Content .. 347 348 349 350 ..

Dodge Sprinter. Manual - part 349

(6) Remove the tape or plugs from the condenser

inlet port and the discharge line fitting.

(7) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the discharge line fit-
ting.

(8) Connect the discharge line fitting to the con-

denser inlet port.

(9) Install the nut that secures the discharge line

fitting to the condenser. Tighten the nut to 33 N·m
(24 ft. lbs.).

(10) Install the grille (Refer to 23 - BODY/EXTE-

RIOR/GRILLE - INSTALLATION).

(11) Evacuate the refrigerant system. (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)

(12) Charge the refrigerant system. (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)

(13) Reconnect the negative battery cable.

A / C EVAPORATOR

DESCRIPTION

The A/C evaporator for the heating-A/C system is

located within the HVAC housing, behind the instru-
ment panel (Fig. 8). The A/C evaporator is positioned
within the HVAC housing so that all air entering the
housing must pass over the evaporator fins before it
is distributed through the heating-A/C system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the A/C compres-
sor is engaged and circulating refrigerant through
the A/C evaporator.

The A/C evaporator tubes are connected and sealed

to the A/C expansion valve by use of rubber O-rings
and a tapping block.

The A/C evaporator is serviced by removing and

disassembling the HVAC housing.

OPERATION

Refrigerant enters the evaporator from the expan-

sion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas
before it leaves the evaporator.

The evaporator cannot be repaired and, if faulty or

damaged, it must be replaced.

REMOVAL

WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental

restraint

system

before

attempting

any

steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent 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 precau-
tions could result in accidental airbag deployment.

Fig. 8 Front A/C Evaporator

1 - A/C EVAPORATOR
2 - EVAPORATOR TUBES
3 - TAPPING BLOCK

24 - 72

PLUMBING

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) Remove the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).

(2) Disassemble the HVAC housing to access the

A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC

HOUSING

DISASSEMBLY).

(3) Lift the A/C evaporator out of the lower half of

the HVAC housing (Fig. 9).

INSTALLATION

NOTE: If the A/C evaporator is being replaced, add
60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the

type recommended for the A/C compressor in the
vehicle.

(1) Install the A/C evaporator into the lower half of

the HVAC housing.

(2) Assemble the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).

(3) Install the HVAC housing (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).

A / C EXPANSION VALVE

DESCRIPTION

The A/C expansion valve controls the amount of

refrigerant entering the A/C evaporator and is of a
thermostatic expansion valve (TXV) design (Fig. 10).
The A/C expansion valve consists of an aluminum
H-valve type body with an integral thermal sensor.

The A/C expansion valve is located at the dash

panel between the A/C refrigerant lines and the A/C
evaporator.

OPERATION

High-pressure, high temperature liquid refrigerant

from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the A/C evaporator. A thermal sensor in the
A/C expansion valve monitors the temperature of the
refrigerant leaving the A/C evaporator and adjusts
the orifice size at the evaporator inlet to allow the
proper amount of refrigerant into the A/C evaporator

Fig. 9 HVAC Housing

1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)

Fig. 10 Front A/C Expansion Valve

1 - A/C EXPANSION VALVE
2 - THERMAL SENSOR

PLUMBING

24 - 73

in order to meet vehicle cooling requirements. Con-
trolling the refrigerant flow through the A/C evapo-
rator ensures that none of the refrigerant leaving the
evaporator is still in a liquid state, which could cause
damage to the A/C compressor.

The A/C expansion valve is factory calibrated and

cannot be adjusted or repaired and, if faulty or dam-
aged, it must be replaced.

DIAGNOSIS AND TESTING

A / C EXPANSION VALVE

The A/C expansion valve is located on the engine

side of the dash panel near the shock tower.

The A/C expansion valve can fail in three different

positions (open, closed or restricted).

In an Open Position: this will result in a noisy A/C

compressor or no cooling. The cause can be broken
spring, broken ball or excessive moisture in the A/C
system. If the spring or ball are found to be defective,
replace the A/C expansion valve. If excessive mois-
ture is found in the A/C system, recycle the refriger-
ant.

