battery MERCEDES-BENZ SPRINTER 2006 Service Manual

(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(8) Connect the discharge line fitting to the con-
denser inlet port.
(9) Install the nut that secures the discharge line
fitting to the condenser. Tighten the nut to 33 N´m
(24 ft. lbs.).
(10) Install the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - INSTALLATION).
(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)
(13) Reconnect the negative battery cable.
A/CEVAPORATOR
DESCRIPTION
The A/C evaporator for the heating-A/C system is
located within the HVAC housing, behind the instru-
ment panel (Fig. 8). The A/C evaporator is positioned
within the HVAC housing so that all air entering the
housing must pass over the evaporator fins before it
is distributed through the heating-A/C system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the A/C compres-
sor is engaged and circulating refrigerant through
the A/C evaporator.
The A/C evaporator tubes are connected and sealed
to the A/C expansion valve by use of rubber O-rings
and a tapping block.
The A/C evaporator is serviced by removing and
disassembling the HVAC housing.
OPERATION
Refrigerant enters the evaporator from the expan-
sion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas
before it leaves the evaporator.
The evaporator cannot be 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.
Fig. 8 Front A/C Evaporator
1 - A/C EVAPORATOR
2 - EVAPORATOR TUBES
3 - TAPPING BLOCK
24 - 72 PLUMBINGVA

in order to meet vehicle cooling requirements. Con-
trolling the refrigerant flow through the A/C evapo-
rator ensures that none of the refrigerant leaving the
evaporator is still in a liquid state, which could cause
damage to the A/C compressor.
The A/C expansion valve is factory calibrated and
cannot be adjusted or repaired and, if faulty or dam-
aged, it must be replaced.
DIAGNOSIS AND TESTING
A / C EXPANSION VALVE
The A/C expansion valve is located on the engine
side of the dash panel near the shock tower.
The A/C expansion valve can fail in three different
positions (open, closed or restricted).
In an Open Position: this will result in a noisy A/C
compressor or no cooling. The cause can be broken
spring, broken ball or excessive moisture in the A/C
system. If the spring or ball are found to be defective,
replace the A/C expansion valve. If excessive mois-
ture is found in the A/C system, recycle the refriger-
ant.
In a Closed Position: There will be low suction
pressure and no cooling. This may be caused by a
failed power dome or excessive moisture in the A/C
system. If the power dome on the A/C expansion
valve is found to be defective replace the A/C expan-
sion valve. If excessive moisture is found recycle the
refrigerant.
A Restricted Orifice: There will be low suction
pressure and no cooling. This may be caused by
debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the A/C expansion valve and the receiver-drier.
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) Recover the refrigerant from the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the nut that secures the suction and
liquid line fittings to the stud on the A/C expansion
valve (Fig. 11).(4) Disconnect the suction and liquid lines from
the expansion valve.
(5) Remove the seals from the suction and liquid
line fitting and discard.
(6) Install plugs in, or tape over the opened liquid
and suction line fittings and both expansion valve
ports.
(7) Remove the two bolts that secure the expan-
sion valve to the evaporator tube tapping plate.
(8) Remove the expansion valve from the evapora-
tor tube tapping plate.
(9) Remove the seals from the evaporator inlet and
outlet tube fittings and discard.
(10) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the tapping
plate evaporator inlet and outlet tube fittings and
both ports on the back of the A/C expansion valve.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the tapping plate
evaporator inlet and outlet tube fittings.
(3) Position the A/C expansion valve onto the tap-
ping plate evaporator inlet and outlet tube fittings.
Fig. 11 A/C Expansion Valve
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE
4 - BOLT (2)
5 - A/C SUCTION LINE
6 - NUT
7 - A/C LIQUID LINE
8 - O-RING SEAL (2)
24 - 74 PLUMBINGVA

