MERCEDES-BENZ SPRINTER 2005 Service Repair Manual

(15) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(16) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and all expansion
valve ports.
INSTALLATION
(1) Remove the tape or plug from the rear evapo-
rator inlet and outlet tube fittings and expansion
valve ports.
(2) Lubricate new rubber o-ring seals with clean
refrigerant oil and install them on the rear evapora-
tor inlet and outlet tube fittings.
(3) Position the rear expansion valve onto the rear
evaporator tapping plate fittings.
(4) Install and tighten the two bolts that secure
the expansion valve to the evaporator tube tapping
plate. Tighten the bolts to 5 N´m (45 in. lbs.).
(5) Remove the tape or plug from the refrigerant
line fittings and the solenoid and expansion valve
ports.
(6) Lubricate new rubber o-ring seals with clean
refrigerant oil and install them on the liquid line fit-
tings.
(7) Install the liquid line between the rear expan-
sion valve and the solenoid valve.(8) Install and tighten the nuts that secures the
liquid line fittings to the rear expansion valve and
solenoid valve. Tighten the nuts to 16 N´m (142 in.
lbs.).
(9) Install the rear evaporator panel and the three
push-pin fasteners.
(10) If equipped, connect the interior motion sen-
sor wire harness connector and install the interior
motion sensor into the evaporator panel.
(11) Install the five evaporator panel screws at the
front of the panel. Tighten the screws to 2 N´m (17
in. lbs.).
(12) Install the roof duct panel and six push-pin
fasteners.
(13) Connect the dome light wire harness connec-
tor and install the dome light into the rear roof duct
panel.
(14) Reconnect the battery negative cable.
(15) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(16) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
Fig. 14 Rear A/C Evaporator
1 - CONDENSATION TRAP
2 - SCREW (4)
3 - LIQUID REFRIGERANT LINE
4 - EVAPORATOR TEMPERATURE SENSOR
5 - TEMPERATURE SENSOR PROBE
6 - REAR EXPANSION VALVE7 - O-RING
8 - HUMIDITY PROTECTION SLEEVE
9 - REAR EVAPORATOR
10 - O-RING
11 - BOLT (2)
VAPLUMBING 24 - 63
REAR EXPANSION VALVE (Continued)

RECEIVER/DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the left front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the liquid line between the
condenser outlet and the evaporator inlet. The receiv-
er/drier cannot be repaired. If the receiver/drier is
faulty or damaged, or if the refrigerant system has
been contaminated or left open to the atmosphere for
an indeterminable period or if the compressor has
failed, it must be replaced.
OPERATION
The receiver/drier performs a filtering action to
prevent foreign material in the refrigerant from con-
taminating the expansion valve. A desiccant bag is
mounted inside the receiver/drier canister to absorb
any moisture which may have entered and become
trapped within the refrigerant system. In addition,
during periods of high demand air conditioner opera-
tion, the receiver/drier acts as a reservoir to store
surplus refrigerant. Refrigerant enters the receiver/
drier as a high-pressure, low-temperature liquid.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Recover the refrigerant from the refrigerant
system(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
(2) Remove the bolts that secure the front and rear
sections of the liquid line to the top of the receiver/
drier (Fig. 15).
(3) Disconnect the liquid line fittings from the
receiver/drier.
(4) Remove the seals from the liquid line fittings
and discard.
(5) Install a plug in, or tape over the opened liquid
line fittings and the receiver/drier ports.
(6) Loosen the clamp that secures the receiver/
drier to the mounting bracket.
(7) Remove the receiver/drier from the engine com-
partment.
INSTALLATION
NOTE: If the receiver/drier 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 compressor in the vehi-
cle.
(1) Position the receiver/drier onto the mounting
bracket on the front left strut tower.
(2) Tighten the clamp that secures the receiver/
drier to the mounting bracket.
(3) Remove the tape or plugs from the liquid line
fittings and the receiver/drier ports.
(4) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line fit-
tings.
(5) Connect the front and rear sections of the liq-
uid line to the receiver/drier.
(6) Install the bolts that secures the liquid line fit-
tings to the receiver/drier. Tighten the bolts to 7 N´m
(62 in. lbs.).
(7) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(8) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
Fig. 15 Receiver/Drier
1 - RECEIVER/DRIER
2 - LIQUID LINE (REAR SECTION)
3 - A/C PRESSURE TRANSDUCER
4 - LIQUID LINE (FRONT SECTION)
5 - CLAMP
24 - 64 PLUMBINGVA

REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
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 10PA17
compressor used in this vehicle is designed to use an
ND8 PAG refrigerant oil. Use only refrigerant oil of
this same 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 air conditioning 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
compressor is dispersed throughout the refrigerant
system. 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 compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the
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 compo-
nent, 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, evaporator coil, or condenser are replaced. See
the Refrigerant Oil Capacities chart. When a com-
pressor 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.
VAPLUMBING 24 - 65

REFRIGERANT OIL CAPACITIES
Component ml fl oz
Total System Fill410 (425
w/rear A/C)13.9 (14.4
w/rear A/C
Receiver/Drier 30 1.0
Condenser 30 1.0
Front Evaporator 60 2.0
Rear Evaporator 30 1.0
CompressorDrain and measure the oil
from the old compressor -
see text.
SUCTION LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Recover the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT
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 suction line.
(4) Disengage the plastic routing clip located near
the expansion valve from the suction line.
(5) Remove the nut that secures the suction and
liquid line fittings to the stud on the expansion valve
(Fig. 16).
(6) Disconnect the suction and liquid lines from
the expansion valve.
(7) Remove the seals from the suction and liquid
line fitting and discard.
(8) Install plugs in, or tape over the opened liquid
and suction line fittings and both expansion valve
ports.
(9) Remove the bolt that secures the suction line
fitting to the top of the compressor (Fig. 17).
(10) Disconnect the suction line fitting from the
compressor suction port.
(11) Remove the O-ring seal from the suction line
fitting and discard.
(12) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(13) Remove the suction line from the vehicle.
INSTALLATION
(1) Position the suction line into the engine com-
partment.
(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 suction line fitting to the compres-
sor suction port.
(5) Install the bolt that secures the suction line fit-
ting to the top of the 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) Reconnect the liquid line fitting to the expan-
sion valve.
(9) Reconnect the suction line fitting to the expan-
sion valve.
(10) Install the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve. Tighten the nut to 10 N´m (89 in. lbs.).
Fig. 16 Expansion Valve
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - EXPANSION VALVE
4 - BOLT (2)
5 - SUCTION LINE
6 - NUT
7 - LIQUID LINE
8 - O-RING SEAL (2)
24 - 66 PLUMBINGVA
REFRIGERANT OIL (Continued)

(11) Position the metal routing clip around the
suction line and install the routing clip onto the body
stud.
(12) Install the routing clip retaining nut. Tighten
the nut to 5 N´m (45 in. lbs.).
(13) Install the plastic routing clip retainer onto
the suction line.
(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) 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 battery negative
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE).(3) Disconnect the wire harness connector from the
heater water valve (Fig. 18).
(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.
Fig. 17 A/C Compressor - Refrigerant Lines
1 - A/C COMPRESSOR
2 - O-RING SEAL
3 - SUCTION LINE
4 - BOLT
5 - RETAINING CLIP
6 - BOLT
7 - DISCHARGE LINE
8 - O-RING SEAL
Fig. 18 Pulsed Water Control 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
VAPLUMBING 24 - 67
SUCTION LINE (Continued)

