Content .. 353 354 355 356 ..

Dodge Sprinter. Manual - part 355

(2) Install a new rear receiver/drier (Refer to 24 -

HEATING

AIR

CONDITIONING/PLUMBING/

REAR RECEIVER/DRIER - INSTALLATION).

(3) Position the rear refrigerant reservoir to the

rear A/C condenser housing and install the retaining
bracket and bolt. Tighten the bolt to 25 N·m (18 ft.
lbs.).

(4) Remove the tape or plugs from the rear liquid

line fitting and receiver/drier and reservoir ports.

(5) Lubricate a new O-ring seal with clean refrig-

erant oil and install it onto the rear receiver/drier fit-
ting. Use only the specified O-ring seal as it is 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.

(6) Connect the rear receiver/drier to the rear

refrigerant reservoir. Tighten the nut to 35 N·m (26
ft. lbs.).

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

erant oil and install it onto the rear liquid line fit-
ting. Use only the specified O-ring seal as it is 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.

(8) Connect the rear liquid line to the rear refrig-

erant reservoir. Tighten the nut to 35 N·m (26 ft.
lbs.).

(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to

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

(11) Charge the rear refrigerant system (Refer to

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

(12) Install the rear air filter (Refer to 24 - HEAT-

ING

AIR

CONDITIONING/DISTRIBUTION

REAR/AIR FILTER - INSTALLATION).

(13) 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).

REAR SUCTION LINE

DESCRIPTION

The rear A/Csuction line is the refrigerant line that

carries refrigerant from the rear A/C evaporator to
the A/C underbody suction line (Fig. 35). The rear
A/C suction line is retained to the left 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 suction 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 rub-
ber not affected by R-134a refrigerant and must be
replaced whenever the rear A/C suction line is
removed and installed.

If the rear A/C suction 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 insulating tape from around the

area of the rear A/C suction line and evaporator out-
let tube (Fig. 36).

Fig. 35 Rear A/C Suction Line

1 - REAR A/C SUCTION LINE
2 - TO UNDERBODY SUCTION LINE
3 - RETAINING CLIPS
4 - LEFT INNER QUARTER PANEL
5 - TO REAR A/C EVAPORATOR

24 - 96

PLUMBING

(5) From inside the vehicle, disconnect the rear

A/C suction line from the rear A/C evaporator and
remove and discard the O-ring seal.

(6) From underneath the vehicle, disconnect the

rear A/C suction line from the underbody suction line
and remove and discard the O-ring seal.

(7) Remove the left quarter trim panel (Refer to 23

BODY/INTERIOR/QUARTER

TRIM

PANEL

REMOVAL).

(8) Remove the three foam insulators from the left

inner quarter panel.

(9) Remove the foam rubber seal from the opening

in the floor of the cargo compartment.

(10) Disengage the rear A/C suction line from the

two retaining clips located on the inner quarter panel
and remove the suction line.

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

rear suction and underbody line fittings and evapora-
tor tube.

PLUMBING

24 - 97

INSTALLATION

(1) Remove the tape or plugs from the rear suction

and underbody line fittings and the rear evaporator
tube.

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

ant oil and install them onto the rear suction line fit-
tings. 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) Position the rear A/C suction line to the left

inner quarter panel and install it into the two retain-
ing clips.

(4) From inside the vehicle, connect the rear A/C

suction line to the rear A/C evaporator. Tighten the
nut to 35 N·m (26 ft. lbs.).

(5) From underneath the vehicle, connect the rear

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

(6) Install the three foam insulators to the left

inner quarter panel.

(7) Install the foam rubber seal into the floor

panel.

(8) Install the left quarter trim panel (Refer to 23 -

BODY/INTERIOR/QUARTER

TRIM

PANEL

INSTALLATION).

(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to

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

(11) Charge the rear refrigerant system (Refer to

24 - HEATING & AIR CONDITIONING/PLUMBING

- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

(12) 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).

REFRIGERANT LINE COUPLER

DESCRIPTION

A spring-lock type refrigerant line coupler is used

to connect the front section of the underbody dis-
charge line to the compressor section of the discharge
line. A secondary retaining clip may be installed over
the connected coupler for added protection.

The spring-lock refrigerant line coupler requires a

special disconnect tool for disengaging the two cou-
pler halves.

OPERATION

The spring-lock coupler is held together by a garter

spring inside a circular cage on the male half of the
fitting (Fig. 37). When the two coupler halves are
connected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the
cage.

Fig. 36 Rear A/C Suction Line

1 - REAR A/C SUCTION LINE
2 - RETAINING CLIPS
3 - EVAPORATOR OUTLET TUBE
4 - UNDERBODY SUCTION LINE

5 - FOAM RUBBER SEAL
6 - FOAM INSULATORS
7 - LEFT INNER QUARTER PANEL

24 - 98

PLUMBING

Two O-rings on the male half of the fitting are

used to seal the connection. These O-rings are com-
patible with R-134a refrigerant and must be replaced
with O-rings made of the same material.

Secondary clips are installed over the two con-

nected coupler halves at the factory for added blowoff
protection. In addition, some models have a plastic
ring that is used at the factory as a visual indicator
to confirm that these couplers are connected. After
the coupler is connected, the plastic indicator ring is
no longer needed; however, it will remain on the
refrigerant line near the coupler cage.

REMOVAL

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Remove the secondary retaining clip from the

spring-lock coupler.

(3) Fit the proper size A/C line disconnect tool

(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 38).

(4) Close the two halves of the A/C line disconnect

tool around the spring-lock coupler.

(5) Push the A/C line disconnect tool into the open

side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.

NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.

(6) Open and remove the A/C line disconnect tool

from the disconnected spring-lock coupler.

(7) Complete the separation of the two halves of

the coupler fitting.

INSTALLATION

(1) Check to ensure that the garter spring is

located within the cage of the male coupler fitting,
and that the garter spring is not damaged.

(a) If the garter spring is missing, install a new

spring by pushing it into the coupler cage opening.

(b) If the garter spring is damaged, remove it

from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both

halves of the coupler fitting.

(3) Install new O-rings on the male half of the cou-

pler fitting.

Fig. 37 Spring-Lock Coupler - Typical

1 - MALE HALF SPRING-LOCK COUPLER
2 - FEMALE HALF SPRING-LOCK COUPLER
3 - SECONDARY CLIP
4 - CONNECTION INDICATOR RING
5 - COUPLER CAGE
6 - GARTER SPRING
7 - COUPLER CAGE
8 - O-RING SEALS

Fig. 38 Refrigerant Line Spring-Lock Coupler

Disconnect

PLUMBING

24 - 99

Content .. 353 354 355 356 ..