engine oil MERCEDES-BENZ SPRINTER 2006 Service Manual

AMBIENT TEMPERATURE SEN-
SOR
DESCRIPTION
The ambient air temperature sensor is a variable
resistor that monitors the air temperature outside of
the vehicle. The ambient air temperature sensor is
connected to the instrument cluster through a two-
wire harness lead and connector of the vehicle elec-
trical system (Fig. 13). The instrument cluster sends
out a message on the CAN bus to the ATC control
module which uses the sensor data to maintain opti-
mum cabin temperature levels.
The ambient air temperature sensor is mounted to
the front licence plate bracket by three integral
retaining tabs.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the instrument cluster. The resistance in
the sensor changes as temperature changes. Based
upon the resistance in the sensor, the instrument
cluster sends the ATC control module a specific volt-
age on the temperature sensor signal circuit, which
is programmed to correspond to a specific tempera-
ture.
The ambient temperature sensor is diagnosed
using the DRBIIItscan tool. Refer to Body Diagnos-
tic Procedures.
The ambient temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front license plate bracket (Refer
to 23 - BODY/EXTERIOR/LICENSE PLATE
BRACKET - REMOVAL).
(3) Disconnect the wire harness connector from the
ambient temperature sensor (Fig. 14).
(4) Disengage the sensor retaining tabs and
remove the ambient temperature sensor from the
front license plate bracket.
INSTALLATION
(1) Install the ambient temperature sensor onto
the front license plate bracket. Make sure the retain-
ing tabs are fully engaged.
(2) Connect the wire harness connector to the
ambient temperature sensor.
(3) Install the front license plate bracket (Refer to
23 - BODY/EXTERIOR/LICENSE PLATE BRACKET
- INSTALLATION).
(4) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
DESCRIPTION
This temperature control system uses a blower
motor resistor (Fig. 15). The blower motor resistor is
mounted to the top of ventilation housing located in
the engine compartment. The blower motor resistor
consists of a molded plastic mounting plate with an
integral retaining tab and wire connector receptacle.
Concealed behind the mounting plate are coiled resis-
tor wires contained within a ceramic heat sink.
Fig. 13 Ambient Air Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
3 - RETAINING TABS (3)
Fig. 14 Ambient Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - FRONT LICENSE PLATE BRACKET
VACONTROLS-FRONT 24 - 17

(3) Remove the gasket located at the A/C evapora-
tor and heater core tubes and the gasket that seals
the ventilation housing to the HVAC housing (Fig. 9).
(4) Remove the 12 screws that secure the two
housing halves together.
(5) Seperate the two housing halves.
(6) Remove the heater core from the lower hous-
ing.
(7) Remove the wire harness.
(8) Remove the three heater core tube retaining
bolts and the heater core tube assembly from the
heater core.
(9) Remove the heater core tube seals and discard.
(10) Install plug in, or tape over the opened heater
core fittings.
(11) Remove the A/C evaporator from the lower
housing.
ASSEMBLY
(1) Install the A/C evaporator into the lower hous-
ing.
(2) Remove the tape or plugs from the heater core
fittings.(3) Lubricate two new rubber O-ring seals with
clean engine coolant and install them onto the heater
core fitting.
(4) Connect the heater core tube assembly to the
heater core and install the three retaining bolts.
Tighten the bolts to 5 N´m (45 in. lbs.).
(5) Install the wire harness.
(6) Install the heater core into the lower housing.
(7) Install the two housing halves together.
(8) Install the 12 screws that secure the two hous-
ing halves together. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Install the gasket for the A/C evaporator and
heater core tube outlets and the gasket that seals the
ventilation housing to the HVAC housing.
(10) Install the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
INSTALLATION
NOTE: High pressures are produced in the refriger-
ant system when the A/C compressor is operating.
Extreme care must be exercised to make sure that
each of the refrigerant system connections is pres-
sure-tight and leak free.
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
is positioned correctly.
(2) Install the screws that secure the HVAC hous-
ing to the dash panel. Tighten the screws to 4.5 N´m
(40 in. lbs.).
(3) Connect the HVAC housing wire harness con-
nectors and install the wiring harness to the bracket.
(4) Connect the A/C-heater control cables to the
mode door levers (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR CABLE
- INSTALLATION).
(5) Reinstall the passenger airbag bracket (Refer
to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG - INSTALLATION).
(6) Reconnect the two bulkhead ground connection
near the instrument cluster area.
(7) Reinstall the defroster, floor distribution and
instrument panel ducts.
(8) Reinstall the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(9) Unplug or remove the tape from the opened
refrigerant line fittings.
(10) Lubricate two new rubber O-ring seals with
clean refrigerant oil and install them onto the evap-
orator core fittings.
(11) Connect the refrigerant line terminal block to
the evaporator tubes.
Fig. 9 HVAC Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
24 - 50 DISTRIBUTION - FRONTVA

