Sprinter 3500 L5-2.7L DSL Turbo (2004)
Housing Assembly HVAC: Removal and Replacement
REMOVAL
WARNING:
-
ON VEHICLES EQUIPPED WITH AIR-BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
-
REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION.
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. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair,
Instrument Panel Assembly Replacement, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and
Repair/Instrument Panel Assembly
17. Remove the defroster, floor distribution and instrument panel ducts.
18. Disconnect the two bulkhead ground connections near instrument cluster area.