Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 520

all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.

REFRIGERANT OIL

DESCRIPTION

The refrigerant oil used in R-134a refrigerant sys-

tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.

There are different PAG oils available, and each

contains a different additive package. The A/C com-
pressors for this vehicle are designed to use an ND-8
PAG refrigerant oil. Use only the refrigerant oil of
this type to service the refrigerant system.

OPERATION

After performing any refrigerant recovery or recy-

cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.

PAG refrigerant oil is much more hygroscopic than

mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.

STANDARD PROCEDURE

REFRIGERANT OIL LEVEL

When an A/C system is assembled at the factory,

all components except the compressor are refrigerant
oil free. After the refrigerant system has been
charged and operated, the refrigerant oil in the com-
pressor is dispersed throughout the refrigerant sys-
tem. The receiver-drier, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.

It is important to have the correct amount of oil in

the refrigerant system. This ensures proper lubrica-
tion of the A/C compressor. Too little oil will result in
damage to the A/C compressor. Too much oil will
reduce the cooling capacity of the A/C system.

It will not be necessary to check the oil level in the

A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or

leak from a refrigerant line, a connector fitting, a
component, or a component seal. If a leak occurs, add
30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.

Refrigerant oil must be added when a receiver/

drier, A/C evaporator, or A/C condenser are replaced.
See the Refrigerant Oil Capacities chart. When an
A/C compressor is replaced, the refrigerant oil must
be drained from the old compressor and measured.
Drain all of the refrigerant oil from the new compres-
sor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the
old compressor.

REFRIGERANT OIL CAPACITIES

Component

ml

fl oz

Total A/C System Fill

410

13.9

Receiver/Drier

30

1.0

A/C Condenser

30

1.0

A/C Evaporator

60

2.0

A/C Compressor

Drain and measure the oil
from the old compressor -
see text.

SUCTION LINE

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) Recover the refrigerant system. (Refer to 24 -

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

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the routing clip retaining nut and dis-

engage the metal routing clip from the A/C suction
line.

(4) Disengage the plastic routing clip located near

the A/C expansion valve from the A/C suction line.

(5) Remove the nut that secures the A/C suction

and liquid lines to the stud on the A/C expansion
valve (Fig. 19).

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24 - 81

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

from the A/C expansion valve and remove and dis-
card the O-ring seals.

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

and suction line fittings and both expansion valve
ports.

(8) Remove the bolt that secures the A/C suction

line to the A/C compressor (Fig. 20).

(9) Disconnect the A/C suction line from the A/C

compressor and remove and discard the O-ring seal.

(10) Install plugs in, or tape over the opened suc-

tion line fitting and the compressor suction port.

(11) Remove the A/C suction line from the engine

compartment.

INSTALLATION

(1) Position the A/C suction line into the engine

compartment.

(2) Remove plugs or tape from the suction line fit-

ting and the compressor suction port.

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

refrigerant oil and install it onto the suction line fit-
ting.

(4) Connect the A/C suction line to the A/C com-

pressor.

(5) Install the bolt that secures the A/C suction

line to the A/C compressor. Tighten the bolt to 23
N·m (17 ft. lbs.).

(6) Remove the tape or plugs from the liquid and

suction line fittings and both expansion valve ports.

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

refrigerant oil and install them on the liquid and suc-
tion line fittings.

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

A/C expansion valve.

(9) Install the nut that secures the A/C liquid and

suction lines to the A/C expansion valve. Tighten the
nut to 10 N·m (89 in. lbs.).

(10) Position the metal routing clip around the A/C

suction line and install the routing clip onto the body
stud.

(11) Install the routing clip retaining nut. Tighten

the nut to 5 N·m (45 in. lbs.).

Fig. 19 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)

Fig. 20 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

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(12) Install the plastic routing clip retainer onto

the A/C suction line.

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

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

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

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

WATER VALVE

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Partially

drain

the

engine

cooling

system

(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE - DRAINING COOLING SYS-
TEM).