REAR REFRIGERANT RESERVOIR
REMOVAL.............................95
INSTALLATION.........................95
REAR SUCTION LINE
DESCRIPTION.........................96
REMOVAL.............................96
INSTALLATION.........................98
REFRIGERANT LINE COUPLER
DESCRIPTION.........................98OPERATION...........................98
REMOVAL.............................99
INSTALLATION.........................99
UNDERBODY LINES
REMOVAL............................100
INSTALLATION........................102
PLUMBING
DESCRIPTION
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
OPERATION
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNINGS
WARNING: The A/C system contains refrigerant
under high pressure. Repairs should only be per-
formed by qualified service personnel. Severe per-
sonal injury or death may result from improper
service procedures.
WARNING: Avoid breathing the refrigerant and
refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protectionwhen servicing the A/C refrigerant system. Serious
eye injury can result from direct contact with the
refrigerant. If eye contact occurs, seek medical
attention immediately.
WARNING: Do not expose the refrigerant to open
flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recom-
mended. Severe personal injury or death may result
from improper service procedures.
WARNING: If accidental system discharge occurs,
ventilate the work area before resuming service.
Large amounts of refrigerant released in a closed
work area will displace the oxygen and cause suf-
focation and death.
WARNING: The evaporation rate of R-134a refriger-
ant at average temperature and altitude is extremely
high. As a result, anything that comes in contact
with the refrigerant will freeze. Always protect the
skin or delicate objects from direct contact with the
refrigerant.
WARNING: The R-134a service equipment or the
vehicle refrigerant system should not be pressure
tested or leak tested with compressed air. Some
mixtures of air and R-134a have been shown to be
combustible at elevated pressures. These mixtures
are potentially dangerous, and may result in fire or
explosion causing property damage, personal injury
or death.
WARNING: The engine cooling system is designed
to develop internal pressures of 97 to 123 kilopas-
cals (14 to 18 pounds per square inch). Do not
remove or loosen the coolant pressure cap, cylin-
der block drain plugs, radiator drain, radiator
hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 min-
utes before opening the cooling system for service.
Failure to observe this warning can result in seri-
ous burns from the heated engine coolant.
VAPLUMBING 24 - 61

SYSTEM EMPTY
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approximately 28 in Hg.)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM EVACUATE). Determine if the
system holds a vacuum for 15 minutes. If vacuum is
held, a leak is probably not present. If system will
not maintain vacuum level, proceed to Step 2.
(2) Prepare and dispense 0.284 kilograms (10
ounces) of R-134a refrigerant into the evacuated
refrigerant system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE) and
proceed to Step 1 of the System Low procedure.
SYSTEM LOW
(1) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(2) Operate the heating-A/C system with the
engine at idle under the following conditions for at
least five minutes.
²Doors or windows open
²Transmission in Park
²A/C-heater controls set to outside air, full cool,
panel mode, high blower and with A/C compressor
engaged
CAUTION: A leak detector only designed for R-12
refrigerant will not detect leaks in a R-134a refriger-
ant system.
(3) Shut the vehicle Off and wait 2-7 minutes.
Then use an electronic leak detector that is designed
to detect R-134a refrigerant and search for leaks. Fit-
tings, lines or components that appear to be oily usu-
ally indicate a refrigerant leak. To inspect the A/C
evaporator for leaks, insert the leak detector probe
into the drain tube opening or an air outlet. A dye for
R-134a is available to aid in leak detection. Use only
DaimlerChrysler approved refrigerant dye.
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: Eye protection must be worn when ser-
vicing an A/C refrigerant system. Turn off (rotate
clockwise) all valves on the equipment being used,
before connecting to or disconnecting from the
refrigerant system. Failure to observe these warn-
ings may result in possible personal injury.
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 (Referto 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 must be used.
Contact an automotive service equipment supplier for
refrigerant recovery/recycling/charging equipment.
Refer to the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 1). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
Fig. 1 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK
STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
VAPLUMBING 24 - 63

CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrig-
erant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more infor-
mation.
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant charge can be
injected into the system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.
PARTIAL CHARGE METHOD
The partial charge method is used to add a partial
charge to a refrigerant system that is low on refrig-
erant. To perform this procedure the evaporator inlet
and outlet tube temperatures are measured. The
temperature difference is measured with a tempera-
ture meter with one or two clamp-on thermocouple
probes. The difference between the evaporator inlet
and outlet tube temperatures will determine the
amount of refrigerant needed.
Before adding a partial refrigerant charge, check
for refrigerant system leaks. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - DIAGNOSIS
AND TESTING - REFRIGERANT SYSTEM LEAKS)
If a leak is found, make the necessary repairs before
attempting a full or partial refrigerant charge.
(1) Attach a manifold gauge set to the refrigerant
system service ports.
(2) Attach the two clamp-on thermocouple probes
to the inlet and outlet tubes of the evaporator coil.
²If a single thermocouple probe is used, attach
the probe to the evaporator inlet tube just before the
collar of the refrigerant line connector fitting. The
probe must make contact with the bottom surface of
the evaporator inlet tube.
²If dual thermocouple probes are used, attach
probe 1 to the evaporator inlet tube, and probe 2 to
the evaporator outlet tube. Attach both probes to the
evaporator tubes just before the collar of the refrig-erant line connector fittings. The probes must make
contact with the bottom surfaces of the evaporator
inlet and outlet tubes.
(3) Open all of the windows or doors of the passen-
ger compartment.
(4) Set the A/C button on the A/C Heater controls
to the on position, the temperature control knob in
the full cool position, select Recirculation Mode, and
place the blower motor switch in the highest speed
position.
(5) Start the engine and hold the engine idle speed
at 1,000 rpm. Allow the engine to warm up to normal
operating temperature.
(6) The compressor clutch may cycle, depending
upon ambient temperature, humidity, and the refrig-
erant system charge level.
(7) Hold the engine idle speed at 1,000 rpm.
(8) Allow three to five minutes for the refrigerant
system to stabilize, then record the temperatures of
the evaporator inlet and outlet tubes.
²If a single probe is used, record the temperature
of the evaporator inlet tube. Then remove the probe
from the inlet tube and attach it to the evaporator
outlet tube just before the collar of the refrigerant
line connector fitting. The probe must make contact
with the bottom surface of the evaporator outlet tube.
Allow the thermocouple and meter time to stabilize,
then record the temperature of the evaporator outlet
tube. Subtract the inlet tube temperature reading
from the outlet tube temperature reading.
²If dual probes are used, record the temperatures
of both the evaporator inlet and outlet tubes. Then
subtract the inlet tube temperature reading from the
outlet tube temperature reading.
(9) If the measured temperature differential is
higher than 22É C to 26É C (40É F to 47É F), add 0.4
kilograms (14 ounces) of refrigerant.
(10) Allow three to five minutes for the refrigerant
system to stabilize, then take a second set of thermo-
couple measurements. Record the temperature differ-
ence to determine if an additional charge is required.
(11) Record the compressor discharge pressure. If
the reading is higher than the pressure shown in the
Compressor Discharge Pressure Chart, the system
could be overcharged. If the reading is equal to, or
lower, than the pressure shown in the chart, continue
with this procedure.
Compressor Discharge Pressure Chart
Ambient Tempera-
ture16ÉC
(60ÉF)21ÉC
(70ÉF)27ÉC
(80ÉF)32ÉC
(90ÉF)38ÉC
(100ÉF)43ÉC
(110ÉF)
Compressor Dis-
charge Pressure1378 kPa
(200 psi)1516 kPa
(220 psi)1723 kPa
(250psi)1930 kPa
(280 psi)2206 kPa
(320 psi)2413 kPa
(350 psi)
VAPLUMBING 24 - 65

