Dodge Sprinter. Manual - part 353

REAR DISCHARGE LINE

DESCRIPTION

The rear A/C discharge line is the refrigerant line

that carries refrigerant from the underbody discharge
line to the rear A/C condenser (Fig. 26). The rear A/C
discharge line is retained to the right quarter panel
by two plastic retaining clips.

CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrig-
erant system connections to leak.

The rear A/C discharge line has no serviceable

parts except for the O-ring seals. The O-ring seals
used on the connections are made from a special type
of rubber not affected by R-134a refrigerant and
must be replaced whenever the rear discharge line is
removed and installed.

If the rear A/C discharge line is found to be leaking

or damaged, it must be replaced.

REMOVAL

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) Disconnect and isolate the negative battery

cable.

(2) Remove the cover from the rear A/C evaporator

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - REMOVAL).

(3) Recover the refrigerant from the rear refriger-

ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).

(4) Remove the cover from the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

REAR/A/C

CON-

DENSER COVER - REMOVAL).

(5) Remove the screw and bracket that secures the

rear A/C discharge line to the right side of the rear
A/C condenser housing (Fig. 27).

(6) Disconnect the rear A/C discharge line from the

rear A/C condenser and remove and discard the
O-ring seal.

(7) Disengage the discharge line grommet from the

roof panel and push the grommet down into the
cargo compartment.

(8) Remove the right quarter trim panel (Refer to

23 - BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL).

(9) Remove the retaining strap that secures the

rear A/C wire harness to the rear A/C discharge line
at the ceiling and position the wire harness out of
the way (Fig. 28).

Fig. 26 Rear A/C Discharge Line

1 - REAR A/C DISCHARGE LINE
2 - RETAINING CLIPS
3 - TO REAR A/C CONDENSER
4 - RIGHT INNER QUARTER PANEL
5 - TO UNDERBODY DISCHARGE LINE

Fig. 27 Rear A/C Discharge Line to Rear Condenser

1 - REAR A/C CONDENSER
2 - GROMMET
3 - REAR A/C DISCHARGE LINE
4 - CONDENSER INLET TUBE
5 - SCREW AND BRACKET

24 - 88

PLUMBING

(10) Remove the three foam insulators from the

right inner quarter panel (Fig. 29).

(11) Disengage the rear A/C discharge line from

the two retaining clips located on the inner quarter
panel and pull the discharge line down from the top
of the vehicle into the cargo compartment.

(12) Disengage the rear A/C discharge line from

the two retaining clips located underneath of the
vehicle.

(13) Disconnect the rear A/C discharge line from

the underbody discharge line and remove and discard
the O-ring seal.

(14) Remove the foam rubber seal from the open-

ing in the floor of the cargo compartment and pull
the rear A/C discharge line out from underneath the
vehicle.

(15) Install plugs into, or tape over the opened

rear discharge and underbody line fittings and con-
denser tube.

Fig. 28 Rear A/C Wire Harness

1 - REAR A/C EVAPORATOR HOUSING
2 - REAR A/C DISCHARGE LINE
3 - RETAINING STRAP
4 - REAR A/C WIRE HARNESS

PLUMBING

24 - 89

INSTALLATION

(1) Remove the tape or plugs from the rear dis-

charge and underbody line fittings and the rear con-
denser tube.

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

ant oil and install them onto the rear discharge line
fittings. Use only the specified O-ring seals as they
are made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.

(3) From underneath the vehicle, route the rear

A/C discharge line into the cargo compartment and
install it into the two retaining clips located under
the vehicle.

(4) Connect the rear A/C discharge line to the

underbody discharge line. Tighten the nut to 35 N·m
(26 ft. lbs.).

(5) Install the foam rubber seal into the floor

panel.

(6) From inside the vehicle, install the rear A/C

discharge line into the two retaining clips located on
the inner quarter panel and route the discharge line
through the opening in the roof.

(7) Seat the grommet to the roof panel and install

a new rear A/C wire harness retaining strap.

(8) Install the three foam insulators to the right

inner quarter panel.

(9) Install the right quarter trim panel (Refer to

23 - BODY/INTERIOR/QUARTER TRIM PANEL -
INSTALLATION).

(10) Connect the rear discharge line to the rear

A/C condenser. Tighten the nut to 35 N·m (26 ft.
lbs.).

(11) Install the bracket and screw that secures the

rear discharge line to the right side of the rear con-
denser housing. Tighten the screw securely.

(12) Reconnect the negative battery cable.
(13) Evacuate the rear refrigerant system (Refer to

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

(14) Charge the rear refrigerant system (Refer to

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

(15) Install the cover onto the rear A/C evaporator

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/A/C EVAPORA-
TOR COVER-REAR - INSTALLATION).

(16) Install the cover onto the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

REAR/A/C

CON-

DENSER COVER - INSTALLATION).

Fig. 29 Rear A/C Discharge Line to Underbody

1 - REAR A/C DISCHARGE LINE
2 - RETAINING CLIPS
3 - TO REAR CONDENSER
4 - FOAM RUBBER SEAL
5 - BRACKETS

6 - UNDERBODY DISCHARGE LINE
7 - RIGHT INNER QUARTER PANEL
8 - FOAM INSULATORS
9 - TO UNDERBODY

24 - 90

PLUMBING

REAR LIQUID LINE

DESCRIPTION

The rear liquid line is the refrigerant line that car-

ries refrigerant from the rear condenser to the rear
A/C expansion valve. The rear A/C liquid line on this
vehicle is serviced in two sections (Fig. 30).

CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrig-
erant system connections to leak.

The rear A/C liquid lines have no serviceable parts

except for the O-ring seals. The O-ring seals used on
the connections are made from a special type of rub-
ber not affected by R-134a refrigerant and must be
replaced whenever the rear liquid line is removed
and installed.

If either of the rear liquid lines is found to be leak-

ing or damaged, it must be replaced.

REMOVAL

CONDENSER TO RECEIVER / DRIER

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the air filter from the rear A/C evapo-

rator housing (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION - REAR/AIR FILTER -
REMOVAL).

(3) Recover the refrigerant from the rear refriger-

ant system (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).

(4) Remove the cover from the rear A/C condenser

housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION

REAR/A/C

CON-

DENSER COVER - REMOVAL).

(5) Disconnect the rear liquid line from the rear

receiver/drier and remove and discard the O-ring seal
(Fig. 31).

(6) Disconnect the rear liquid line from the rear

condenser and remove and discard the O-ring seal.

(7) Remove the retaining straps that secure the

rear A/C wire harness to the rear liquid line and
remove the liquid line.

(8) Install plugs into, or tape over the opened rear

liquid line fittings and receiver/drier and condenser
ports.

Fig. 30 Rear A/C Liquid Lines

1 - REAR A/C CONDENSER
2 - REAR LIQUID LINE (FROM CONDENSER)
3 - REAR RECIEVER/DRIER AND RESERVOIR
4 - REAR LIQUID LINE (TO EXPANSION VALVE)

PLUMBING

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