wheel MERCEDES-BENZ SPRINTER 2006 Service Manual

OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is
part of the pulley.
The compressor clutch engagement is controlled by
several components:
²A/C switch on the A/C-heater control panel
²Evaporator temperature sensor
²A/C pressure transducer
²Air temperature sensor
²CAN bus messages
The compressor clutch is de-energized under any of
the following conditions:
²Blocked compressor (thermal fuse in the pulley)
²Low pressure in the system
²Low evaporator temperature
²Hard acceleration (WOT)
²High coolant temperatures
STANDARD PROCEDURE
A / C COMPRESSOR CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between specifications
(Refer to 24 - HEATING & AIR CONDITIONING -
SPECIFICATIONS), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
A / C COMPRESSOR CLUTCH BREAK - IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control in the
Recirculation Mode, the A/C button in the on posi-
tion, the blower motor switch in the highest speed
position, and the engine speed at 1500 to 2000 rpm.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher compressor
clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil
wire harness connector on the top of the compressor.
(4) Remove the retainer securing the compressor
clutch coil lead on the top of the compressor.
(5) Remove the bolt that secures the compressor
clutch to the compressor shaft (Fig. 2). If necessary, a
band-type oil filter wrench or strap wrench can be
placed around the clutch plate to aid in bolt
removal.
Fig. 1 A/C Compressor Clutch
1 - BOLT
2 - CLUTCH PLATE
3 - PULLEY AND BEARING
4 - FIELD COIL
5 - SNAP RING
6 - SNAP RING
7 - SHIM (2)
VACONTROLS-FRONT 24 - 9

radio (Fig. 7). The A/C-heater control contains a rota-
ry-type temperature control, a rotary-type mode con-
trol, a thumbwheel-type blower motor speed control
and an A/C mode push button switch and indicator
lamp. The A/C-heater control also features a push
button switch and indicator lamp for the residual
engine heat utilization (REST) function, cabin heater
or the heater booster (as equipped).
OPERATION
To control the interior temperature, the A/C-heater
control uses the actual values from the temperature
sensors and the CAN bus and compares them with
the nominal value of the temperature control switch.
The A/C-heater control is diagnosed using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The A/C-heater control is diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures.
The A/C-heater control cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
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 negative battery
cable.
(2) Remove the center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(3) Remove the two screws that secure the A/C-
heater control to the instrument panel (Fig. 8).
(4) Pull the A/C-heater control away from the
instrument panel far enough to access the connec-
tions on the back of the control.
(5) Mark and disconnect the two control cables
from the A/C-heater control.
(6) Disconnect the two wiring harness connectors
from the A/C-heater control.
(7) If A/C-heater control is to be replaced, remove
the two mounting brackets from the A/C-heater con-
trol.INSTALLATION
(1) If removed, install the two mounting brackets
to the A/C-heater control.
(2) Connect the two wire harness connectors into
the back of the A/C-heater control.
(3) Connect the two control cables to the A/C-
heater control.
NOTE: Install the control cable of bottom adjust-
ment lever to the front adjustment wheel of the A/C-
heater control.
(4) Position the A/C-heater control into the instru-
ment panel.
Fig. 7 A/C-Heater Control
Fig. 8 A/C-Heater Control
1 - A/C-HEATER CONTROL
2 - CONTROL CABLE
3 - CONTROL CABLE
4 - WIRE HARNESS CONNECTOR
5 - WIRE HARNESS CONNECTOR
6 - MOUNTING BRACKET (2)
7 - SCREW (2)
VACONTROLS-FRONT 24 - 13