(12)EXAMPLE:The ambient temperature is 21É
C (70É F). The evaporator inlet tube temperature is
12É C (54É F) and the evaporator outlet tube temper-
ature is 10É C (50É F). Subtract the inlet tube tem-
perature from the outlet tube temperature. The
difference is -2É C (-4É F). With a -2É C (-4É F) tem-
perature differential at 21É C (70É F) ambient tem-
perature, the system is fully charged.
(13) Add enough refrigerant to bring the refriger-
ant system up to a full charge.
(14) Remove the jumper wire from the low pres-
sure cycling clutch switch wire harness connector
and plug the connector back into the switch.
A / C COMPRESSOR
DESCRIPTION
The standard front A/C system uses a Denso
7SBU16C seven cylinder, variable displacement
swash plate-type A/C compressor (Fig. 2). This A/C
compressor has a volume control which is regulated
by an internal control valve and has both the suction
and discharge ports located at the rear of the com-
pressor.
The optional independant Konvekta rear A/C sys-
tem uses theDenso 10S17C ten cylinder, double-act-
ing swash plate-type A/C compressor (Fig. 3). This
A/C compressor has a fixed displacement of 170 cubic
centimeters (10.374 cubic inches), and has both the
suction and discharge ports located on the cylinder
head at the rear of the compressor.A label identifying the use of R-134a refrigerant is
located on both A/C compressors.
OPERATION
The A/C compressor is driven by the engine
through an electric clutch, drive pulley and belt
arrangement. The A/C compressor is lubricated by
refrigerant oil that is circulated throughout the
refrigerant system with the refrigerant.
The A/C compressor draws in low-pressure refrig-
erant vapor from the A/C evaporator through its suc-
tion port. It then compresses the refrigerant into a
high-pressure, high-temperature refrigerant vapor,
which is then pumped to the A/C condenser through
the compressor discharge port.
The A/C compressor cannot be repaired and, if
faulty or damaged, it must be replaced. The compres-
sor clutch, pulley and bearing assembly, and clutch
field coil are available for service. If an internal fail-
ure of the A/C compressor has occurred, the receiver/
drier must also be replaced.
DIAGNOSIS AND TESTING
A / C COMPRESSOR NOISE
When investigating an air conditioning related
noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation can often be misleading.
For example: What sounds like a failed front bearing
or connecting rod, may be caused by loose bolts, nuts,
Fig. 2 Denso 7SBU16C A/C Compressor
1 - A/C COMPRESSOR (DENSO 7SBU16C)
2 - SUCTION AND DISCHARGE PORT
3 - INTERNAL CONTROL VALVE
Fig. 3 Denso 10S17C A/C Compressor
1 - A/C COMPRESSOR (DENSO 10S17C)
2 - SUCTION AND DISCHARGE PORT
3 - CYLINDER HEAD
24 - 66 PLUMBINGVA

mounting brackets, or a loose compressor clutch
assembly.
Drive belts are speed sensitive. At different engine
speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and pulley are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH - INSTALLATION)
(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAU-
TION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(5) If the noise is from opening and closing of the
high pressure relief valve, reclaim, evacuate, and
recharge the refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM EVACUATE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE) If the high pressure relief valve still
does not seat properly, replace the a/c compressor.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C COMPRESSOR - REMOVAL)
(6) If the noise is from liquid slugging on the suc-
tion line, check the refrigerant oil level and the
refrigerant system charge. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-ANT OIL - STANDARD PROCEDURE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
SPECIFICATIONS - CHARGE CAPACITY).
(7) If the noise continues, replace the compressor
and repeat Step 1.
REMOVAL
DENSO 7SBU16CA/CCOMPRESSOR
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 A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres-
sor clutch, clutch coil or the engine.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
(3) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
(4) Disconnect the wire harness connector from the
A/C compressor clutch coil.
(5) Remove the bolts that secure the A/C suction
and discharge lines to the A/C compressor.
(6) Disconnect the A/C suction and discharge lines
from the A/C compressor and remove and discard the
O-ring seals (Fig. 4).
(7) Install plugs in, or tape over the opened refrig-
erant line fittings and the compressor ports.
(8) Raise the vehicle on a hoist.
(9) If equipped with an add-on rear A/C system,
remove the lower A/C compressor and position it out
of the way (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL - DENSO 10S17).
(10) Support the A/C compressor and remove the
compressor mounting bolts.
(11) Remove the A/C compressor from the engine
compartment.
VAPLUMBING 24 - 67

