2006 MERCEDES-BENZ SPRINTER Service Manual

auxiliary battery location USB oil filter seat memory seat adjustment fuel consumption

Page 2129 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual RESERVOIR TO EXPANSION VALVE
(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 -

Page 2130 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
CONDENSER TO RECEIVER / DRIER
(1) Remove the tape or plugs from the rear liquid
line fittings and receiver/drier and condenser ports.
(2) Lubricate new O-ring seals with clean refriger-
a

INSTALLATION
CONDENSER TO RECEIVER / DRIER
(1) Remove the tape or plugs from the rear liquid
line fittings and receiver/drier and condenser ports.
(2) Lubricate new O-ring seals with clean refriger-
ant oil and install them onto the rear liquid line fit-
tings. 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) Connect the rear liquid line to the rear receiv-
er/drier. Tighten the nut to 35 N´m (26 ft. lbs.).
(4) Connect the rear liquid line to the rear A/C
condenser. Tighten the nut to 35 N´m (26 ft. lbs.).
(5) Install the retaining straps that secure the rear
A/C wire harness to the rear liquid line.
(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(8) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(9) Install the rear air filter (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/AIR FILTER - INSTALLATION).(10) 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).
RESERVOIR TO EXPANSION VALVE
(1) Remove the tape or plugs from the rear liquid
line fittings and the reservoir and expansion valve
ports.
(2) Lubricate new O-ring seals with clean refriger-
ant oil and install them onto the rear liquid line fit-
tings. 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) Connect the rear liquid line to the rear A/C
expansion valve. Tighten the nut to 35 N´m (26 ft.
lbs.).
(4) Route the liquid line through the opening in
the roof and engage the grommet to the roof panel.
(5) Connect the rear liquid line to the rear refrig-
erant reservoir. Tighten the nut to 35 N´m (26 ft.
lbs.).
(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
Fig. 32 Rear Liquid Line - Reservoir to Expansion Valve
1 - GROMMET
2 - LIQUID LINE (TO EXPANSION VALVE)3 - REAR REFRIGERANT RESERVOIR
4 - REAR A/C EXPANSION VALVE
VAPLUMBING 24 - 93

Page 2131 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (8) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(9) Install the cover onto the rear A/C evaporator
housin

(8) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(9) 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).
(10) 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).
REAR 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) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evapo-
rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
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) Disconnect the rear refrigerant reservoir from
the rear receiver/drier and remove and discard the
O-ring seal (Fig. 33).
(6) Disconnect the liquid line from the rear receiv-
er/drier and remove and discard the O-ring seal.
(7) Remove the bolt and retaining bracket that
secures the rear receiver/drier to the rear A/C con-
denser housing and remove the receiver/drier.
(8) Install plugs into, or tape over the opened rear
liquid line fitting and reservoir and receiver/drier
ports.
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
receiver/drier is being replaced. The refrigerant oil
must be drained from the old receiver/drier and
measured to determine the amount of refrigerant oil
to add to the new receiver/drier. Use only refriger-
ant oil of the type recommended for the rear A/C
compressor in the vehicle.
(1) If the rear receiver/drier is being replaced,
install the correct amount and type of refrigerant oil
into the new rear receiver/drier. Drain the old receiv-
er/drier and measure the refrigerant oil. Fill the new
receiver/drier with the same amount of new refriger-
ant oil that was drained out of the old receiver/drier.
NOTE: The rear receiver/drier is labeled with a
direction-of-flow arrow to indicate refrigerant flow
through the receiver/drier. Make sure to properly
install the rear receiver/drier in the correct direc-
tion.
(2) Position the rear receiver/drier to the rear A/C
condenser housing and install the retaining bracket
and bolt. Tighten the bolt to 25 N´m (18 ft. lbs.).
(3) Remove the tape or plugs from the rear liquid
line fitting and reservoir and receiver/drier ports.
(4) 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 made
of a special material for the R-134a system. Use only
Fig. 33 Rear Receiver/Drier
1 - REAR A/C CONDENSER HOUSING
2 - REFRIGERANT RESEVOIR
3 - REAR RECEIVER/DRIER
4 - BOLT
5 - LIQUID LINE
6 - RETAINING BRACKET
24 - 94 PLUMBINGVA

Page 2132 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(5) Connect the rear liquid line to the rear receiv-
er/drier. Tighten the nut to 35 N´m (26 ft. lbs.).
(6) Lubrica

refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(5) Connect the rear liquid line to the rear receiv-
er/drier. Tighten the nut to 35 N´m (26 ft. lbs.).
(6) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the receiver/drier outlet
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.
(7) Connect the rear refrigerant reservoir to the
rear receiver/drier. Tighten the nut to 35 N´m (26 ft.
lbs.).
(8) Reconnect the negative battery cable.
(9) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(10) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(11) Install the rear air filter (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/AIR FILTER - INSTALLATION).
(12) 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).
REAR REFRIGERANT RESER-
VOIR
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 air filter from the rear A/C evapo-
rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
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) Disconnect the rear liquid line from the rear
refrigerant reservoir and remove and discard the
O-ring seal (Fig. 34).
(6) Disconnect the rear refrigerant reservoir from
the rear receiver/drier and remove and discard the
O-ring seal.
(7) Remove the bolt and retaining bracket that
secures the rear refrigerant reservoir to the rear A/C
condenser housing and remove the reservoir.
(8) Install plugs into, or tape over the opened rear
liquid line fitting and receiver/drier and reservoir
ports.
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
refrigerant reservoir is being replaced. The refriger-
ant oil must be drained from the old refrigerant res-
ervoir and measured to determine the amount of
refrigerant oil to add to the new reservoir. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(1) If the rear refrigerant reservoir is being
replaced, install the correct amount and type of
refrigerant oil into the new rear refrigerant reservoir.
Drain the old refrigerant reservoir and measure the
refrigerant oil. Fill the new refrigerant reservoir with
the same amount of new refrigerant oil that was
drained out of the old reservoir.
Fig. 34 Rear Refrigerant Reservoir
1 - REAR A/C CONDENSER HOUSING
2 - LIQUID LINE
3 - REAR REFRIGERANT RESERVOIR
4 - BOLT
5 - REAR RECEIVER/DRIER
6 - RETAINING BRACKET
VAPLUMBING 24 - 95

