2006 MERCEDES-BENZ SPRINTER roof rack

INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C condenser is being replaced. The refrigerant oil
must be drained from the old condenser and mea-
sured to determine the amount of refrigerant oil to
add to the new condenser. Use only refrigerant oil
of the type recommended for the rear A/C compres-
sor in the vehicle.
(1) If the rear A/C condenser is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C condenser. Drain the old con-
denser and measure the refrigerant oil. Fill the new
condenser with the same amount of new refrigerant
oil that was drained out of the old condenser.
(2) Install new body sealant and any removed
shims onto the top of the roof panel.
(3) With help from an assistant, position the rear
A/C condenser housing onto the top of the roof panel.
(4) Install the eight nuts and washers that secure
the rear A/C condenser housing to the roof panel.
Tighten the nuts to 25 N´m (18 ft. lbs.).
(5) Remove the tape or plugs from the rear liquid
line fitting and rear refrigerant reservoir port.
(6) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is madeof a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(7) Connect the rear liquid line to the rear refrig-
erant reservoir outlet. Tighten the liquid line nut to
35 N´m (26 ft. lbs.).
(8) Remove the tape or plugs from the rear dis-
charge line fitting and rear condenser port.
(9) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear discharge line
fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(10) Connect the rear discharge line to the rear
A/C condenser. Tighten the discharge line nut to 35
N´m (26 ft. lbs.).
(11) Install the bracket and screw that secures the
rear discharge line to the right side of the rear con-
denser housing. Tighten the screw securely.
(12) Connect the rear A/C wire harness to the rear
blower motor suppression filter and to the rear A/C
high pressure switch.
(13) Install new retaining straps to secure the rear
A/C wire harness to the rear liquid line.
(14) Install a new rear receiver/drier (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
Fig. 2 Rear A/C Condenser Housing
1 - REAR A/C CONDENSER HOUSING
2 - LIQUID LINE
3 - REAR REFRIGERANT RESERVOIR
4 - REAR A/C HIGH PRESSURE SWITCH
5 - REAR CONDENSER OUTLET TUBE6 - SUCTION LINE
7 - NUT AND WASHER (8)
8 - REAR A/C WIRE HARNESS
9 - REAR BLOWER MOTOR SUPPRESSION FILTER
24 - 54 DISTRIBUTION - REARVA

REAR DISCHARGE LINE
DESCRIPTION
The rear A/C discharge line is the refrigerant line
that carries refrigerant from the underbody discharge
line to the rear A/C condenser (Fig. 26). The rear A/C
discharge line is retained to the right quarter panel
by two plastic retaining clips.
CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrig-
erant system connections to leak.
The rear A/C discharge line has no serviceable
parts except for the O-ring seals. The O-ring seals
used on the connections are made from a special type
of rubber not affected by R-134a refrigerant and
must be replaced whenever the rear discharge line is
removed and installed.
If the rear A/C discharge line is found to be leaking
or damaged, it 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) 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 cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C CON-
DENSER COVER - REMOVAL).
(5) Remove the screw and bracket that secures the
rear A/C discharge line to the right side of the rear
A/C condenser housing (Fig. 27).
(6) Disconnect the rear A/C discharge line from the
rear A/C condenser and remove and discard the
O-ring seal.
(7) Disengage the discharge line grommet from the
roof panel and push the grommet down into the
cargo compartment.
(8) Remove the right quarter trim panel (Refer to
23 - BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL).
(9) Remove the retaining strap that secures the
rear A/C wire harness to the rear A/C discharge line
at the ceiling and position the wire harness out of
the way (Fig. 28).
Fig. 26 Rear A/C Discharge Line
1 - REAR A/C DISCHARGE LINE
2 - RETAINING CLIPS
3 - TO REAR A/C CONDENSER
4 - RIGHT INNER QUARTER PANEL
5 - TO UNDERBODY DISCHARGE LINEFig. 27 Rear A/C Discharge Line to Rear Condenser
1 - REAR A/C CONDENSER
2 - GROMMET
3 - REAR A/C DISCHARGE LINE
4 - CONDENSER INLET TUBE
5 - SCREW AND BRACKET
24 - 88 PLUMBINGVA

INSTALLATION
(1) Remove the tape or plugs from the rear dis-
charge and underbody line fittings and the rear con-
denser tube.
(2) Lubricate new O-ring seals with clean refriger-
ant oil and install them onto the rear discharge line
fittings. Use only the specified O-ring seals as they
are made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) From underneath the vehicle, route the rear
A/C discharge line into the cargo compartment and
install it into the two retaining clips located under
the vehicle.
(4) Connect the rear A/C discharge line to the
underbody discharge line. Tighten the nut to 35 N´m
(26 ft. lbs.).
(5) Install the foam rubber seal into the floor
panel.
(6) From inside the vehicle, install the rear A/C
discharge line into the two retaining clips located on
the inner quarter panel and route the discharge line
through the opening in the roof.
(7) Seat the grommet to the roof panel and install
a new rear A/C wire harness retaining strap.
(8) Install the three foam insulators to the right
inner quarter panel.(9) Install the right quarter trim panel (Refer to
23 - BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION).
(10) Connect the rear discharge line to the rear
A/C condenser. Tighten the nut to 35 N´m (26 ft.
lbs.).
(11) Install the bracket and screw that secures the
rear discharge line to the right side of the rear con-
denser housing. Tighten the screw securely.
(12) Reconnect the negative battery cable.
(13) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(14) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(15) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).
(16) 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).
Fig. 29 Rear A/C Discharge Line to Underbody
1 - REAR A/C DISCHARGE LINE
2 - RETAINING CLIPS
3 - TO REAR CONDENSER
4 - FOAM RUBBER SEAL
5 - BRACKETS6 - UNDERBODY DISCHARGE LINE
7 - RIGHT INNER QUARTER PANEL
8 - FOAM INSULATORS
9 - TO UNDERBODY
24 - 90 PLUMBINGVA