BLOWER MOTOR SWITCH
DESCRIPTION
The blower motor is controlled by a thumbwheel-
type blower motor control, mounted in the A/C-heater
control (Fig. 17). The switch allows the selection of
four blower motor speeds with the ignition switch in
the On position.
NOTE: The blower motor will operate only at the
lowest speed when the Residual Engine Heat Utili-
zation (REST) function is selected, regardless of the
blower speed setting on the A/C-heater control.
OPERATION
When the ignition is turned to On, the integral
blower motor switch within the ATC A/C-heater con-
trol supplies power to the blower motor switch. The
switch directs power to the individual blower driver
circuits through the blower motor resistor block to
the blower motor and then to ground.
The blower motor switch cannot be adjusted or
repaired, and if faulty or damaged, the A/C-heater
control must be replaced (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/A/C HEATER
CONTROL - REMOVAL).
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH
The blower motor switch can be diagnosed by using
the DRBIIItscan tool. Refer to Body Diagnostic Pro-
cedures. For circuit descriptions and diagrams, refer
to the appropriate wiring information.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
The evaporator temperature sensor measures the
temperature of the conditioned air downstream of the
A/C evaporator (Fig. 18). The evaporator temperature
sensor is an electrical thermistor within a molded
plastic case that is inserted into the HVAC housing
near the coldest point of the A/C evaporator. Two ter-
minals within the connector receptacle connect the
sensor to the vehicle electrical system through a wire
lead and connector of the HVAC wire harness.
The external location of the evaporator tempera-
ture sensor allows the sensor to be removed or
installed without disturbing the refrigerant in the
A/C system.
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the tem-
peratures it monitors. The A/C-heater control is con-
nected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator tem-
perature increases, the resistance of the sensor
decreases and the voltage monitored by the A/C-
heater control decreases. The A/C-heater control uses
this monitored voltage reading to an indication of the
evaporator temperature. The A/C-heater control is
programmed to respond to this input by cycling the
A/C compressor clutch off if the evaporator tempera-
ture sensor reads between 1É C (33É F) and 3.5É C
(38É F) to protect the A/C evaporator from freezing.
Fig. 17 A/C-Heater Control
Fig. 18 Sensor-Evaporator Temperature
1 - EVAPORATOR TEMPERATUE SENSOR
2 - A/C EVAPORATOR
3 - HVAC HOUSING
4 - WIRE CONNECTOR
VACONTROLS-FRONT 24 - 19

IN - CAR TEMPERATURE SEN-
SOR
DESCRIPTION
The in-car temperature sensor measures the actual
air temperature within the passenger compartment.
The in-car temperature sensor is located inside of the
A/C-heater control behind a vented panel (Fig. 20)
and is not a separate serviceable component. The
A/C-heater control must be replaced if there is a fault
relating to the in-car temperature sensor.
OPERATION
Air from the passenger compartment flows over the
thermistor of the in-car temperature sensor. The
thermistor changes resistance with air temperature.
The ATC A/C-heater control measures this resistance
and calculates the temperature of the air. The A/C-
heater control then makes adjustments to maintain
the selected passenger compartment temperature.
The in-car temperature sensor cannot be adjusted
or repaired, and if faulty or damaged, the A/C-heater
control must be replaced (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/A/C HEATER
CONTROL - REMOVAL).
DIAGNOSIS AND TESTING
IN - CAR TEMPERATURE SENSOR
The in-car temperature sensor is diagnosed by per-
forming the ATC Function Test using the DRBIIIt
scan tool. Refer to Body Diagnostic Procedures. For
circuit descriptions and diagrams, refer to the appro-
priate wiring information.
MODE DOOR CABLES
REMOVAL
The air distribution control cables (mode door
cables) can be removed and installed without having
to remove the instrument panel from the vehicle.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(3) Remove the A/C-heater control (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL).
(4) Mark and disconnect the control cables from
the A/C-heater control.
(5) Mark and disconnect the control cables from
the HVAC housing retainers (Fig. 21).
(6) Disconnect the control cables from the mode
door levers and remove the cables from the vehicle.
INSTALLATION
(1) Connect the two control cables to the mode
door levers (Fig. 22).
(2) Connect the two control cables to the A/C-
heater control.
NOTE: Install the control cable of bottom adjust-
ment lever to the front adjustment wheel of the A/C-
heater control.
(3) Hold the A/C-heater control in its installation
position.
Fig. 20 In-Car Temperature Sensor
1 - A/C-HEATER CONTROL
2 - IN-CAR TEMPERATURE SENSOR
Fig. 21 Air Distribution Control Cables
1 - AIR DISTRIBUTION CONTROL CABLES
2 - ADJUSTMENT LEVERS
3 - HVAC HOUSING
VACONTROLS-FRONT 24 - 21

