2006 MERCEDES-BENZ SPRINTER low oil pressure

²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) If equipped with an add-on rear A/C system,
install the lower A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION - DENSO 10S17).
(3) Lower the vehicle.
(4) Remove the tape or plugs from the opened suc-
tion line fitting and the discharge line fitting and the
compressor ports.
(5) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(6) Connect the A/C suction and discharge lines to
the A/C compressor.
(7) Install the bolts that secure the A/C suction
and discharge lines to the A/C compressor. Tighten
the bolts to 23 N´m (17 ft. lbs.).
(8) Connect the wire harness connector to the A/C
compressor clutch coil.
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Replace the receiver/drier if the A/C compres-
sor is being replaced due to an internal failure (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER/DRIER - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
DENSO 10S17A/CCOMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine com-
partment and loosely install the three compressorretaining bolts. Tighten the bolts using the following
sequence to 20 N´m (14 ft. lbs.).
²The upper bolt at the front of the compressor.
²The lower bolt at the front of the compressor.
²The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened
underbody suction and discharge line fittings and
compressor ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(4) Connect the underbody suction and discharge
lines to the A/C compressor.
(5) Install the bolts that secure the underbody suc-
tion and discharge lines to the A/C compressor.
Tighten the bolts to 21 N´m (15 ft. lbs.).
(6) Connect the wire harness connector to the A/C
compressor clutch coil.
(7) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
INSTALLATION).
(8) Lower the vehicle.
(9) Replace the receiver/drier if the A/C compressor
is being replaced due to an internal failure (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
CEIVER/DRIER - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(12) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
A / C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
VAPLUMBING 24 - 69

(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

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 HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
DISASSEMBLY).
(3) Lift the A/C evaporator out of the lower half of
the HVAC housing (Fig. 9).
INSTALLATION
NOTE: If the A/C evaporator is being replaced, add
60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of thetype recommended for the A/C compressor in the
vehicle.
(1) Install the A/C evaporator into the lower half of
the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
A / C EXPANSION VALVE
DESCRIPTION
The A/C expansion valve controls the amount of
refrigerant entering the A/C evaporator and is of a
thermostatic expansion valve (TXV) design (Fig. 10).
The A/C expansion valve consists of an aluminum
H-valve type body with an integral thermal sensor.
The A/C expansion valve is located at the dash
panel between the A/C refrigerant lines and the A/C
evaporator.
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 A/C evaporator. A thermal sensor in the
A/C expansion valve monitors the temperature of the
refrigerant leaving the A/C evaporator and adjusts
the orifice size at the evaporator inlet to allow the
proper amount of refrigerant into the A/C evaporator
Fig. 9 HVAC Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER 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)
Fig. 10 Front A/C Expansion Valve
1 - A/C EXPANSION VALVE
2 - THERMAL SENSOR
VAPLUMBING 24 - 73

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

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

The receiver/drier cannot be repaired. If the receiv-
er/drier is faulty or damaged, or if an internal failure
of the A/C compressor has occurred, the receiver/drier
must be replaced.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
(2) Remove the bolts that secure the front and rear
sections of the A/C liquid line to the top of the receiv-
er/drier (Fig. 18).
(3) Disconnect the liquid line fittings from the
receiver/drier and remove and discard the O-ring
seals.
(4) Install a plug in, or tape over the opened liquid
line fittings and the receiver/drier ports.
(5) Loosen the clamp that secures the receiver/
drier to the mounting bracket.
(6) Remove the receiver/drier from the engine com-
partment.
INSTALLATION
NOTE: If the receiver/drier is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Position the receiver/drier onto the mounting
bracket on the front left strut tower.
(2) Tighten the clamp that secures the receiver/
drier to the mounting bracket.
(3) Remove the tape or plugs from the liquid line
fittings and the receiver/drier ports.
(4) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line fit-
tings.
(5) Connect the front and rear sections of the liq-
uid line to the receiver/drier.
(6) Install the bolts that secures the liquid line fit-
tings to the receiver/drier. Tighten the bolts to 7 N´m
(62 in. lbs.).
(7) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(8) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
Fig. 18 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
24 - 80 PLUMBINGVA

INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C evaporator is being replaced. The refrigerant oil
must be drained from the old evaporator and mea-
sured to determine the amount of refrigerant oil to
add to the new evaporator. Use only refrigerant oil
of the type recommended for the rear A/C compres-
sor in the vehicle.
(1) If the rear A/C evaporator is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C evaporator. Drain the old evap-
orator and measure the refrigerant oil. Fill the new
evaporator with the same amount of new refrigerant
oil that was drained out of the old evaporator.
(2) Position the rear A/C evaporator to the bottom
of the rear A/C evaporator housing and install four
new rivets.
(3) Position the three covers to the rear A/C evap-
orator and install eight new rivets.
(4) Install the left blower motor onto the rear A/C
evaporator housing (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION - REAR/BLOWER
MOTOR - INSTALLATION).
(5) Connect the rear A/C expansion valve to the
rear A/C evaporator and install new insulating tape
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REAR A/C EXPANSION VALVE -
INSTALLATION).
(6) Position the condensate drain pan to the bot-
tom of the rear A/C evaporator and install the five
screws and washers that secure the drain pan to the
evaporator. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(7) Install the rear A/C evaporator housing (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/REAR A/C EVAPORATOR HOUSING -
INSTALLATION).
REARA/CEXPANSION VALVE
DESCRIPTION
The rear A/C expansion valve controls the amount
of refrigerant entering the rear A/C evaporator (Fig.
24). The rear A/C expansion valve is of an externally-
equalized thermostatic expansion valve (TXV) design
and consists of a cast metal body with a removable
equalizer tube and an integral thermal sensor which
uses a capillary tube and sensing bulb.
The rear A/C expansion valve is located to the left
of the rear blower motors in the rear evaporator
housing.
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 A/C evaporator. A thermal sensor in the
rear A/C expansion valve monitors the temperature
of the refrigerant leaving the rear evaporator by use
of a sensing bulb positioned next to the evaporator
outlet tube. The thermal sensor adjusts the orifice
size at the evaporator inlet to allow the proper
amount of refrigerant into the rear A/C evaporator in
order to meet vehicle cooling requirements. Control-
ling the refrigerant flow through the A/C evaporator
ensures that none of the refrigerant leaving the evap-
orator is still in a liquid state, which could cause
damage to the A/C compressor.
To overcome the effect of the pressure drop within
the rear A/C evaporator, an external equalizer tube is
connected to the evaporator outlet tube and runs to
the underside if the diaphragm within the expansion
valve.
The rear A/C expansion valve is factory calibrated
and cannot be adjusted or repaired and, if faulty or
damaged, it must be replaced.
Fig. 24 Rear A/C Expansion Valve
1 - REAR A/C EXPANSION VALVE
2 - EQUALIZER TUBE
3 - CAPILLARY TUBE
4 - SENSING BULB
VAPLUMBING 24 - 85

INSTALLATION
(1) Remove the oil fill cap, clean the oil return pas-
sage in the cylinder head cover, then blow out with
low pressure compressed air.
(2) Clean mating surfaces.
(3) Install the CCV breather and tighten fasteners
to 11 N´m (97 in.lbs.) (Fig. 3).
(4) Connect the CCV breather outlet hose (Fig. 3).
(5) Install the engine cover (Refer to 9 - ENGINE -
INSTALLATION).
Fig. 3 CCV BREATHER
1 - FUEL RAIL 6 - CAM POSITION SENSOR
2 - FUEL RAIL PRESSURE SENSOR 7 - FUEL INJECTOR
3 - FUEL INJECTOR RETURN LINE 8 - HIGH PRESSURE FUEL INJECTOR SUPPLY LINE
4 - CCV BREATHER 9 - FUEL PRESSURE SOLENOID
5 - CYLINDER HEAD COVER 10 - FUEL RAIL SUPPLY LINE
VAEVAPORATIVE EMISSIONS 25 - 3