Sprinter 2500 L5-2.7L DSL Turbo (2003)
Hose/Line HVAC: Service Precautions
WARNING:
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THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY
RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE
PERSONNEL.
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AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE
EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT
OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.
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DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED.
AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED.IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE
THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION. THE EVAPORATION RATE OF R-134a REFRIGERANT
AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN
CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM
DIRECT CONTACT WITH THE REFRIGERANT.
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THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE
COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used.
Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result. R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can cause noise and system failure.
Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open
or loosen a connection before recovering the refrigerant.
The refrigerant system must always be evacuated before charging.
Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. This will prevent contamination in the
system.
Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system.
Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug.
Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal with clean refrigerant oil before connecting.
Do not remove the sealing caps from a replacement component until it is to be installed.
When installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. Position the refrigerant lines away from exhaust system
components or any sharp edges, which may damage the line.
Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refrigerant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a wrench on both halves of the fitting. This will prevent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container.
Keep service tools and the work area clean. Contamination of the refrigerant system through careless work habits must be avoided.
REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is
operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight.
A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice
to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed.
