was drained out of the old receiver/drier.

NOTE: The rear receiver/drier is labeled with a
direction-of-flow arrow to indicate refrigerant flow
through the receiver/drier. Make sure to properly
install the rear receiver/drier in the correct direc-
tion.

(2) Position the rear receiver/drier to the rear A/C

condenser housing and install the retaining bracket
and bolt. Tighten the bolt to 25 N·m (18 ft. lbs.).

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

line fitting and reservoir and receiver/drier ports.

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

erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only

Fig. 33 Rear Receiver/Drier

1 - REAR A/C CONDENSER HOUSING
2 - REFRIGERANT RESEVOIR
3 - REAR RECEIVER/DRIER
4 - BOLT
5 - LIQUID LINE
6 - RETAINING BRACKET

24 - 94

PLUMBING

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refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.

(5) Connect the rear liquid line to the rear receiv-

er/drier. Tighten the nut to 35 N·m (26 ft. lbs.).

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

erant oil and install it onto the receiver/drier outlet
fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.

(7) Connect the rear refrigerant reservoir to the

rear receiver/drier. Tighten the nut to 35 N·m (26 ft.
lbs.).

(8) Reconnect the negative battery cable.
(9) Evacuate the rear refrigerant system (Refer to

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

(10) Charge the rear refrigerant system (Refer to

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

(11) Install the rear air filter (Refer to 24 - HEAT-

ING

&

AIR

CONDITIONING/DISTRIBUTION

-

REAR/AIR FILTER - INSTALLATION).

(12) Install the cover onto the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - INSTALLATION).

REAR REFRIGERANT RESER-
VOIR

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) Remove the air filter from the rear A/C evapo-

rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).

(3) Recover the refrigerant from the rear refriger-

ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).

(4) Remove the cover from the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-

TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - REMOVAL).

(5) Disconnect the rear liquid line from the rear

refrigerant reservoir and remove and discard the
O-ring seal (Fig. 34).

(6) Disconnect the rear refrigerant reservoir from

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

(7) Remove the bolt and retaining bracket that

secures the rear refrigerant reservoir to the rear A/C
condenser housing and remove the reservoir.

(8) Install plugs into, or tape over the opened rear

liquid line fitting and receiver/drier and reservoir
ports.

INSTALLATION

NOTE: Be certain to add refrigerant oil if the rear
refrigerant reservoir is being replaced. The refriger-
ant oil must be drained from the old refrigerant res-
ervoir and measured to determine the amount of
refrigerant oil to add to the new reservoir. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.

(1) If

the

rear

refrigerant

reservoir

is

being

replaced, install the correct amount and type of
refrigerant oil into the new rear refrigerant reservoir.
Drain the old refrigerant reservoir and measure the
refrigerant oil. Fill the new refrigerant reservoir with
the same amount of new refrigerant oil that was
drained out of the old reservoir.

Fig. 34 Rear Refrigerant Reservoir

1 - REAR A/C CONDENSER HOUSING
2 - LIQUID LINE
3 - REAR REFRIGERANT RESERVOIR
4 - BOLT
5 - REAR RECEIVER/DRIER
6 - RETAINING BRACKET

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PLUMBING

24 - 95

(2) Install a new rear receiver/drier (Refer to 24 -

HEATING

&

AIR

CONDITIONING/PLUMBING/

REAR RECEIVER/DRIER - INSTALLATION).

(3) Position the rear refrigerant reservoir to the

rear A/C condenser housing and install the retaining
bracket and bolt. Tighten the bolt to 25 N·m (18 ft.
lbs.).

(4) Remove the tape or plugs from the rear liquid

line fitting and receiver/drier and reservoir ports.

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

erant oil and install it onto the rear receiver/drier fit-
ting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.

(6) Connect the rear receiver/drier to the rear

refrigerant reservoir. Tighten the nut to 35 N·m (26
ft. lbs.).

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

erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.

(8) Connect the rear liquid line to the rear refrig-

erant reservoir. Tighten the nut to 35 N·m (26 ft.
lbs.).

(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to

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

(11) Charge the rear refrigerant system (Refer to

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

(12) Install the rear air filter (Refer to 24 - HEAT-

ING

&

AIR

CONDITIONING/DISTRIBUTION

-

REAR/AIR FILTER - INSTALLATION).

(13) Install the cover onto the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

-

REAR/A/C

CON-

DENSER COVER - INSTALLATION).

REAR SUCTION LINE

DESCRIPTION

The rear A/Csuction line is the refrigerant line that

carries refrigerant from the rear A/C evaporator to
the A/C underbody suction line (Fig. 35). The rear
A/C suction line is retained to the left quarter panel
by two plastic retaining clips.

CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrig-
erant system connections to leak.

The rear A/C suction line has no serviceable parts

except for the O-ring seals. The O-ring seals used on
the connections are made from a special type of rub-
ber not affected by R-134a refrigerant and must be
replaced whenever the rear A/C suction line is
removed and installed.

If the rear A/C suction line is found to be leaking

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) Remove the cover from the rear A/C evaporator

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - REMOVAL).

(3) Recover the refrigerant from the rear refriger-

ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).

(4) Remove the insulating tape from around the

area of the rear A/C suction line and evaporator out-
let tube (Fig. 36).

Fig. 35 Rear A/C Suction Line

1 - REAR A/C SUCTION LINE
2 - TO UNDERBODY SUCTION LINE
3 - RETAINING CLIPS
4 - LEFT INNER QUARTER PANEL
5 - TO REAR A/C EVAPORATOR

24 - 96

PLUMBING

VA