Sprinter 2005-2007

Removal & Installation

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Front



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine air cleaner housing cover.
  4.  
  5. Position the ventilation housing insulation blanket out of the way of the blower motor assembly.
  6.  
  7. Disconnect the wire harness connector from the blower motor.
  8.  
  9. Remove the three blower motor retaining screws.
  10.  
  11. Remove the blower motor assembly from the ventilation housing.
  12.  

To install:

  1. Install the blower motor assembly into the ventilation housing.
  2.  
  3. Install the three blower motor retaining screws and tighten to 17 inch lbs. (2 Nm).
  4.  
  5. Connect the wire harness connector to the blower motor.
  6.  
  7. Install the ventilation housing insulation blanket.
  8.  
  9. Install the engine air cleaner cover.
  10.  
  11. Reconnect the negative battery cable.
  12.  

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the glove box from the instrument panel as follows:
    1. Remove the trim below the air outlet.
    2.  
    3. Open the glove box, push up on the two rear stops and fold the box down completely.
    4.  
    5. Remove the hinge screws and remove the glove box.
    6.  
    7. Remove the screws and remove the inner compartment liner.
    8.  
    9. Disconnect the glove box light electrical connector and remove the coolant air hose.
    10.  

  4.  
  5. Remove the right side floor duct.
  6.  
  7. Remove the screw that secures the instrument panel cover to the lower right portion of instrument panel.
  8.  
  9. Disengage the locking feature and rotate the blower motor counterclockwise until it is loose from the HVAC housing.
  10.  
  11. Gently pull the lower right portion of the instrument panel cover slightly rearward to gain clearance and remove the blower motor from the HVAC housing.
  12.  
  13. Disconnect the wire harness connector from the blower motor and remove the blower motor from the passenger compartment.
  14.  

To install:

  1. Connect the wire harness connector to the blower motor.
  2.  
  3. Gently pull the lower right portion of the instrument panel cover slightly rearward to gain clearance and position the blower motor into the HVAC housing.
  4.  
  5. Rotate the blower motor clockwise until it is fully seated in the HVAC housing. Make sure the blower motor locking feature is fully engaged to the housing.
  6.  
  7. Install the screw that secures the instrument panel cover to the instrument panel. Tighten the screw securely.
  8.  
  9. Install the right side floor duct.
  10.  
  11. Install the glove box as follows:
    1. Install the coolant air hose to the inner glove box liner and connect the glove box light electrical connector.
    2.  
    3. Install the inner glove box liner and install the screws.
    4.  
    5. Install the glove box and install the hinge screws.
    6.  
    7. Position the glove box up into the instrument panel and engage the rear retaining stop tabs.
    8.  
    9. Install the trim panel below the air outlet.
    10.  

  12.  
  13. Reconnect the negative battery cable.
  14.  

Rear



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cover from the rear A/C evaporator housing as follows:
    1. Remove the rear dome lamps from the center and rear roof duct panels.
    2.  
    3. Remove the push-pin fasteners that secure the center and rear roof duct panels to the roof duct and remove the panels.
    4.  
    5. Disconnect the dome light wire harness connector and remove the dome light wire harness from the roof duct.
    6.  
    7. Remove the six screws that secure the rear A/C evaporator cover to the front of the rear A/C evaporator housing.
    8.  
    9. Remove the three push-pin fasteners that secure the rear A/C evaporator cover to the rear of the evaporator housing and remove the cover.
    10.  

  4.  
  5. Disconnect the wire harness connectors from the rear blower motor suppression filter and from the rear blower motor being serviced and remove the suppression filter.
  6.  
  7. Remove the body sealer from around the rear blower motor area being serviced.
  8.  
  9. Remove the screws that secure each rear blower motor to the rear evaporator housing and remove blower motor.
  10.  

To install:

  1. Position the rear blower motor being serviced to the rear A/C evaporator housing.
  2.  
  3. Install the screws that secure each rear blower motor to the rear A/C evaporator housing and tighten the screws to 45 inch lbs. (5 Nm).
  4.  
  5. Install a new bead of body sealant to the blower motor area being serviced.
  6.  
  7. Install the rear blower motor suppression filter and connect the wiring harness connectors to the suppression filter and to the rear blower motor being serviced.
  8.  
  9. Install the cover onto the rear A/C evaporator housing as follows:
    1. Position the rear A/C evaporator cover to the rear A/C evaporator housing.
    2.  
    3. Install the three push-pin fasteners that secure the rear A/C evaporator cover to the rear of the evaporator housing.
    4.  
    5. Install the six screws that secure the rear A/C evaporator cover to the front of the evaporator housing and tighten the screws to 21 inch lbs. (2.2 Nm).
    6.  
    7. Install the dome light wire harness to the roof duct and reconnect the harness.
    8.  
    9. Position the center and rear roof duct panels to the roof duct and install the push-pin fasteners.
    10.  
    11. Install the rear dome lamps into the center and rear roof duct panels.
    12.  

  10.  
  11. Connect the negative battery cable.
  12.  

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the screws that secure the rear condenser cover to the top of the vehicle and remove the cover.
  4.  
  5. Remove the nut and bolt that secure the rear A/C suction line to the rear condenser cover bracket.
  6.  
  7. Remove the four bolts that secure the rear condenser cover bracket to the rear condenser bracket and remove the cover bracket.
  8.  
  9. Remove the screws that secure the rear evaporator cover and insulator to the top of the vehicle and remove the cover and insulator.
  10.  
  11. Disconnect the wire harness connectors from the rear blower motor.
  12.  
  13. Remove the screws that secure the rear blower motor to the rear evaporator housing and remove the blower motor.
  14.  

To install:

  1. Position the rear blower motor to the rear evaporator housing and tighten the retaining screws to 44 inch lbs. (5 Nm).
  2.  
  3. Connect the wire harness connectors to the blower motor.
  4.  
  5. Install the rear evaporator insulator and cover to the top of the vehicle and tighten the retaining screws to 17 inch lbs. (2 Nm).
  6.  
  7. Install the rear condenser cover bracket onto the rear condenser bracket and install the four retaining bolts. Tighten the bolts securely.
  8.  
  9. Install the nut and bolt that secure the rear A/C suction line to the rear condenser cover bracket. Tighten the nut securely.
  10.  
  11. Install the rear condenser cover to the top of the vehicle and tighten the retaining screws to 17 inch lbs. (2 Nm).
  12.  
  13. Reconnect the negative battery cable.
  14.  

 
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