(7) Connect the wire harness connector to the
heater water valve.
(8) Reconnect the battery negative cable.
(9) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
UNDERBODY LINES
REMOVAL
The rear refrigerant lines for the optional rear A/C
system is serviced in four sections. The liquid line for
the optional rear A/C system uses a spring-lock
refrigerant line coupler which requires the use of a
3/8 inch quick-disconnect tool (part of Special Tool,
A/C Line Disconnect Kit 7193).
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
FRONT LIQUID LINE
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the rear section of the front liquid
line from the receiver-drier and the evaporator (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/LIQUID LINE - REMOVAL).
(4) Disconnect the fitting to the intermediate liq-
uid line using Special Tool, A/C Line Disconnect Kit
7193.
(5) Remove the seals from the liquid line fittings
and discard.
(6) Install plug in, or tape over the open liquid line
fittings, the reciever-drier outlet port and the expan-
sion valve ports.
(7) Remove the front liquid line from the engine
compartment.
FRONT SUCTION LINE
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the nut that secures the intermediate
suction line fitting to the stud on the front suction
line tapping plate.
(4) Disconnect the intermediate suction line fitting
from the front suction line tapping plate.(5) Install plug in, or tape over the open suction
line fitting and the front suction line tapping plate
inlet port.
(6) Disconnect the front suction line from the com-
pressor and front evaporator valve (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
SUCTION LINE - REMOVAL).
(7) Remove the seals from the open suction line fit-
tings and discard.
(8) Install plug in, or tape over the open suction
line fittings, the compressor inlet port and the expan-
sion valve ports.
(9) Remove the front suction line from the engine
compartment.
(10) If necessary, remove the bolt that secures the
compressor portion of the front suction line to the
front suction line tapping plate, separate the front
suction lines, remove and discard the seal and, plug
in, or tape over the open suction line fittings.
INTERMEDIATE REFRIGERANT LINES
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the intermediate liquid line from
the front liquid line using Special Tool, A/C Line Dis-
connect Kit 7193.
(4) Remove the nut that secures the intermediate
suction line fitting to the stud on the front suction
line tapping plate.
(5) Disconnect the intermediate suction line from
the front suction line tapping plate.
(6) Remove the seals from the liquid and suction
line fittings and discard.
(7) Install plug in, or tape over the open suction
and liquid line fittings and the front suction line tap-
ping plate inlet port.
(8) Raise and support the vehicle.
(9) Disconnect the fittings that secure the interme-
diate refrigerant lines to the rear refrigerant lines.
(10) Remove the seals from the open liquid and
suction line fittings and discard.
(11) Install plugs in, or tape over the open liquid
and suction line fittings.
(12) Remove the bolts that secure the two interme-
diate refrigerant line retaining blocks to the vehicle
underbody.
(13) Remove the intermediate section of the rear
refrigerant lines from the vehicle underbody.
REAR REFRIGERANT LINES
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
24 - 68 PLUMBINGVA
WATER VALVE (Continued)

ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the interior trim panel from the right
quarter panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - REMOVAL).
(4) Disconnect the fittings that secure the rear
refrigerant lines to the sidewall refrigerant lines.
(5) Remove the seals from the open liquid and suc-
tion line fittings and discard.
(6) Install plugs in, or tape over the open liquid
and suction line fittings.
(7) Raise and support the vehicle.
(8) Disconnect the fittings that secure the interme-
diate refrigerant lines to the rear refrigerant lines.
(9) Remove the seals from the open liquid and suc-
tion line fittings and discard.
(10) Install plugs in, or tape over the open liquid
and suction line fittings.
(11) Remove the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).
(12) Remove the seal from the right inner sidewall.
(13) Carefully pull the rubber rear refrigerant
lines out from the sidewall.
(14) Remove the bolts that secure the four rear
refrigerant line retaining blocks to the vehicle under-
body.
(15) Remove the rear section of the rear refriger-
ant lines from the vehicle underbody.
SIDEWALL REFRIGERANT LINES
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the suction line from the rear
expansion valve outlet port (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REAR EXPAN-
SION VALVE - REMOVAL).
(4) Disconnect the liquid line from rear solenoid
valve inlet port (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/SOLENOID - REMOVAL).
(5) Remove the seals from the open liquid and suc-
tion line fittings and discard.
(6) Install plugs in, or tape over the open liquid
and suction line fittings and, the rear solenoid and
expansion valve ports.
(7) Remove the interior trim panel from the right
quarter panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - REMOVAL).
(8) Disconnect the fittings that secure the rear
refrigerant lines to the sidewall refrigerant lines.(9) Remove the seals from the open liquid and suc-
tion line fittings and discard.
(10) Install plugs in, or tape over the open liquid
and suction line fittings.
(11) Remove the bolts that secure the two refriger-
ant line retaining blocks to the vehicle sidewall.
(12) Carefully pull the rubber refrigerant lines out
from the sidewall.
(13) Remove the sidewall section of the rear refrig-
erant lines from the vehicle.
INSTALLATION
FRONT LIQUID LINE
(1) Install the front liquid line into the engine
compartment.
(2) Remove plugs or tape from the liquid line fit-
tings, the reciever-drier outlet port and the expan-
sion valve ports.
(3) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the liquid
line fittings.
(4) Connect the quick-disconnect front liquid line
fitting to the intermediate liquid line.
(5) Connect the rear section of the front liquid line
to the receiver-drier and the evaporator (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
LIQUID LINE - INSTALLATION).
(6) Reconnect the battery negative cable.
(7) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(8) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
FRONT SUCTION LINE
(1) If the compressor portion of the front suction
line was separated from the front suction line tap-
ping plate, remove plugs or tape from the suction
line fitting, lubricate a new rubber o-ring seal with
clean refrigerant oil and install the seal onto the suc-
tion line fitting and, install the bolt that secures the
compressor portion of the front suction line to the
front suction line tapping plate. Tighten the bolt to 5
N´m (45 in. lbs.).
(2) Install the front suction line into the engine
compartment.
(3) Remove plugs or tape from the suction line fit-
tings, the compressor inlet port and the expansion
valve ports.
(4) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the suction
line fittings.
VAPLUMBING 24 - 69
UNDERBODY LINES (Continued)