Page 2133 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (2) Install a new rear receiver/drier (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
(3) Position the rear refrigerant reservoir to the
rear A/C condenser hou

(2) Install a new rear receiver/drier (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
(3) Position the rear refrigerant reservoir to the
rear A/C condenser housing and install the retaining
bracket and bolt. Tighten the bolt to 25 N´m (18 ft.
lbs.).
(4) Remove the tape or plugs from the rear liquid
line fitting and receiver/drier and reservoir ports.
(5) Lubricate a new O-ring seal with clean refrig-
erant oil and install it onto the rear receiver/drier fit-
ting. 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.
(6) Connect the rear receiver/drier to the rear
refrigerant reservoir. Tighten the nut to 35 N´m (26
ft. lbs.).
(7) 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 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.
(8) Connect the rear liquid line to the rear refrig-
erant reservoir. Tighten the nut to 35 N´m (26 ft.
lbs.).
(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(11) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(12) Install the rear air filter (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/AIR FILTER - INSTALLATION).
(13) 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).
REAR SUCTION LINE
DESCRIPTION
The rear A/Csuction line is the refrigerant line that
carries refrigerant from the rear A/C evaporator to
the A/C underbody suction line (Fig. 35). The rear
A/C suction line is retained to the left 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 suction 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 rub-
ber not affected by R-134a refrigerant and must be
replaced whenever the rear A/C suction line is
removed and installed.
If the rear A/C suction 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 insulating tape from around the
area of the rear A/C suction line and evaporator out-
let tube (Fig. 36).
Fig. 35 Rear A/C Suction Line
1 - REAR A/C SUCTION LINE
2 - TO UNDERBODY SUCTION LINE
3 - RETAINING CLIPS
4 - LEFT INNER QUARTER PANEL
5 - TO REAR A/C EVAPORATOR
24 - 96 PLUMBINGVA

Page 2134 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual (5) From inside the vehicle, disconnect the rear
A/C suction line from the rear A/C evaporator and
remove and discard the O-ring seal.
(6) From underneath the vehicle, disconnect the
rear A/C suction

Page 2135 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual INSTALLATION
(1) Remove the tape or plugs from the rear suction
and underbody line fittings and the rear evaporator
tube.
(2) Lubricate new O-ring seals with clean refriger-
ant oil and install them o

INSTALLATION
(1) Remove the tape or plugs from the rear suction
and underbody line fittings and the rear evaporator
tube.
(2) Lubricate new O-ring seals with clean refriger-
ant oil and install them onto the rear suction line fit-
tings. 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) Position the rear A/C suction line to the left
inner quarter panel and install it into the two retain-
ing clips.
(4) From inside the vehicle, connect the rear A/C
suction line to the rear A/C evaporator. Tighten the
nut to 35 N´m (26 ft. lbs.).
(5) From underneath the vehicle, connect the rear
A/C suction line to the underbody suction line.
Tighten the nut to 35 N´m (26 ft. lbs.).
(6) Install the three foam insulators to the left
inner quarter panel.
(7) Install the foam rubber seal into the floor
panel.
(8) Install the left quarter trim panel (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION).
(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(11) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(12) 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).
REFRIGERANT LINE COUPLER
DESCRIPTION
A spring-lock type refrigerant line coupler is used
to connect the front section of the underbody dis-
charge line to the compressor section of the discharge
line. A secondary retaining clip may be installed over
the connected coupler for added protection.
The spring-lock refrigerant line coupler requires a
special disconnect tool for disengaging the two cou-
pler halves.
OPERATION
The spring-lock coupler is held together by a garter
spring inside a circular cage on the male half of the
fitting (Fig. 37). When the two coupler halves are
connected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the
cage.
Fig. 36 Rear A/C Suction Line
1 - REAR A/C SUCTION LINE
2 - RETAINING CLIPS
3 - EVAPORATOR OUTLET TUBE
4 - UNDERBODY SUCTION LINE5 - FOAM RUBBER SEAL
6 - FOAM INSULATORS
7 - LEFT INNER QUARTER PANEL
24 - 98 PLUMBINGVA

Page 2136 of 2305

MERCEDES-BENZ SPRINTER 2006 Service Manual Two O-rings on the male half of the fitting are
used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Seconda

Two O-rings on the male half of the fitting are
used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Secondary clips are installed over the two con-
nected coupler halves at the factory for added blowoff
protection. In addition, some models have a plastic
ring that is used at the factory as a visual indicator
to confirm that these couplers are connected. After
the coupler is connected, the plastic indicator ring is
no longer needed; however, it will remain on the
refrigerant line near the coupler cage.
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 secondary retaining clip from the
spring-lock coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 38).(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C line disconnect tool
from the disconnected spring-lock coupler.
(7) Complete the separation of the two halves of
the coupler fitting.
INSTALLATION
(1) Check to ensure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.
(3) Install new O-rings on the male half of the cou-
pler fitting.
Fig. 37 Spring-Lock Coupler - Typical
1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - O-RING SEALS
Fig. 38 Refrigerant Line Spring-Lock Coupler
Disconnect
VAPLUMBING 24 - 99

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