DENSO 10S17A/CCOMPRESSOR
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 A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres-
sor clutch, clutch coil or the engine.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Raise and support the vehicle.(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
(5) Disconnect the wire harness connector from the
clutch field coil of the A/C compressor (Fig. 5).
(6) Remove the bolts that secure the underbody
suction and discharge lines to the A/C compressor.
(7) Disconnect the underbody suction and dis-
charge lines from the A/C compressor and remove
and discard the O-ring seals.
(8) Install plugs in, or tape over the opened refrig-
erant line fittings and the compressor ports.
(9) Remove the bolts that secure the A/C compres-
sor to the mounting bracket.
(10) Remove the A/C compressor from the engine
compartment.
INSTALLATION
DENSO 7SBU16CA/CCOMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine com-
partment and loosely install the three compressor
retaining bolts. Tighten the bolts using the following
sequence to 20 N´m (15 ft. lbs.).
Fig. 4 Denso 7SBU16C A/C Compressor
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
Fig. 5 Denso 10S17 A/C Compressor
1 - REFRIGERANT LINES
2 - WIRE HARNESS CONNECTOR
3 - BOLTS (3)
4 - A/C COMPRESSOR
24 - 68 PLUMBINGVA

²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) If equipped with an add-on rear A/C system,
install the lower A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION - DENSO 10S17).
(3) Lower the vehicle.
(4) Remove the tape or plugs from the opened suc-
tion line fitting and the discharge line fitting and the
compressor ports.
(5) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(6) Connect the A/C suction and discharge lines to
the A/C compressor.
(7) Install the bolts that secure the A/C suction
and discharge lines to the A/C compressor. Tighten
the bolts to 23 N´m (17 ft. lbs.).
(8) Connect the wire harness connector to the A/C
compressor clutch coil.
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Replace the receiver/drier if the A/C compres-
sor is being replaced due to an internal failure (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER/DRIER - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
DENSO 10S17A/CCOMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine com-
partment and loosely install the three compressorretaining bolts. Tighten the bolts using the following
sequence to 20 N´m (14 ft. lbs.).
²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened
underbody suction and discharge line fittings and
compressor ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(4) Connect the underbody suction and discharge
lines to the A/C compressor.
(5) Install the bolts that secure the underbody suc-
tion and discharge lines to the A/C compressor.
Tighten the bolts to 21 N´m (15 ft. lbs.).
(6) Connect the wire harness connector to the A/C
compressor clutch coil.
(7) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
INSTALLATION).
(8) Lower the vehicle.
(9) Replace the receiver/drier if the A/C compressor
is being replaced due to an internal failure (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
CEIVER/DRIER - INSTALLATION).
(10) Reconnect the negative battery 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).
A / C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
VAPLUMBING 24 - 69

there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.
The condenser cannot be repaired and, if faulty 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) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
(3) Remove the front fascia.
(4) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(5) Remove the headlamps from their mounts.
(6) Remove the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
REMOVAL).
(7) Disconnect the A/C discharge and liquid lines
from the A/C condenser and remove and discard the
O-ring seals (Fig. 6).
(8) Install plug in, or tape over the opened liquid
line fitting and the condenser ports.
(9) Disconnect the wire harness connector from the
auxiliary fan.
(10) Remove the auxiliary fan and upper bracket
assembly.
(11) Remove the auxiliary fan lower bracket
retainers and bracket.
(12) Remove the four condenser retaining screws.
(13) Carefully remove the condenser from the vehi-
cle.
INSTALLATION
NOTE: If the A/C condenser 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 A/C compressor in the
vehicle.
(1) Carefully position the A/C condenser into the
engine compartment.
(2) Install the four screws that secure the A/C con-
denser. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Install the lower auxiliary fan bracket and
retaining nuts. Tighten the nuts to 5 N´m (45 in.
lbs.).
(4) Install the auxiliary fan and upper bracket
assembly. Tighten the screws to 5 N´m (45 in. lbs.).
(5) Connect the wire harness connector to the aux-
iliary fan.
(6) Remove the tape or plug from the condenser
ports and the opened refrigerant line fittings.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the refrigerant line
fittings.
(8) Connect the A/C discharge and liquid lines to
the A/C condenser.
Fig. 6 A/C Condenser
1 - SCREW (4)
2 - CONDENSER
3 - LIQUID REFRIGERANT LINE
4 - COMPRESSOR DISCHARGE LINE
5 - NUT (2)
6 - LOWER AUXILIARY FAN BRACKET
7 - NUT (2)
8 - WIRE HARNESS CONNECTOR
9 - AUXILIARY COOLING FAN
10 - SCREW (2)
24 - 70 PLUMBINGVA