2005 MERCEDES-BENZ SPRINTER heating

INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
CAUTION: Check the oil level before installing the
new compressor (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT OIL -
STANDARD PROCEDURE).
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.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.
(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.).
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) Lower the vehicle.
(3) Connect the wire harness connector to the com-
pressor clutch.
(4) Remove plugs or tape from the discharge line
fitting and the compressor discharge port.
(5) Lubricate a new rubber o-ring seal with clean
refrigerant oil and install the seal onto the discharge
line fitting.
Fig. 2 2.7L Diesel Compressor-RHD (LHD typical)
1 - SUCTION LINE MOUNTING SCREW
2 - SUCTION LINE TO H-BLOCK
3 - H-BLOCK
4 - RECEIVER DRIER
5 - LIQUID LINE SERVICE PORT6 - LIQUID LINE AND RECEIVER DRIER
7 - A/C COMPRESSOR
8 - A/C COMPRESSOR DRIVE BELT
9 - RADIATOR - CONDENSOR ASSEMBLY
VAPLUMBING 24 - 51
A/C COMPRESSOR (Continued)

(6) Connect the discharge line fitting to the com-
pressor discharge port.
(7) Install the bolt that secures the discharge line
fitting to the top of the compressor. Tighten the bolt
to 23 N´m (17 ft. lbs.).
(8) Remove plugs or tape from the suction line fit-
ting and the compressor suction port.
(9) Lubricate a new rubber o-ring seal with clean
refrigerant oil and install the seal onto the suction
line fitting.
(10) Connect the suction line fitting to the com-
pressor suction port.
(11) Install the bolt that secures the suction line
fitting to the top of the compressor. Tighten the bolt
to 23 N´m (17 ft. lbs.).
(12) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(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).
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
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: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT 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 liquid line fitting from the con-
denser outlet port (Fig. 3).
(8) Remove the seal from the liquid line fitting and
discard.
(9) Install plug in, or tape over the opened liquid
line fitting and the condenser outlet port.
(10) Disconnect the discharge line fitting from the
condenser inlet port.
(11) Remove the seal from the discharge line fit-
ting and discard.
(12) Install plug in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(13) Disconnect the wire harness connector from
the auxiliary fan.
(14) Remove the auxiliary fan and upper bracket
assembly.
(15) Remove the auxiliary fan lower bracket
retainers and bracket.
(16) Remove the four condenser retaining screws.
(17) Carefully remove the condenser from the vehi-
cle.
INSTALLATION
NOTE: If the 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 compressor in the vehi-
cle.
(1) Carefully position the condenser in the vehicle.
(2) Install the four condenser retaining screws.
Tighten the screws to 2 N´m (17 in. lbs.).
24 - 52 PLUMBINGVA
A/C COMPRESSOR (Continued)

(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
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) Reconnect the discharge line fitting to the con-
denser inlet port.
(9) Install and tighten the nut that secures the
discharge line fitting to the condenser inlet port.
Tighten the nut to 33 N´m (24 ft. lbs.).
(10) Remove the tape or plug from the condenser
outlet port and the liquid line fitting.
(11) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(12) Reconnect the liquid line fitting to the con-
denser outlet port.(13) Install and tighten the nut that secures the
liquid line fitting to the condenser outlet port.
Tighten the nut to 17 N´m (12 ft. lbs.).
(14) Install the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER -
INSTALLATION).
(15) Install the headlamps into their mounts.
(16) Install the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - INSTALLATION).
(17) Install the front fascia.
(18) Reconnect the battery negative cable.
(19) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(20) Recharge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
A/C DISCHARGE LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(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. 4).
(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.
Fig. 3 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)
VAPLUMBING 24 - 53
A/C CONDENSER (Continued)

(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.).
(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/EXTERI-
OR/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/C EVAPORATOR
DESCRIPTION
The evaporator is located in the heater housing,
behind the instrument panel. The evaporator is posi-
tioned in the housing so that all air that enters the
housing must pass over the fins of the evaporator
coils before it is distributed through the system ducts
and outlets. However, air passing over the evaporator
coil fins will only be conditioned when the compres-
sor is engaged and refrigerant is circulating through
the evaporator coil tubes.
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.
Fig. 4 A/C Compressor - Refrigerant Lines
1 - A/C COMPRESSOR
2 - O-RING SEAL
3 - SUCTION LINE
4 - BOLT
5 - RETAINING CLIP
6 - BOLT
7 - DISCHARGE LINE
8 - O-RING SEAL
24 - 54 PLUMBINGVA
A/C DISCHARGE LINE (Continued)

