MERCEDES-BENZ SPRINTER 2006 Service Manual

OPERATION
The rear condenser fan suppression filter provides
protection against transient interference signals or
similar interference to the electronic rear condenser
fan circuits which can effect the performance of the
rear A/C control module circuits and radio reception
quality. The suppression filter for the rear condenser
fan consist of capacitors and inductance coils.
The rear condenser fan suppression filter cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for complete HVAC wiring diagrams.
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-REAR - REMOVAL).
(3) Disconnect the two wire harness connectors
from the rear condenser fan suppression filter (Fig.
24).
(4) Remove the rear condenser fan (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C CONDENSER FAN - REMOVAL).
(5) Remove the two bolts, washers and nuts that
secure the rear condenser fan suppression filter to
the rear A/C condenser housing and remove the sup-
pression filter.
INSTALLATION
(1) Position the rear condenser fan suppression fil-
ter to the rear A/C condenser housing.
(2) Install the two bolts, washers and nuts that
secure the rear condenser fan suppression filter to
the rear A/C condenser housing. Tighten the bolts to
5 N´m (44 in. lbs.).
(3) Install the rear condenser fan (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C CONDENSER FAN - INSTALLATION).
(4) Connect the wiring harness connectors to the
rear condenser fan suppression filter and the rear
condenser fan.
(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).
(6) Reconnect the negative battery cable.
Fig. 23 Rear Condenser Fan Suppression Filter
1 - REAR CONDENSER FAN SUPPRESSION FILTER
2 - WIRE CONNECTOR (TO CONDENSER FAN)
3 - MOUNTING BRACKET
4 - WIRE CONNECTOR (TO REAR A/C HARNESS)
Fig. 24 Rear Condenser Fan Suppression Filter
1 - REAR A/C CONDENSER HOUSING
2 - CONDENSER FAN WIRE CONNECTOR
3 - BOLT, WASHER AND NUT (2)
4 - SUPPRESSION FILTER WIRE CONNECTOR
5 - REAR CONDENSER FAN SUPPRESSION FILTER
24 - 44 CONTROLS - REARVA

DISTRIBUTION - FRONT
TABLE OF CONTENTS
page page
AIR FILTER
REMOVAL.............................45
INSTALLATION.........................45
AIR OUTLETS
REMOVAL.............................45
INSTALLATION.........................46
BLOWER MOTOR
REMOVAL.............................47
INSTALLATION.........................47
DEFROSTER DUCTS
REMOVAL.............................47
INSTALLATION.........................47FLOOR DISTRIBUTION DUCTS
REMOVAL.............................47
INSTALLATION.........................48
HVAC HOUSING
REMOVAL.............................48
DISASSEMBLY.........................49
ASSEMBLY............................50
INSTALLATION.........................50
INSTRUMENT PANEL DUCTS
REMOVAL.............................51
INSTALLATION.........................51
AIR FILTER
REMOVAL
(1) Remove the insulation blanket from the venti-
lation housing in the engine compartment (Fig. 1).
(2) Open the locking clips at the front and rear of
the ventilation housing.
(3) Slide the ventilation housing cover in the direc-
tion of the arrow shown.
(4) Remove the air filter.
INSTALLATION
(1) Install the air filter into the ventilation hous-
ing.(2) Install the ventilation housing cover
(3) Close the locking clips at the front and rear of
the ventilation housing.
NOTE: The locking tabs should retain the ventila-
tion housing cover securely.
(4) Install the insulation blanket onto the ventila-
tion housing.
AIR OUTLETS
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.
(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
VADISTRIBUTION - 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 - FRONTVA

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
VADISTRIBUTION - 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 - FRONTVA

(11) Disconnect the heater hoses from the heater
core.
(12) Disconnect the heater hoses from the heater
core tubes. Install plugs in, or tape over the opened
heater core tubes.
(13) Remove the two bolts securing the refrigerant
lines to the evaporator tubes and disconnect the lines
from the tubes. Install plugs in, or tape over all of
the opened refrigerant line fittings.
(14) Remove the seals from the refrigerant line fit-
tings and discard.
(15) Install plugs in, or tape over the opened
refrigerant line fittings and evaporator tubes.
(16) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(17) Remove the defroster, floor distribution and
instrument panel ducts (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/DEFROSTER
DUCTS - REMOVAL), (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/FLOOR DIS-
TRIBUTION DUCTS - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
INSTRUMENT PANEL DUCTS - REMOVAL).
(18) Disconnect the two bulkhead ground connec-
tions near instrument cluster area.
(19) Remove the passenger airbag bracket (Refer
to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG - REMOVAL).(20) Disconnect the wire harness connector from
the evaporator temperature sensor and air outlet
temperature sensor (Fig. 8).
(21) Remove the wire harness from the bracket
located on the right side of the heater housing and
position the wire harness out of the way.
(22) Disconnect the A/C-heater control cables from
the mode door levers (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR CABLE
- REMOVAL).
(23) Disconnect the evaporator drain tube from the
HVAC housing.
(24) Remove the five bolts securing the HVAC
housing to the body.
NOTE: Make sure that the interior is protected in
case of loss of residual fluids from the heater core
and the A/C evaporator.
(25) Remove the HVAC housing from the vehicle.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Place the HVAC housing in the upright position
on a work bench, making allowance for leakage of
fluids.
Fig. 7 Ventilation Housing
1 - NUT (5)
2 - WASHER (5)
3 - VENTILATION HOUSING
4 - HOUSING COVER
Fig. 8 Heater Housing
1 - HEATER HOUSING
2 - AIR TEMP SENSOR WIRE CONNECTOR
3 - WIRE HARNESS
4 - WIRE HARNESS CONNECTOR
5 - BOLT (4)
6 - EVAP TEMP SENSOR WIRE CONNECTOR
7 - EVAPORATOR DRAIN TUBE
VADISTRIBUTION - FRONT 24 - 49