(5) Connect the front suction line to the compres-
sor and front evaporator valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/SUCTION
LINE - INSTALLATION).
(6) Remove plugs or tape from the intermediate
suction line fitting and the front suction line tapping
plate inlet port.
(7) Lubricate a new rubber o-ring seal with clean
refrigerant oil and install the seal onto the interme-
diate suction line fitting.
(8) Connect the intermediate suction line fitting to
the front suction line tapping plate.
(9)
Install the nut that secures the intermediate
suction line fitting to the stud on the front suction line
tapping plate. Tighten the nut to 10 N´m (89 in. lbs.).
(10) Reconnect the battery negative 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).
INTERMEDIATE REFRIGERANT LINES
(1) Raise and support the vehicle.
(2) Install the intermediate section of the rear
refrigerant lines to the vehicle underbody.
(3) Install the bolts that secure the two intermedi-
ate refrigerant line retaining blocks to the vehicle
underbody. Tighten the bolts to 5 N´m (45 in. lbs.).
(4) Remove plugs or tape from the open intermedi-
ate and rear refrigerant line fittings.
(5) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the interme-
diate-to-rear refrigerant line fittings.
(6) Connect the fittings that secure the intermedi-
ate refrigerant lines to the rear refrigerant lines.
Tighten the liquid line fitting to 16 N´m (142 in. lbs.).
Tighten the suction line fitting to 30 N´m (22 ft. lbs.).
(7) Lower the vehicle.
(8) Connect the quick-disconnect front liquid line
fitting to the intermediate liquid line.
(9) Remove plugs or tape from the intermediate
suction line fitting and the front suction line tapping
plate inlet port.
(10) Lubricate a new rubber o-ring seal with clean
refrigerant oil and install the seal onto the interme-
diate suction line fitting.
(11) Connect the intermediate suction line fitting
to the front suction line tapping plate.
(12) Install the nut that secures the intermediate
suction line fitting to the stud on the front suction
line tapping plate. Tighten the nut to 10 N´m (89 in.
lbs.).(13) Reconnect the battery negative 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).
REAR REFRIGERANT LINES
(1) Raise and support the vehicle.
(2) Install the rear section of the rear refrigerant
lines to the vehicle underbody.
(3) Install the bolts that secure the four rear
refrigerant line retaining blocks to the vehicle under-
body. Tighten the bolts to 5 N´m (45 in. lbs.).
(4) Carefully route the rubber rear refrigerant
lines into the right sidewall.
(5) Install the seal into the inner sidewall.
(6) Install the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION).
(7) Remove plugs or tape from the open intermedi-
ate and rear refrigerant line fittings.
(8) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the interme-
diate-to-rear refrigerant line fittings.
(9) Connect the fittings that secure the intermedi-
ate refrigerant lines to the rear refrigerant lines.
Tighten the liquid line fitting to 16 N´m (142 in. lbs.).
Tighten the suction line fitting to 30 N´m (22 ft. lbs.).
(10) Lower the vehicle.
(11) Remove plugs or tape from the open sidewall
and rear refrigerant line fittings.
(12) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the rear-to-
sidewall refrigerant line fittings.
(13) Connect the fittings that secure the rear
refrigerant lines to the sidewall refrigerant lines.
Tighten the liquid line fitting to 16 N´m (142 in. lbs.).
Tighten the suction line fitting to 30 N´m (22 ft. lbs.).
(14) Install the interior trim panel from the right
quarter panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - INSTALLATION).
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(17) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
24 - 70 PLUMBINGVA
UNDERBODY LINES (Continued)

