FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Freightliner Truck >> 2008 >> Sprinter 3500 V6-3.0L DSL Turbo >> Repair and Diagnosis >> Heating and Air Conditioning >> Hose/Line HVAC >> Service and Repair >> A/C Line - Installation >> Suction Line

Suction Line







INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system .

NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.

NOTE: The A/C suction line is serviced in three sections.

FRONT SECTION





1. Remove the tape or plugs from the opened refrigerant line fittings and compressor port.
2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant 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.
3. Position the front section of the A/C suction line (10) into the engine compartment.
4. Connect the front section of the A/C suction line to the middle section of the A/C suction line (11).
5. Install the bolt that secures the front section of the A/C suction line to the middle section of the A/C suction line. Tighten the bolt to 8 Nm (70 in. lbs.).
6. Connect the A/C suction line to the A/C compressor (9).
7. Install the bolt that secures the A/C suction line to the A/C compressor. Tighten the bolt to 22 Nm (16 ft. lbs.).
8. On diesel engine equipped models, install the turbo resonator and the charge air outlet tube to the left side of the engine.
9. Install the windshield washer reservoir .
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system .
12. Adjust the refrigerant oil level .
13. Charge the refrigerant system .
14. Install the air cleaner housing Service and Repair.
MIDDLE SECTION





15. Remove the tape or plugs from the opened refrigerant line fittings.
16. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant 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.
17. Position the middle section of the A/C suction line (11) into the engine compartment.
18. Install the nut that secures the middle section of the A/C suction line to the stud (12) located at the left of the dash panel in the engine compartment. Tighten the nut to 4 Nm (35 in. lbs.).
19. If equipped with rear A/C, install the A/C underbody lines .
20. Connect the front section of the A/C suction line (10) to the middle section of the A/C suction line.
21. Install the bolt that secures the front section of the A/C suction line to the middle section of the A/C suction line. Tighten the bolt to 8 Nm (70 in. lbs.).
22. Connect the rear section of the A/C suction line (2) to the middle section of the A/C suction line.
23. Install the bolt that secures the rear section of the A/C suction line to the middle section of the A/C suction line. Tighten the bolt to 8 Nm (70 in. lbs.).
24. Reconnect the negative battery cable.
25. Evacuate the refrigerant system .
26. Adjust the refrigerant oil level .
27. Charge the refrigerant system .
28. Install the air cleaner housing Service and Repair.
REAR SECTION

NOTE: The rear section of the A/C suction line and A/C liquid line are serviced as an assembly.





29. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve ports.
30. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant 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.
31. Position the rear section of the A/C suction line (2) and the rear section of the A/C liquid line (3) into the engine compartment as an assembly.
32. Install the nut that secures the rear section of the A/C suction line and the rear section of the A/C liquid line to the dash panel at the rear of the engine compartment. Tighten the nut to 4 Nm (35 in. lbs.).
33. Connect the rear section of the A/C suction line to the middle section of the A/C suction line (11).
34. Install the nut and bolt that secures the rear section of the A/C suction line to the middle section of the A/C suction line. Tighten the nut to 8 Nm (70 in. lbs.).
35. Connect the rear section of the A/C liquid line to the middle section of the A/C liquid line (4).
36. Install the nut and bolt that secures the rear section of the A/C liquid line to the middle section of the A/C liquid line. Tighten the nut to 8 Nm (70 in. lbs.).
37. Install the rear section of the A/C suction and liquid lines onto the A/C expansion valve (1).
38. Install the nut that secures the A/C suction and liquid lines to the A/C expansion valve. Tighten the nut to 6 Nm (53 in. lbs.).
39. Reconnect the negative battery cable.
40. Evacuate the refrigerant system .
41. Adjust the refrigerant oil level .
42. Charge the refrigerant system .
43. Install the air cleaner housing Service and Repair.

pro multis Credits:Operation CHARM About Operation CHARM