ECU MERCEDES-BENZ SPRINTER 2006 Service Manual

(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - 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 condenser fan suppression filter and the rear
A/C high pressure switch and remove the retaining
straps that secure the wire harness to the rear liquid
line (Fig. 4).
(6) Disengage the rear A/C wire harness grommet
from the roof panel and pull the wire harness down
into the vehicle (Fig. 5).
(7) Disconnect the rear body wire harness connec-
tor from the rear A/C wire harness.
(8) Remove the retaining straps that secure the
rear dome lamp harness to the rear A/C evaporator
housing and position the rear dome lamp harness out
of the way.
(9) Remove the nut that secures the positive wire
lead to the rear A/C system terminal block and posi-
tion the wire lead out of the way.
(10) Remove the insulating tape from around the
rear evaporator connections.(11) Disconnect the rear liquid line from the rear
A/C expansion valve and remove and discard the
O-ring seal.
(12) Disconnect the rear suction line from the rear
evaporator outlet tube and remove and discard the
O-ring seal.
(13) Install plugs into, or tape over the opened
refrigerant line fittings and rear expansion valve and
evaporator tube ports.
(14) Disconnect and install plugs into the two rear
evaporator drain hoses.
(15) Support the rear A/C evaporator housing and
remove the nine screws, four bolts and washers and
four damping washers that secure the rear A/C evap-
orator housing to the roof panel.
(16) With help from an assistant, remove the rear
A/C evaporator housing from the vehicle.
(17) If required, remove the rear A/C evaporator
from the rear A/C evaporator housing (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C EVAPORATOR - REMOVAL).
Fig. 4 Rear A/C Wire Harness - Condenser Side
1 - REAR CONDERSER FAN SUPPRESSION FILTER
2 - REAR A/C HIGH PRESSURE SWITCH
3 - REAR A/C WIRE HARNESS
4 - GROMMET
5 - RETAINING STRAPS
24 - 56 DISTRIBUTION - REARVA

INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C evaporator is being replaced. The refrigerant oil
must be drained from the old evaporator and mea-
sured to determine the amount of refrigerant oil to
add to the new evaporator. Use only refrigerant oil
of the type recommended for the rear A/C compres-
sor in the vehicle.
(1) If the rear A/C evaporator is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C evaporator. Drain the old evap-
orator and measure the refrigerant oil. Fill the new
evaporator with the same amount of new refrigerant
oil that was drained out of the old evaporator.
(2) With help from an assistant, position and sup-
port the rear A/C evaporator housing into the vehicle.
(3) Inspect the four rubber damping washers for
correct sealing. Replace the washers as required.
CAUTION: Be sure to install the rear A/C system
ground lead with one of the rear evaporator hous-
ing retaining bolts. Failure to correctly install theground lead could result in improper operation or
possible damage to the rear A/C system.
(4) Position the ground lead to the rear A/C evap-
orator housing and install the four bolts and washers
and four damping washers that secure the evapora-
tor housing to the roof panel. Tighten the bolts to 25
N´m (18 ft. lbs.).
(5) Install the nine screws that secure the rear A/C
evaporator housing to the roof panel. Tighten the
screws to 5 N´m (45 in. lbs.).
(6) Unplug and connect the two rear evaporator
drain hoses.
(7) Remove the tape or plugs from the refrigerant
line fittings and the rear expansion valve and evap-
orator tube ports.
(8) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(9) Connect the rear liquid line to the rear A/C
expansion valve. Tighten the liquid line nut to 35
N´m (26 ft. lbs.).
Fig. 5 Rear A/C Evaporator Housing
1 - REAR A/C EVAPORATOR HOUSING
2 - REAR A/C WIRE HARNESS
3 - REAR BODY WIRE HARNESS
4 - NUT
5 - POSITIVE WIRE LEAD
6 - GROUND LEAD
7 - GROMMET
8 - SEALING WASHER (4)
9 - BOLT AND WASHER (4)10 - REAR EVAPORATOR DRAIN HOSES
11 - SCREW (9)
12 - REAR DOME LAMP HARNESS
13 - REAR A/C EVAPANSION VALVE
14 - REAR LIQUID LINE FITTING
15 - REAR A/C EVAPORATOR OUTLET TUBE
16 - REAR SUCTION LINE FITTING
17 - INSULATING TAPE
VADISTRIBUTION - REAR 24 - 57