(4) Install the two bolts that secure the A/C expan-
sion valve to the evaporator tube tapping plate.
Tighten the bolts to 5 N´m (45 in. lbs.).
(5) Remove the tape or plugs from the liquid and
suction line fittings and both expansion valve ports.
(6) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid and suc-
tion line fittings.
(7) Connect the liquid line fitting to the A/C expan-
sion valve.
(8) Connect the suction line fitting to the A/C
expansion valve.
(9) Install the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve. Tighten the nut to 10 N´m (89 in. lbs.).
(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).
ELECTRIC COOLANT PUMP
DESCRIPTION
The electric coolant pump ensures the uniform flow
of coolant through the heater core without bubbles,
even at low speeds (Fig. 12). The electric coolant
pump is located in the left side of the engine com-
partment near the battery and is controlled by the
A/C-heater control.
The electric coolant pump housing contains two
coolant hose connections and an electric motor which
drives the vane-type pump using a magnetic
clutch.
OPERATION
The electric coolant pump is controlled by the ATC
A/C-heater control and is only operational when the
ignition switch is on under the following conditions:
(1) Vehicle speed below 27 Km/h (17 mph).
(2) Coolant temperature above 65É C (150É F) but
less than 110É C (230 É F).
(3) Any blower motor speed setting.
(4) Temperature heat setting above the halfway
setting (60% heat).
(5) The pump will turn off at speeds above 48
Km/h (30 mph).
(6) The pump will turn off if the coolant tempera-
ture rises above 110É C (230 É F).
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE - DRAINING COOLANT SYS-
TEM).
(3) Disconnect the wire harness connector from the
electric coolant pump (Fig. 13).
(4) Loosen both hose clamps from the electric cool-
ant pump.
(5) Using a twisting motion gently remove both
heater hoses from the electric coolant pump.
(6) Remove the two electric coolant pump bracket
retaining nuts from the body studs.
(7) Remove the electric coolant pump from the
vehicle.
Fig. 12 Electric Coolant Pump
1 - ELECTRIC COOLANT PUMP
2 - COOLANT HOSE CONNECTIONS
3 - WIRE CONNECTOR
VAPLUMBING 24 - 75

INSTALLATION
(1) Install the electric coolant pump and mounting
bracket onto the body studs.
(2) Install the two bracket retaining nuts. Tighten
the nuts to 5 N´m (45 in. lbs.).
(3) Using a twisting motion gently install both
hoses onto the electric coolant pump.
(4) Tighten both hose clamps securely.
(5) Connect the wire harness connector to the elec-
tric coolant pump.
(6) Reconnect the negative battery cable.
(7) Fill the engine cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE - COOLING SYSTEM FILL).
HEATER CORE
DESCRIPTION
The heater core is mounted into the HVAC hous-
ing, located behind the instrument panel (Fig. 14).
The heater core is a heat exchanger made of rows of
tubes and fins. The heater core tubes are attached to
the heater core by using O-ring seals and bolts.
The heater core is serviced by removing and disas-
sembling the HVAC housing.
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core whenever the heater water
valve is cycled open by the ATC A/C-heater control.
As the coolant flows through the heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
heater water valve controls the heater output air
temperature by controlling the amount of heated
engine coolant flowing through the heater core. The
blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be 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.
Fig. 13 Electric Coolant Pump
1 - HEATER HOSE
2 - HOSE CLAMP (2)
3 - HEATER HOSE
4 - ELECTRIC COOLANT PUMP
5 - WIRE HARNESS CONNECTOR
6 - NUT (2)
Fig. 14 Front Heater Core
1 - HEATER CORE
2 - BOLT (3)
3 - HEATER CORE TUBES
4 - O-RING SEALS
24 - 76 PLUMBINGVA

(4) Remove the nut that secures the A/C liquid line
to the A/C condenser.
(5) Disconnect the A/C liquid line to the A/C con-
denser and remove and discard the O-ring seal.
(6) Install plug in, or tape over the opened liquid
line fitting and the condenser outlet port.
(7) Remove the routing clip retaining nut and dis-
engage the routing clip retainer on top of the left
frame rail from the front section of the liquid line.
(8) Remove the A/C pressure sensor from the front
liquid line fitting (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C PRESSURE
TRANSDUCER - REMOVAL).
(9) Remove the bolt that secures the front section
of the liquid line to the top of the receiver/drier (Fig.
16).
(10) Disconnect the front section of the liquid line
from the receiver/drier and remove and discard the
O-ring seal.
(11) Install plug in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
(12) Remove the front section of the A/C liquid line
from the engine compartment.
REAR SECTION
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE - REFRIGERANT SYSTEM RECOV-
ERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).(4) Remove the nut that secures the A/C suction
and liquid lines to the stud on the A/C expansion
valve (Fig. 17).
(5) Disconnect the A/C suction and liquid lines
from the A/C expansion valve and remove and dis-
card the O-ring seals.
(6) Disengage the routing clip retainer from the
rear section of the A/C liquid line.
(7) Remove the bolt that secures the rear section
of the liquid line to the top of the receiver/drier (Fig.
16).
(8) Disconnect the rear section of the liquid line
from the receiver/drier.
(9) Remove the seal from the liquid line fitting
outlet port and discard.
(10) Install plugs in, or tape over the opened liquid
and suction line fittings, both receiver/drier ports and
both expansion valve ports.
(11) Remove the rear section of the liquid line from
the engine compartment.
Fig. 16 Receiver-Drier
1 - RECEIVER/DRIER
2 - A/C LIQUID LINE (REAR SECTION)
3 - A/C PRESSURE TRANSDUCER
4 - A/C LIQUID LINE (FRONT SECTION)
5 - CLAMP
Fig. 17 A/C Expansion Valve
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE
4 - BOLT (2)
5 - A/C SUCTION LINE
6 - NUT
7 - A/C LIQUID LINE
8 - O-RING SEAL (2)
24 - 78 PLUMBINGVA