SIDEWALL REFRIGERANT LINES
(1) Install the sidewall section of the rear refriger-
ant lines to the vehicle.
(2) Carefully route the rubber refrigerant lines
through the sidewall.
(3) Install the bolts that secure the two refrigerant
line retaining blocks to the vehicle sidewall. Tighten
the bolts to 5 N´m (45 in. lbs.).
(4) Remove plugs or tape from the open rear and
sidewall refrigerant line fittings.
(5) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the rear-to-
sidewall refrigerant line fittings.
(6) Connect the fittings that secure the rear refrig-
erant lines to the sidewall refrigerant lines. Tighten
the liquid line fitting to 16 N´m (142 in. lbs.). Tighten
the suction line fitting to 30 N´m (22 ft. lbs.).
(7) Install the interior trim panel from the right
quarter panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - INSTALLATION).
(8) Remove plugs or tape from the open sidewall
liquid and suction line fittings and, the rear solenoid
and expansion valve ports.(9) Lubricate new rubber o-ring seals with clean
refrigerant oil and install the seals onto the sidewall
refrigerant line fittings.
(10) Connect the liquid line to the rear solenoid
valve inlet port (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/SOLENOID - INSTALLA-
TION).
(11) Connect the suction line to the rear expansion
valve outlet port and reinstall the rear A/C evapora-
tor panel and duct (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REAR EXPANSION
VALVE - INSTALLATION).
(12) Connect the battery negative cable.
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
VAPLUMBING 24 - 71
UNDERBODY LINES (Continued)

CABIN HEATER
TABLE OF CONTENTS
page page
CABIN HEATER
DESCRIPTION.........................72
OPERATION...........................72
DIAGNOSIS AND TESTING - DIESEL
SUPPLEMENTAL HEATER - DCHA........72
EXHAUST TUBE
REMOVAL.............................73
INSTALLATION.........................73
FUEL DOSING PUMP
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL.............................74
INSTALLATION.........................74
FUEL LINE
STANDARD PROCEDURE - CLEANING......75REMOVAL.............................75
INSTALLATION.........................76
HEATER UNIT
REMOVAL
REMOVAL...........................77
REMOVAL...........................77
INSTALLATION
INSTALLATION.......................78
INSTALLATION.......................78
INLET HOSE
REMOVAL.............................78
INSTALLATION.........................78
CABIN HEATER
DESCRIPTION
Vehicles equipped with the optional diesel engine
are also equipped with a supplemental heater unit.
This unit is mounted under the vehicle and operates
similar to an oil fired furnace. The heater burns
small amounts of fuel to provide additional heat to
the coolant. Coolant is routed from the engine, to the
supplemental heater, and then to the front heater
core. This provides additional heat to the passenger
compartment. The system is interfaced to the vehi-
cles on-board computer systems and DRBIIItdiag-
nostics.
The supplemental heater unit has an electronic
control module that monitors the heat output of the
heater. The heater operates at full load (5 kW), half
load or idle mode (no additional heat) depending on
coolant temperature.
OPERATION
The supplemental heater is activated via the tem-
perature control on the heater-A/C control. The
heater is activated when the temperature control is
set to/or above the upper set point. The supplemental
heater can operate in a full or partial load range aswell as an idle mode, all dependent on the engine
coolant temperature. The heater unit will also turn
off if the temperature control is set to less than the
lower set point. The supplemental heater can take up
to three minutes to completely shut down when
either the heater temperature is set below the lower
set point or the vehicle ignition is turned off.
The supplemental heater only operates when the
engine is running, the mileage exceeds 8 kilometer (5
mph) and the fuel tank volume exceeds 1/8 of a tank.
The heater should start if the coolant temperature is
below 40É C (104É F).
NOTE: Do not apply a strong vacuum directly on
the supplemental heater exhaust line. Place the vac-
uum within 75 mm (3 inches) of the exhaust port.
Too strong of a vacuum can prevent the heater from
starting. The heater control module monitors the
supplemental blower speed and combustion during
its start-up.DIAGNOSIS AND TESTING - DIESEL
SUPPLEMENTAL HEATER - DCHA
Refer to the Symptoms Diagnosis table for basic
checks of the diesel fueled supplemental heater.
24 - 72 CABIN HEATERVA