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the heater housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the heater housing to access the
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).
(3) Lift the evaporator out of the lower half of the
heater housing (Fig. 5).
INSTALLATION
(1) Install the evaporator coil into the bottom half
of the heater housing.
(2) Assemble the heater housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the heater housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
NOTE: If the evaporator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system.
A/C EXPANSION VALVE
DESCRIPTION
The ªHº valve type thermal expansion valve (TXV)
is mounted in the engine compartment between the
liquid and suction lines and the evaporator.
The expansion valve is a factory calibrated unit
and cannot be adjusted or repaired. If faulty or dam-
aged, the expansion valve must be replaced.
OPERATION
High-pressure, high temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the evaporator coil. A thermal sensor in the
expansion valve monitors the temperature of the
refrigerant leaving the evaporator coil through the
suction line, and adjusts the orifice size at the liquid
line to let the proper amount of refrigerant into the
evaporator to meet the vehicle cooling requirements.
Controlling the refrigerant flow through the evapora-
Fig. 5 Heater Housing
1 - SCREW (12)
2 - HEATER HOUSING COVER
3 - EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
4 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - HEATER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
VAPLUMBING 24 - 55
A/C EVAPORATOR (Continued)

tor ensures that none of the refrigerant leaving the
evaporator is still in a liquid state, which could cause
damage to the compressor.
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE
The expansion valve is located on the engine side
of the dash panel near the shock tower.
The expansion valve can fail in three different
positions (open, closed or restricted).
In an Open Position: this will result in a noisy
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 expansion valve. If excessive moisture is
found in the A/C system, recycle the refrigerant.
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 expansion valve is
found to be defective replace the expansion 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 expansion valve and the receiver-drier.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Recover the refrigerant from the A/C system-
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the nut that secures the suction and
liquid line fittings to the stud on the expansion valve
(Fig. 6).
(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 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 expansion valve onto the tapping
plate evaporator inlet and outlet tube fittings.
(4) Install and tighten the two bolts that secure
the expansion 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) Reconnect the liquid line fitting to the expan-
sion valve.
(8) Reconnect the suction line fitting to the expan-
sion valve.
Fig. 6 Expansion Valve
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - EXPANSION VALVE
4 - BOLT (2)
5 - SUCTION LINE
6 - NUT
7 - LIQUID LINE
8 - O-RING SEAL (2)
24 - 56 PLUMBINGVA
A/C EXPANSION VALVE (Continued)

(9) Install and tighten the nut that secures the
suction line and liquid line fittings to the stud on the
expansion valve. Tighten the nut to 10 N´m (89 in.
lbs.).
(10) Reconnect the battery negative cable.
(11) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(12) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
ELECTRIC COOLANT PUMP
DESCRIPTION
The electric coolant pump is used on all vehicles.
The pump is located in the left side of the engine
compartment near the battery.
OPERATION
The pump is controlled by the ATC control module
and is only operational under the following condi-
tions:
(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 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 battery negative
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE).
(3) Disconnect the wire harness connector from the
electric coolant pump (Fig. 7).
(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.
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 battery negative cable.
(7) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
HEATER CORE
DESCRIPTION
The heater core is located in the heater housing,
behind the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core whenever the heater water
valve is cycled open by the ATC control module. 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
Fig. 7 Electric Coolant Pump
1 - HEATER HOSE
2 - HOSE CLAMP (2)
3 - HEATER HOSE
4 - ELECTRIC COOLANT PUMP
5 - WIRE HARNESS CONNECTOR
6 - NUT (2)
VAPLUMBING 24 - 57
A/C EXPANSION VALVE (Continued)

blower motor speed controls the volume of air flowing
through the heater housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the heater housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the heater housing to access the
heater core (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).
(3) Lift the heater core out of the lower half of the
heater housing (Fig. 8).
(4) If necessary, remove the three heater core tube
retaining bolts and the heater core tube assembly
from the heater core.
(5) Remove the heater core tube seals and discard
as required.
INSTALLATION
(1) If the heater core tube assembly was removed
from the heater core, lubricate two new rubber o-ring
seals with clean engine coolant and install them onto
the heater core fitting.
(2) If required, connect the heater core tube
assembly to the heater core and install the three
retaining bolts. Tighten the bolts to 5 N´m (45 in.
lbs.).
(3) Install the heater core into the bottom half of
the heater housing.(4) Assemble the heater housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(5) Install the heater housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
LIQUID LINE
REMOVAL
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the receiver/drier and includes the
high side service port and the A/C pressure sensor on
the fitting for the receiver/drier. The rear section con-
nects between the receiver/drier and the expansion
valve.
Fig. 8 Heater Housing
1 - SCREW (12)
2 - HEATER HOUSING COVER
3 - EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
4 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - HEATER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
24 - 58 PLUMBINGVA
HEATER CORE (Continued)