airbag disable MERCEDES-BENZ SPRINTER 2006 Repair Manual

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

(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

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