Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 511

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.

(1) Disconnect and isolate the battery negative

cable.

(2) If servicing the driver side air outlets, remove

the instrument cluster bezel (Refer to 23 - BODY/IN-
STRUMENT

PANEL/CLUSTER

BEZEL

REMOVAL).

(3) If servicing the passenger side air outlets,

remove the passenger side airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER

AIRBAG

REMOVAL).

Fig. 1 Air Filter Element

1 - VENTILATION HOUSING INSULATION BLANKET
2 - LOCKING CLIP (2)
3 - AIR FILTER

DISTRIBUTION - FRONT

24 - 45

(4) If servicing the passenger side air outlets,

remove the passenger side air nozzle reinforcing
plate screws and the reinforcing plate (Fig. 2).

(5) If servicing the passenger side air outlets,

remove the passenger side air nozzle assembly using
a trim stick or other suitable wide flat blade tool,
until the snap features on the nozzle assembly are
released.

(6) If servicing the passenger side air outlets,

remove the air outlet retaining bracket from the
right side of the instrument panel (Fig. 3).

(7) Remove the instrument panel end cover screws

and the left and/or right side cover.

(8) Remove the air outlet retaining screws and the

air outlets as required.

INSTALLATION

(1) Install the air outlets and retaining screws as

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

(2) Install the left and/or right side instrument

panel end cover and retaining screws as required.
Tighten the screws to 2 N·m (17 in. lbs.).

(3) If servicing the passenger side air outlets,

install the air outlet retaining bracket to the right
side of the instrument panel. Tighten the screw to 2
N·m (17 in. lbs.).

(4) If servicing the passenger side air outlets,

install the passenger side air nozzle assembly by
pressing the nozzle assembly firmly and evenly into
the instrument panel, until the snap features are
fully engaged.

(5) If servicing the passenger side air outlets,

install the passenger side air nozzle reinforcing plate
and retaining screws. Tighten the screws to 2 N·m
(17 in. lbs.).

(6) If servicing the passenger side air outlets,

install the passenger side airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER

AIRBAG

INSTALLATION).

(7) If servicing the driver side air outlets, install

the instrument cluster bezel (Refer to 23 - BODY/IN-
STRUMENT PANEL/CLUSTER BEZEL - INSTAL-
LATION).

(8) Reconnect the battery negative cable.

Fig. 2 Passenger Side Air Nozzle Cover

1 - FRONT SCREWS (2)
2 - BRACKET
3 - BRACKET SCREWS
4 - NOZZLE COVER
5 - INSTRUMENT PANEL

Fig. 3 Instrument Panel Air Outlets

1 - SCREW (15)
2 - LH END COVER
3 - RH END COVER
4 - BRACKET
5 - PASSENGER SIDE AIR OUTLET (2)
6 - DRIVER SIDE AIR OUTLET (2)

24 - 46

DISTRIBUTION - FRONT

BLOWER MOTOR

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the engine air cleaner housing cover

(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER ELEMENT - REMOVAL).

(3) Position

the

ventilation

housing

insulation

blanket out of the way of the blower motor assembly.

(4) Disconnect the wire harness connector from the

blower motor (Fig. 4).

(5) Remove

the

three

blower

motor

retaining

screws.

(6) Remove the blower motor assembly from the

ventilation housing.

INSTALLATION

(1) Install the blower motor assembly into the ven-

tilation housing.

(2) Install

the

three

blower

motor

retaining

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

(3) Connect the wire harness connector to the

blower motor.

(4) Install the ventilation housing insulation blan-

ket.

(5) Install the engine air cleaner cover (Refer to 9 -

ENGINE/AIR

INTAKE

SYSTEM/AIR

CLEANER

HOUSING - INSTALLATION).

(6) Reconnect the negative battery cable.

DEFROSTER DUCTS

REMOVAL

(1) Remove the instrument panel (Refer to 23 -

BODY/INSTRUMENT PANEL - REMOVAL).

(2) Remove the screw that secures the left and/or

right side defroster duct to the heater housing,
depending on the duct being removed (Fig. 5).

(3) Remove the defroster duct(s) from the hous-

ing.

INSTALLATION

(1) Install the left and/or right side defroster duct

on to the heater housing.

(2) Install the screw that secures the defroster

duct to the housing. Tighten the screw(s) to 2 N·m
(17 in. lbs.).

(3) Install the instrument panel (Refer to 23 -

BODY/INSTRUMENT PANEL - INSTALLATION).

FLOOR DISTRIBUTION DUCTS

REMOVAL

(1) Remove the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - REMOVAL).

(2) Remove the defroster ducts (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL).

(3) Remove the screws that secure the left and

right floor distribution ducts to the instrument panel
support (Fig. 6).

(4) Remove floor distribution ducts from the center

floor distribution duct.

Fig. 4 Blower Motor Assembly

1 - VENTILATION HOUSING
2 - SCREWS (3)
3 - WIRE HARNESS CONNECTOR
4 - BLOWER MOTOR
5 - INSULATION BLANKET

Fig. 5 Defroster Duct - RH Shown, LH Typical

1 - HEATER HOUSING
2 - SCREW
3 - DEFROSTER DUCT

DISTRIBUTION - FRONT

24 - 47

(5) Remove the shift mechanism (Refer to 21 -

TRANSMISSION/TRANSAXLE/AUTOMATIC

NAG1/SHIFT MECHANISM - REMOVAL).

(6) Remove center floor distribution duct from the

heater housing.

INSTALLATION

(1) Install the center floor distribution duct onto

the heater housing.

(2) Install the shift mechanism (Refer to 21 -

TRANSMISSION/TRANSAXLE/AUTOMATIC

NAG1/SHIFT MECHANISM - INSTALLATION).

(3) Install the left and right floor distribution

ducts onto the center floor distribution duct.

(4) Install the left and right floor distribution duct

retaining screws to the instrument panel support.
Tighten the screws to 2 N·m (17 in. lbs.).

(5) Install the defroster ducts (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/DE-
FROSTER DUCTS - INSTALLATION).

(6) Install the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - INSTALLATION).

HVAC HOUSING

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.

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.

NOTE: The HVAC housing must be removed from
the vehicle and the two halves of the housing sep-
arated for service access of the heater core, A/C
evaporator and each of the various mode doors.

(1) Recover the refrigerant from the refrigerant

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

(2) Partially

drain

the

engine

cooling

system

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

(3) Disconnect and isolate the negative battery

cable.

(4) Remove the air cleaner housing (Refer to 9 -

ENGINE/AIR

INTAKE

SYSTEM/AIR

CLEANER

HOUSING - REMOVAL).

(5) Remove the windshield washer reservoir (Refer

to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).

(6) Remove the air filter from the ventilation hous-

ing (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/AIR FILTER - REMOVAL).

(7) Disconnect the wire harness and vacuum con-

nectors from the recirculation door actuator (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - REMOVAL).

(8) Disconnect the wire harness connector from the

blower motor resistor block (Refer to 24 - HEATING
&

AIR

CONDITIONING/CONTROLS/BLOWER

MOTOR RESISTOR BLOCK - REMOVAL).

(9) Disconnect the wire harness connector from the

blower motor (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/BLOWER

MOTOR

REMOVAL).

(10) Remove the nuts and washers that secure the

ventilation housing to the body and remove the ven-
tilation housing from the vehicle (Fig. 7).

Fig. 6 Floor Distribution Duct, RH Shown, LH

Typical

1 - HEATER HOUSING
2 - SCREW (1)
3 - RH FLOOR DUCT
4 - CENTER FLOOR DUCT

24 - 48

DISTRIBUTION - FRONT

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Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 511

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