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Home >> Freightliner Truck >> 2006 >> Sprinter 3500 L5-2.7L DSL Turbo >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement

Removal and Replacement

REMOVAL

WARNING:
- TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS 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 separated 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.
2. Partially drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Remove the air cleaner housing.
5. Remove the windshield washer reservoir.
6. Remove the air filter from the ventilation housing.
7. Disconnect the wire harness and vacuum connectors from the recirculation door actuator.
8. Disconnect the wire harness connector from the blower motor resistor block.
9. Disconnect the wire harness connector from the blower motor.

Ventilation Housing:




10. Remove the nuts and washers that secure the ventilation housing to the body and remove the ventilation housing from the vehicle.
11. Disconnect the heater hoses from the heater core.
12. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
13. Remove the two bolts securing the refrigerant lines to the evaporator tubes and disconnect the lines from the tubes. Install plugs in, or tape over all of the opened refrigerant line fittings.
14. Remove the seals from the refrigerant line fittings and discard.
15. Install plugs in, or tape over the opened refrigerant line fittings and evaporator tubes.
16. Remove the instrument panel from the vehicle.
17. Remove the defroster, floor distribution and instrument panel ducts.
18. Disconnect the two bulkhead ground connections near instrument cluster area.
19. Remove the passenger airbag bracket.

Heater Housing:




20. Disconnect the wire harness connector from the evaporator temperature sensor and air outlet temperature sensor.
21. Remove the wire harness from the bracket located on the right side of the heater housing and position the wire harness out of the way.
22. Disconnect the A/C-heater control cables from the mode door levers.
23. Disconnect the evaporator drain tube from the HVAC housing.
24. Remove the five bolts securing the HVAC housing to the body.

NOTE: Make sure that the interior is protected in case of loss of residual fluids from the heater core and the A/C evaporator.

25. Remove the HVAC housing from the vehicle.

INSTALLATION

NOTE: High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free.

1. Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube is positioned correctly.
2. Install the screws that secure the HVAC housing to the dash panel. Tighten the screws to 4.5 N.m (40 in. lbs.).
3. Connect the HVAC housing wire harness connectors and install the wiring harness to the bracket.
4. Connect the A/C-heater control cables to the mode door levers.
5. Reinstall the passenger airbag bracket.
6. Reconnect the two bulkhead ground connection near the instrument cluster area.
7. Reinstall the defroster, floor distribution and instrument panel ducts.
8. Reinstall the instrument panel.
9. Unplug or remove the tape from the opened refrigerant line fittings.
10. Lubricate two new rubber O-ring seals with clean refrigerant oil and install them onto the evaporator core fittings.
11. Connect the refrigerant line terminal block to the evaporator tubes.
12. Install the two bolts that secure the refrigerant line terminal block to the A/C evaporator. Tighten the bolts to 5 N.m (45 in. lbs.)
13. Unplug or remove the tape from the heater core hoses and tubes.
14. Connect the heater hoses to the heater core tubes and install the heater hose clamps.
15. Install the ventilation housing to the dash panel.
16. Install the nuts and washers that secure the ventilation housing to the dash panel. Tighten the nuts to 5 N.m (45 in. lbs.).
17. Connect the wire harness connectors to the blower motor, blower motor resistor block and the recirculation door actuator.
18. Connect the vacuum harness connector to the recirculation door actuator.
19. Install the air filter into the ventilation housing.
20. Install the windshield washer reservoir.
21. Install the air cleaner housing.
22. Reconnect the negative battery cable.
23. If the heater core is being replaced, flush the cooling system.
24. Refill the engine cooling system.
25. Evacuate the refrigerant system.
26. Charge the refrigerant system.


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