(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

(12) Install the two bolts that secure the refriger-
ant line terminal block to the A/C evaporator.
Tighten the bolts to 5 N´m (45 in. lbs.).
(13) Unplug or remove the tape from the heater
core hoses and tubes.
(14) Connect the heater hoses to the heater core
tubes and install the heater hose clamps.
(15) Install the ventilation housing to the dash
panel.
(16) Install the nuts and washers that secure the
ventilation housing to the dash panel. Tighten the
nuts to 5 N´m (45 in. lbs.).
(17) Connect the wire harness connectors to the
blower motor, blower motor resistor block and the
recirculation door actuator.
(18) Connect the vacuum harness connector to the
recirculation door actuator.
(19) Install the air filter into the ventilation hous-
ing (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/AIR FILTER -
INSTALLATION).
(20) Install the windshield washer reservoir (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - INSTALLATION).
(21) Install the air cleaner housing (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
(22) Reconnect the negative battery cable.
(23) If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).
(24) Refill the engine cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE - COOLANT SYSTEM FILL).
(25) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(26) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
INSTRUMENT PANEL 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 floor distribution ducts (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/FLOOR DISTRIBUTION DUCTS -
REMOVAL).(4) If removing the right instrument panel duct,
remove the passenger air bag module and bracket
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSEN-
GER AIRBAG - REMOVAL).
(5) Remove the screws that secure the left and/or
right instrument panel duct and remove the duct(s)
as required (Fig. 10).
INSTALLATION
(1) Connect the instrument panel duct(s) to the
heater housing as required.
(2) Install the instrument panel duct retaining
screws. Tighten the screws to 2 N´m (17 in. lbs.).
(3) If servicing the right instrument panel duct,
install the passenger air bag module and bracket
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSEN-
GER AIRBAG - INSTALLATION).
(4) Install the floor distribution ducts (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/FLOOR DISTRIBUTION DUCTS - INSTAL-
LATION).
(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).
Fig. 10 Instrument Panel Duct - RH Shown, LH
Typical
1 - RH DEFROSTER DUCT
2 - SCREW (2)
3 - RH INSTRUMENT PANEL DUCT
4 - RH FLOOR DISTRIBUTION DUCT
5 - CENTER FLOOR DISTRIBUTION DUCT
VADISTRIBUTION - FRONT 24 - 51

DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
A/C CONDENSER COVER
REMOVAL.............................52
INSTALLATION.........................52
A/C CONDENSER HOUSING
REMOVAL.............................52
INSTALLATION.........................54
A/C EVAPORATOR COVER
REMOVAL.............................55
INSTALLATION.........................55A/C EVAPORATOR HOUSING
REMOVAL.............................55
INSTALLATION.........................57
AIR FILTER
REMOVAL.............................58
INSTALLATION.........................58
BLOWER MOTOR
REMOVAL.............................58
INSTALLATION.........................59
A / C CONDENSER COVER
REMOVAL
(1) Unlock the six quick-release fasteners by turn-
ing them 90 degrees in either direction (Fig. 1).
(2) Remove the rear A/C condenser cover from the
rear A/C condenser housing.
INSTALLATION
(1) Inspect the six rubber damping washers for
correct sealing. Replace the washers as required.
(2) Position the rear A/C condenser cover over the
rear A/C condenser housing.
(3) Lock the six quick-release fasteners by turning
them 90 degrees in either direction.
A / C CONDENSER HOUSING
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 A/C wire harness from the
rear blower motor suppression filter and the rear A/C
high pressure switch (Fig. 2).
(6) Remove the retaining straps that secure the
rear A/C wire harness to the rear liquid line and
position the wire harness out of the way.
(7) Remove the screw and bracket that secures the
rear discharge line to the right side of the rear con-
denser housing.
(8) Disconnect the rear discharge line from the
rear A/C condenser and remove and discard the
O-ring seal.
Fig. 1 Rear A/C Condenser Cover
1 - QUICK-RELEASE FASTENER AND WASHER (6)
2 - RUBBER DAMPING WASHER (6)
3 - REAR CONDENSER COVER
4 - REAR A/C CONDENSER HOUSING
24 - 52 DISTRIBUTION - REARVA

(9) Disconnect the rear liquid line from the rear
refrigerant reservoir outlet and remove and discard
the O-ring seal.
(10) Install plugs into, or tape over the rear refrig-
erant line fittings and condenser and reservoir ports.
(11) Remove the eight nuts and washers that
secure the rear A/C condenser housing to the roof
panel.
(12) Carefully separate the body sealer between
the rear A/C condenser housing and the roof panel
and with help from an assistant, remove the con-
denser housing.
(13) Remove any shims and trim the body sealer
on top of the roof panel down to a thickness of 2 mm
(0.078 in.).
VADISTRIBUTION - REAR 24 - 53