(3) Disconnect the wire harness connector from the

heater water valve (Fig. 21).

(4) Loosen the hose clamps from the heater water

valve.

(5) Using a twisting motion gently remove the

heater hoses from the heater water valve.

(6) Remove the bolts that secure the heater water

valve bracket.

(7) Remove the bracket and pulsed water control

valve from the engine compartment.

(8) Turn the bracket slightly and remove the water

valve from the rubber mounts.

(9) If necessary, remove the rubber mounts from

the bracket or water valve.

INSTALLATION

(1) If removed, install the rubber mounts to the

heater water valve or bracket.

(2) Turn bracket slightly to the right and install

the heater water valve to the bracket.

(3) Install the water valve and mounting bracket

into the engine compartment.

(4) Install the two bracket retaining bolts. Tighten

the bolts to 5 N·m (45 in. lbs.).

(5) Using a twisting motion gently install the

heater hoses onto the water valve.

(6) Tighten the hose clamps securely.
(7) Connect the wire harness connector to the

heater water valve.

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

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

REAR A / C CONDENSER FAN

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) 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).

Fig. 21 Heater Water Valve

1 - HEATER WATER VALVE
2 - HOSE CLAMP (3)
3 - HEATER HOSE (3)
4 - RUBBER MOUNT (2)
5 - BOLTS (2)
6 - BRACKET
7 - RUBBER MOUNT

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(3) Disconnect the condenser fan wire harness

from the condenser fan suppression filter (Fig. 22).

(4) Loosen the four bolts that secure the rear A/C

condenser fan to the top of the rear A/C condenser
housing.

(5) Rotate the rear A/C condenser fan counter-

clockwise and remove the fan from the top of the rear
A/C condenser housing.

INSTALLATION

(1) Position the rear A/C condenser fan to the top

of the rear A/C condenser housing.

(2) Rotate the rear A/C condenser fan clockwise to

engage the fan to the four retaining bolts. Tighten
the bolts to 12 N·m (106 in. lbs.).

(3) Connect the condenser fan wire harness to the

rear condenser fan suppression filter.

(4) Reconnect the negative battery cable.
(5) 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 A / C EVAPORATOR

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) Remove the rear A/C evaporator housing and

place it on a workbench (Refer to 24 - HEATING &
AIR

CONDITIONING/DISTRIBUTION

-

REAR/

REAR A/C EVAPORATOR HOUSING - REMOVAL).

(2) Remove the five screws and washers that

secure the condensate drain pan to the bottom of the
rear A/C evaporator and remove the drain pan (Fig.
23).

(3) Remove the insulating tape from around the

area of the rear A/C expansion valve and disconnect
the expansion valve from the rear A/C evaporator
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REAR

A/C

EXPANSION

VALVE

-

REMOVAL).

(4) Remove the left blower motor from the rear

A/C evaporator housing (Refer to 24 - HEATING &
AIR

CONDITIONING/DISTRIBUTION

-

REAR/

BLOWER MOTOR - REMOVAL).

CAUTION: Be careful when drilling out rivets to pre-
vent damage to the rear A/C components.

(5) Remove the rivets that secure the three covers

to the rear A/C evaporator and remove the covers.

(6) Remove the four rivets that secure the rear A/C

evaporator the bottom of the rear A/C evaporator
housing and remove the evaporator.

Fig. 22 Rear A/C Condenser Fan

1 - REAR A/C CONDENSER FAN
2 - BOLT (4)
3 - REAR CONDENSER FAN SUPPRESSION FILTER
4 - FAN WIRE HARNESS CONNECTOR
5 - REAR A/C CONDENSER HOUSING

Fig. 23 Rear A/C Evaporator

1 - REAR A/C EVAPORATOR HOUSING
2 - RIVET (12)
3 - COVERS
4 - REAR A/;C EVAPORATOR
5 - SCREW AND WASHER (5)
6 - CONDENSATE DRAIN PAN

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