INSTALLATION
NOTE: The A/C liquid line is serviced in two sec-
tions. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure trans-
ducer on the fitting for the receiver/drier. The rear
section connects between the receiver/drier and the
A/C expansion valve.
FRONT SECTION
(1) Position the front section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the liquid line
fitting and the receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Connect the front section of the liquid line to
the receiver/drier.
(5) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 7 N´m
(62 in. lbs.).
(6) Position the front section of the liquid line into
the routing clip and install the routing clip onto the
body stud on the left frame rail.
(7) Install the routing clip retaining nut. Tighten
the nut to 5 N´m (45 in. lbs.).
(8) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(9) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the liquid line fitting.
(10) Connect the liquid line fitting to the con-
denser outlet port on the right side of the condenser.
(11) Install the nut that secures the liquid line fit-
ting to the condenser. Tighten the nut to 17 N´m (12
ft. lbs.).
(12) Reinstall the A/C pressure transducer (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C PRESSURE TRANSDUCER - INSTAL-
LATION).
(13) Install the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - INSTALLATION).
(14) Reconnect the battery negative cable.
(15) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE).
(16) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the A/C liquid line
into the engine compartment.(2) Remove the tape or plugs from the liquid and
suction line fittings, the receiver/drier outlet port and
both expansion valve ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
liquid line fittings for the expansion valve.
(4) Connect the liquid line and suction line fittings
to the A/C expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve. Tighten the nut to 10 N´m (89 in. lbs.).
(6) Lubricate new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(7) Connect the liquid line fitting to the receiver/
drier outlet port.
(8) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 7 N´m
(62 in. lbs.).
(9) Install the routing clip retainer to the rear sec-
tion of the liquid line.
(10) Install the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE).
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the left front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the A/C liquid line between
the condenser outlet and the evaporator inlet.
The receiver/drier cannot be repaired. If the receiv-
er/drier is faulty or damaged, or if the refrigerant
system has been contaminated or left open to the
atmosphere for an indeterminable period or if the
compressor has failed, it must be replaced.
OPERATION
The receiver/drier performs a filtering action to
prevent foreign material in the refrigerant from con-
taminating the A/C expansion valve. Refrigerant
enters the receiver/drier as a high-pressure, low tem-
perature liquid. Desiccant inside the receiver/drier
absorbs any moisture which may have entered and
become trapped within the refrigerant system. In
addition, during periods of high demand operation of
the A/C system, the receiver/drier acts as a reservoir
to store surplus refrigerant.
VAPLUMBING 24 - 79

all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each
contains a different additive package. The A/C com-
pressors for this vehicle are designed to use an ND-8
PAG refrigerant oil. Use only the refrigerant oil of
this type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.
PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory,
all components except the compressor are refrigerant
oil free. After the refrigerant system has been
charged and operated, the refrigerant oil in the com-
pressor is dispersed throughout the refrigerant sys-
tem. The receiver-drier, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrica-
tion of the A/C compressor. Too little oil will result in
damage to the A/C compressor. Too much oil will
reduce the cooling capacity of the A/C system.
It will not be necessary to check the oil level in the
A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture orleak from a refrigerant line, a connector fitting, a
component, or a component seal. If a leak occurs, add
30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when a receiver/
drier, A/C evaporator, or A/C condenser are replaced.
See the Refrigerant Oil Capacities chart. When an
A/C compressor is replaced, the refrigerant oil must
be drained from the old compressor and measured.
Drain all of the refrigerant oil from the new compres-
sor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the
old compressor.
REFRIGERANT OIL CAPACITIES
Component ml fl oz
Total A/C System Fill 410 13.9
Receiver/Drier 30 1.0
A/C Condenser 30 1.0
A/C Evaporator 60 2.0
A/C CompressorDrain and measure the oil
from the old compressor -
see text.
SUCTION 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) Recover the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM RECOVERY)
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the routing clip retaining nut and dis-
engage the metal routing clip from the A/C suction
line.
(4) Disengage the plastic routing clip located near
the A/C expansion valve from the A/C suction line.
(5) Remove the nut that secures the A/C suction
and liquid lines to the stud on the A/C expansion
valve (Fig. 19).
VAPLUMBING 24 - 81