In a Closed Position: There will be low suction

pressure and no cooling. This may be caused by a
failed power dome or excessive moisture in the A/C
system. If the power dome on the A/C expansion
valve is found to be defective replace the A/C expan-
sion valve. If excessive moisture is found recycle the
refrigerant.

A Restricted Orifice: There will be low suction

pressure and no cooling. This may be caused by
debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the A/C expansion valve and the receiver-drier.

REMOVAL

(1) Recover the refrigerant from the A/C system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM RECOVERY).

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the nut that secures the suction and

liquid line fittings to the stud on the A/C expansion
valve (Fig. 11).

(4) Disconnect the suction and liquid lines from

the expansion valve.

(5) Remove the seals from the suction and liquid

line fitting and discard.

(6) Install plugs in, or tape over the opened liquid

and suction line fittings and both expansion valve
ports.

(7) Remove the two bolts that secure the expan-

sion valve to the evaporator tube tapping plate.

(8) Remove the expansion valve from the evapora-

tor tube tapping plate.

(9) Remove the seals from the evaporator inlet and

outlet tube fittings and discard.

(10) Install plugs in, or tape over the opened evap-

orator inlet and outlet tube fittings and both expan-
sion valve ports.

INSTALLATION

(1) Remove the tape or plugs from the tapping

plate evaporator inlet and outlet tube fittings and
both ports on the back of the A/C expansion valve.

(2) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them on the tapping plate
evaporator inlet and outlet tube fittings.

(3) Position the A/C expansion valve onto the tap-

ping plate evaporator inlet and outlet tube fittings.

Fig. 11 A/C Expansion Valve

1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE
4 - BOLT (2)
5 - A/C SUCTION LINE
6 - NUT
7 - A/C LIQUID LINE
8 - O-RING SEAL (2)

24 - 74

PLUMBING

(4) Install the two bolts that secure the A/C expan-

sion valve to the evaporator tube tapping plate.
Tighten the bolts to 5 N·m (45 in. lbs.).

(5) Remove the tape or plugs from the liquid and

suction line fittings and both expansion valve ports.

(6) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them on the liquid and suc-
tion line fittings.

(7) Connect the liquid line fitting to the A/C expan-

sion valve.

(8) Connect the suction line fitting to the A/C

expansion valve.

(9) Install the nut that secures the suction line

and liquid line fittings to the stud on the A/C expan-
sion valve. Tighten the nut to 10 N·m (89 in. lbs.).

(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

(12) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

ELECTRIC COOLANT PUMP

DESCRIPTION

The electric coolant pump ensures the uniform flow

of coolant through the heater core without bubbles,
even at low speeds (Fig. 12). The electric coolant
pump is located in the left side of the engine com-
partment near the battery and is controlled by the
A/C-heater control.

The electric coolant pump housing contains two

coolant hose connections and an electric motor which
drives

the

vane-type

pump

using

magnetic

clutch.

OPERATION

The electric coolant pump is controlled by the ATC

A/C-heater control and is only operational when the
ignition switch is on under the following conditions:

(1) Vehicle speed below 27 Km/h (17 mph).
(2) Coolant temperature above 65° C (150° F) but

less than 110° C (230 ° F).

(3) Any blower motor speed setting.
(4) Temperature heat setting above the halfway

setting (60% heat).

(5) The pump will turn off at speeds above 48

Km/h (30 mph).

(6) The pump will turn off if the coolant tempera-

ture rises above 110° C (230 ° F).

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Partially

drain

the

engine

cooling

system

(Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
DARD PROCEDURE - DRAINING COOLANT SYS-
TEM).

(3) Disconnect the wire harness connector from the

electric coolant pump (Fig. 13).

(4) Loosen both hose clamps from the electric cool-

ant pump.

(5) Using a twisting motion gently remove both

heater hoses from the electric coolant pump.

(6) Remove the two electric coolant pump bracket

retaining nuts from the body studs.

(7) Remove the electric coolant pump from the

vehicle.

Fig. 12 Electric Coolant Pump

1 - ELECTRIC COOLANT PUMP
2 - COOLANT HOSE CONNECTIONS
3 - WIRE CONNECTOR

PLUMBING

24 - 75

Content .. 347 348 349 350 ..