(10) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear suction line fit-
ting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(11) Connect the rear suction line to the rear evap-
orator outlet tube. Tighten the suction line nut to 35
N´m (26 ft. lbs.).
(12) Install new insulating tape around the rear
evaporator connections.
(13) Install the positive wire lead onto the rear
A/C system terminal block and install the retaining
nut. Tighten the nut securely.
(14) Reposition the rear dome lamp harness and
install the retaining straps that secure the harness
to the rear A/C evaporator housing.
(15) Connect the rear A/C wire harness connector
to the rear body wire harness.
(16) Route the rear A/C wire harness up through
the roof panel and install the grommet.
(17) Connect the rear A/C wire harness to the rear
condenser fan suppression filter and the rear A/C
high pressure switch and install the retaining straps
that secure the wire harness to the rear liquid line.
(18) Reconnect the negative battery cable.
(19) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(20) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(21) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).
(22) 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).
AIR FILTER
REMOVAL
(1) Unlock the eight quick-release fasteners by
turning them 90 degrees counter clockwise (Fig. 6).
(2) Remove the rear air inlet grate from the rear
A/C evaporator cover.
(3) Remove the rear particulate air filter by disen-
gaging the velcro-type retainers.
(4) Carefully clean the rear particulate air filter
using compressed air.
INSTALLATION
NOTE: Replace the rear particulate air filter if it is
heavily soiled or damaged.
(1) Position the rear particulate air filter and
engage the velcro-type retainers.
(2) Install the rear air inlet grate onto the rear
A/C evaporator cover.
(3) Lock the eight quick-release fasteners by turn-
ing them 90 degrees clockwise.
BLOWER MOTOR
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - REMOVAL).
(3) Disconnect the wire harness connectors from
the rear blower motor suppression filter and from the
rear blower motor being serviced and remove the
suppression filter (Fig. 7).
(4) Remove the body sealer from around the rear
blower motor area being serviced.
(5) Remove the screws that secure each rear
blower motor to the rear evaporator housing and
remove blower motor.
Fig. 6 Rear Particulate Air Filter
1 - QUICK-RELEASE FASTENER (8)
2 - REAR A/C EVAPORATOR COVER
3 - REAR PARTICULATE AIR FILTER
4 - REAR AIR INLET GRATE
24 - 58 DISTRIBUTION - REARVA

INSTALLATION
(1) Position the rear blower motor being serviced
to the rear A/C evaporator housing.
(2) Install the screws that secure each rear blower
motor to the rear A/C evaporator housing. Tighten
the screws to 5 N´m (45 in. lbs.).
(3) Install a new bead of body sealant to the
blower motor area being serviced.
(4) Install the rear blower motor suppression filter
and connect the wiring harness connectors to the
suppression filter and to the rear blower motor being
serviced.
(5) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).
(6) Reconnect the negative battery cable.
Fig. 7 Rear Blower Motors - LH shown, RH similar
1 - REAR BLOWER MOTOR (2)
2 - REAR A/C EVAPORATOR HOUSING
3 - SUPPRESSION FILTER WIRE CONNECTOR
4 - BLOWER MOTOR WIRE CONNECTOR
5 - REAR BLOWER MOTOR SUPPRESSION FILTER
6 - SEALER
7 - SCREW (5 PER MOTOR)
VADISTRIBUTION - REAR 24 - 59

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

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

(9) Install the nuts that secure the A/C discharge
and liquid lines to the A/C condenser. Tighten the
nuts to 33 N´m (24 ft. lbs.).
(10) Install the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).
(11) Install the headlamps into their mounts.
(12) Install the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - INSTALLATION).
(13) Install the front fascia.
(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) Recharge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A / C DISCHARGE LINE
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
(1) 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 RECOVERY).
(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(4) Remove the nut that secures the discharge line
fitting to the condenser on the left side of the con-
denser.
(5) Disconnect the discharge line fitting from the
condenser inlet port.
(6) Remove the seal from the discharge line fitting
and discard.
(7) Install plug in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(8) Remove the bolt that secures the discharge line
fitting to the top of the compressor (Fig. 7).
(9) Disconnect the discharge line fitting from the
compressor discharge port.
(10) Remove the seal from the discharge line fit-
ting and discard.(11) Install plug in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(12) Disconnect the discharge line from the retain-
ing clip and remove the discharge line from the vehi-
cle.
INSTALLATION
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.
(1) Position the discharge line into the engine com-
partment.
(2) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(4) Connect the discharge line fitting to the com-
pressor discharge port on the top of the compressor.
(5) Install the bolt that secures the discharge line
fitting to the compressor. Tighten the bolt to 23 N´m
(17 ft. lbs.).
Fig. 7 A/C Compressor - Refrigerant Lines
1 - A/C COMPRESSOR
2 - O-RING SEAL
3 - A/C SUCTION LINE
4 - BOLT
5 - RETAINING CLIP
6 - BOLT
7 - A/C DISCHARGE LINE
8 - O-RING SEAL
VAPLUMBING 24 - 71