(12) Install the plastic routing clip retainer onto
the A/C suction line.
(13) Reconnect the negative battery cable.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
WATER VALVE
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE - DRAINING COOLING SYS-
TEM).
(3) Disconnect the wire harness connector from the
heater water valve (Fig. 21).
(4) Loosen the hose clamps from the heater water
valve.
(5) Using a twisting motion gently remove the
heater hoses from the heater water valve.
(6) Remove the bolts that secure the heater water
valve bracket.
(7) Remove the bracket and pulsed water control
valve from the engine compartment.
(8) Turn the bracket slightly and remove the water
valve from the rubber mounts.
(9) If necessary, remove the rubber mounts from
the bracket or water valve.
INSTALLATION
(1) If removed, install the rubber mounts to the
heater water valve or bracket.
(2) Turn bracket slightly to the right and install
the heater water valve to the bracket.
(3) Install the water valve and mounting bracket
into the engine compartment.
(4) Install the two bracket retaining bolts. Tighten
the bolts to 5 N´m (45 in. lbs.).
(5) Using a twisting motion gently install the
heater hoses onto the water valve.
(6) Tighten the hose clamps securely.
(7) Connect the wire harness connector to the
heater water valve.
(8) Reconnect the negative battery cable.
(9) Fill the engine cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE - COOLING SYSTEM FILL).
REARA/CCONDENSER FAN
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 - REMOVAL).
Fig. 21 Heater Water Valve
1 - HEATER WATER VALVE
2 - HOSE CLAMP (3)
3 - HEATER HOSE (3)
4 - RUBBER MOUNT (2)
5 - BOLTS (2)
6 - BRACKET
7 - RUBBER MOUNT
VAPLUMBING 24 - 83

(3) Disconnect the condenser fan wire harness
from the condenser fan suppression filter (Fig. 22).
(4) Loosen the four bolts that secure the rear A/C
condenser fan to the top of the rear A/C condenser
housing.
(5) Rotate the rear A/C condenser fan counter-
clockwise and remove the fan from the top of the rear
A/C condenser housing.
INSTALLATION
(1) Position the rear A/C condenser fan to the top
of the rear A/C condenser housing.
(2) Rotate the rear A/C condenser fan clockwise to
engage the fan to the four retaining bolts. Tighten
the bolts to 12 N´m (106 in. lbs.).
(3) Connect the condenser fan wire harness to the
rear condenser fan suppression filter.
(4) Reconnect the negative battery cable.
(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).
REARA/CEVAPORATOR
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) Remove the rear A/C evaporator housing and
place it on a workbench (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - REAR/
REAR A/C EVAPORATOR HOUSING - REMOVAL).
(2) Remove the five screws and washers that
secure the condensate drain pan to the bottom of the
rear A/C evaporator and remove the drain pan (Fig.
23).
(3) Remove the insulating tape from around the
area of the rear A/C expansion valve and disconnect
the expansion valve from the rear A/C evaporator
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REAR A/C EXPANSION VALVE -
REMOVAL).
(4) Remove the left blower motor from the rear
A/C evaporator housing (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - REAR/
BLOWER MOTOR - REMOVAL).
CAUTION: Be careful when drilling out rivets to pre-
vent damage to the rear A/C components.
(5) Remove the rivets that secure the three covers
to the rear A/C evaporator and remove the covers.
(6) Remove the four rivets that secure the rear A/C
evaporator the bottom of the rear A/C evaporator
housing and remove the evaporator.
Fig. 22 Rear A/C Condenser Fan
1 - REAR A/C CONDENSER FAN
2 - BOLT (4)
3 - REAR CONDENSER FAN SUPPRESSION FILTER
4 - FAN WIRE HARNESS CONNECTOR
5 - REAR A/C CONDENSER HOUSING
Fig. 23 Rear A/C Evaporator
1 - REAR A/C EVAPORATOR HOUSING
2 - RIVET (12)
3 - COVERS
4 - REAR A/;C EVAPORATOR
5 - SCREW AND WASHER (5)
6 - CONDENSATE DRAIN PAN
24 - 84 PLUMBINGVA

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 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 insulating tape from around the
area of the rear A/C expansion valve (Fig. 25).
(5) Disconnect the equalizer tube from the rear
evaporator outlet tube.
(6) Disconnect the rear liquid line from the rear
A/C expansion valve and remove and discard the
O-ring seal.
(7) Disconnect the rear A/C expansion valve from
the rear evaporator inlet tube and remove and dis-
card the O-ring seal.
(8) Remove the retaining clamp that secures the
sensor bulb to the evaporator outlet tube and remove
the expansion valve, capillary tube and sensor bulb
as an assembly.
(9) Install plugs into, or tape over the opened
refrigerant line and evaporator tube fittings and
expansion valve ports.
24 - 86 PLUMBINGVA