motor, while relay 2 when activated, sends power
directly to the blower motor.
The rear blower motor switch cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING
REAR BLOWER MOTOR SWITCH
Before testing the rear blower motor switch, verify
that the front A/C system is functional by performing
the ATC Fuction Test using the DRBIIItscan tool.
Use a volt/ohmmeter to test the rear blower motor
switch. For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire har-
ness routing and retention, connector pin-out infor-
mation and location views for the various wire
harness connectors, splices and grounds.
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) Unplug the wire harness connector from the
rear blower motor switch.
(3) Check for continuity between terminal 10 and
terminals 1, 7 and 4 of the blower motor switch. In
all instances, there should be continuity.
NOTE: To check the switch's internal circuits, con-
nect the negative lead of the ohmmeter to terminal
10 and the positive ohmmeter lead to terminals 1, 7
and 4. To check the switch's integral light emitting
diodes, reverse the ohmmeter leads.
(4) Check for continuity between the rear blower
motor switch terminals 3 and 7 as you move the
blower motor switch to each of the two speed posi-
tions, and the Off position. There should be continu-
ity in only one blower motor switch speed position.
(5) Check for continuity between the rear blower
motor switch terminals 4 and 8 as you move the
blower motor switch to each of the two speed posi-
tions, and the Off position. There should be continu-ity in only the other blower motor switch speed
position.
(6) If OK, test and repair the rear blower motor
switch wire harness circuits. If not OK, replace the
faulty rear blower motor switch.
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.
NOTE: The rear A/C blower motor switch is used on
vehicles with the optional rear A/C system.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory switch panel from the
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/ACCESSORY SWITCH BEZEL -
REMOVAL).
(3) Disconnect the wire harness connector from the
rear A/C blower motor switch (Fig. 14).
(4) Disengage the retaining tabs and remove the
rear A/C blower motor switch from the accessory
switch panel.
24 - 36 CONTROLS - REARVA

INSTALLATION
(1) Position the rear evaporator temperature sen-
sor to the rear A/C evaporator housing.
(2) Install the two screws that secure the rear
evaporator temperature sensor to the rear A/C evap-
orator housing. Tighten the screws to 2 N´m (17 in.
lbs.).
(3) Install the sensor probe into the rear A/C evap-
orator.
(4) Connect the two wire harness connectors to the
rear evaporator temperature sensor.
(5) Install the rear air filter (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/AIR FILTER - INSTALLATION).
(6) Reconnect the negative battery cable.
TEMPERATURE CONTROL
DESCRIPTION
The temperature control for the optional rear A/C
system is a thumbwheel-type control mounted in the
switch panel on the instrument panel (Fig. 17). The
rear A/C temperature control allows the selection of
four temperature settings when the rear A/C blower
motor is activated.OPERATION
With the front A/C switch and rear blower motor
activated, the rear A/C output temperature can be
selected by rotating the thumbwheel control upwards
(increase cooling) or downwards (decrease cooling).
Depending on the rear A/C temperature control posi-
tion, a temperature command signal is sent to the
Fig. 16 Rear Evaporator Temperature Sensor
1 - REAR A/C EVAPORATOR HOUSING
2 - SCREWS (2)
3 - REAR EVAPORATOR SENSOR SWITCH UNIT4 - WIRE HARNESS CONNECTORS
5 - REAR EVAPORATOR SENSOR PROBE
Fig. 17 Rear A/C Temperature Control
24 - 38 CONTROLS - REARVA

rear A/C control module. The temperature of the cir-
culated internal air of the rear compartment is mea-
sured by a temperature sensor located in the rear
evaporator unit. The value of the temperature sensor
is compared in the rear A/C control module with an
adjusted value at the rear A/C temperature control.
The rear A/C temperature control cannot be
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING
REARA/CTEMPERATURE CONTROL
Before testing the rear A/C temperature control,
verify that the front A/C system is operating correctly
by performing the ATC Function Test using the
DRBIIItscan tool. Use a volt/ohmmeter to test the
control. For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire har-
ness routing and retention, connector pin-out infor-
mation and location views for the various wire
harness connectors, splices and grounds.
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) Unplug the wire harness connector from the
rear A/C temperature control.
(3) Check for continuity between terminal 9 and
terminals 3 and 5 of the A/C temperature control. In
all instances, there should be continuity.
NOTE: To check the switch's internal circuits, con-
nect the positive lead of the ohmmeter to terminal 9
and the negative lead to terminals 3 and 5. To
check the switches integral light emitting diode,
reverse the ohmmeter leads.
(4) Check for resistance between terminal 3 and 5
of the A/C temperature control as you move the con-
trol to each temperature position. Resistance should
be present and should change for each position.(5) If OK, test and repair the rear A/C tempera-
ture control wire harness circuits. If not OK, replace
the faulty rear A/C temperature control.
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.
NOTE: The rear A/C temperature control is used
only on models with the optional rear A/C unit.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory switch panel from the
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/ACCESSORY SWITCH BEZEL -
REMOVAL).
(3) Disconnect the wire harness connector from the
rear A/C temperature control (Fig. 18).
(4) Disengage the retaining tabs and remove the
rear A/C temperature control from the accessory
switch panel.
Fig. 18 Rear A/C Temperature Control
1 - WIRE HARNESS CONNECTOR
2 - REAR A/C TEMPERATURE CONTROL
3 - ACCESSORY SWITCH PANEL
VACONTROLS - REAR 24 - 39

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

(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

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