Sprinter 2005-2007

Removal & Installation

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NOTE
The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil or the engine.


NOTE
If an internal failure of the A/C compressor has occurred, the receiver/drier must be replaced.

  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Disconnect the wire harness connector from the clutch field coil of the A/C compressor.
  10.  
  11. Remove the bolts that secure the underbody suction and discharge lines to the A/C compressor.
  12.  
  13. Disconnect the underbody suction and discharge lines from the A/C compressor and remove and discard the O-ring seals.
  14.  
  15. Install plugs in, or tape over the opened refrigerant line fittings and the compressor ports.
  16.  
  17. Remove the bolts that secure the A/C compressor to the mounting bracket.
  18.  
  19. Remove the A/C compressor from the engine compartment.
  20.  

To install:


NOTE
Be certain to check the refrigerant oil level if the A/C compressor is being replaced. See Refrigerant Oil Level in this group for the procedures. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.


NOTE
If an internal failure of the A/C compressor has occurred, the receiver/drier must be replaced.

  1. Position the A/C compressor in the engine compartment and loosely install the three compressor retaining bolts. Tighten the bolts using the following sequence to 14 ft. lbs. (20 Nm).

    The upper bolt at the front of the compressor.
     
    The lower bolt at the front of the compressor.
     
    The bolt at the rear of the compressor.
     

  2.  
  3. Remove the tape or plugs from the opened underbody suction and discharge line fittings and compressor ports.
  4.  
  5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the suction and the discharge line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  6.  
  7. Connect the underbody suction and discharge lines to the A/C compressor.
  8.  
  9. Install the bolts that secure the underbody suction and discharge lines to the A/C compressor. Tighten the bolts to 15 ft. lbs. (21 N·m).
  10.  
  11. Connect the wire harness connector to the A/C compressor clutch coil.
  12.  
  13. Install the accessory drive belt.
  14.  
  15. Lower the vehicle.
  16.  
  17. Replace the receiver/drier if the A/C compressor is being replaced due to an internal failure.
  18.  
  19. Reconnect the negative battery cable.
  20.  
  21. Evacuate the refrigerant system.
  22.  
  23. Charge the refrigerant system.
  24.  

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Recover the refrigerant from the refrigerant system .
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the accessory drive belt .
  8.  
  9. Disconnect the engine wire harness from the A/C compressor.
  10.  
  11. Remove the bolts that secure the A/C suction line and the A/C discharge line to the A/C compressor.
  12.  
  13. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals.
  14.  
  15. Support the A/C compressor and remove the three bolts that secure the compressor to the engine and remove the compressor.
  16.  
  17. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
  18.  

To install:


CAUTION
Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.


CAUTION
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious A/C compressor damage.


NOTE
When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


NOTE
Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seal may result in a refrigerant system leak.

  1. If the A/C compressor is being replaced, 1.7 oz. (50 milliliters) of refrigerant oil must first be drained from the new A/C compressor . When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  2.  
  3. Position the A/C compressor into the engine compartment.
  4.  
  5. Install the three bolts that secure the A/C compressor to the engine. Tighten the bolts to 15 ft. lbs. (20 N·m).
  6.  
  7. Remove the tape or plugs from the compressor ports and refrigerant line fittings.
  8.  
  9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  10.  
  11. Connect the A/C suction line and the A/C discharge line to the A/C compressor.
  12.  
  13. Install the bolts that secure the A/C discharge and suction lines to the A/C compressor. Tighten the bolts to 16 ft. lbs. (22 N·m).
  14.  
  15. Connect the engine wire harness to the A/C compressor.
  16.  
  17. Install the accessory drive belt.
  18.  
  19. Lower the vehicle.
  20.  
  21. Reconnect the negative battery cable.
    CAUTION
    DO NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.

  22.  
  23. Evacuate the refrigerant system .
  24.  
  25. Charge the refrigerant system .
  26.  

 
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