Sprinter 2005-2007

Removal & Installation

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  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner housing.
  8.  
  9. Remove the windshield washer reservoir.
  10.  
  11. Remove the air filter from the ventilation housing.
  12.  
  13. Disconnect the wire harness and vacuum connectors from the recirculation door actuator.
  14.  
  15. Disconnect the wire harness connector from the blower motor resistor block.
  16.  
  17. Disconnect the wire harness connector from the blower motor
  18.  
  19. Remove the nuts and washers that secure the ventilation housing to the body and remove the ventilation housing from the vehicle.
  20.  
  21. Disconnect the heater hoses from the heater core.
  22.  
  23. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
  24.  
  25. Remove the two bolts securing the refrigerant lines to the evaporator tubes and disconnect the lines from the tubes. Cap all of the opened refrigerant line fittings.
  26.  
  27. Remove the seals from the refrigerant line fittings and discard.
  28.  
  29. Install plugs in, or tape over the opened refrigerant line fittings and evaporator tubes.
  30.  
  31. Remove the instrument panel from the vehicle as follows:
    1. Remove the radio.
    2.  
    3. Remove the glove compartment.
    4.  
    5. Remove the cup holder.
    6.  
    7. Remove the instrument cluster.
    8.  
    9. Remove the passenger airbag.
    10.  
    11. Remove the right and left speakers.
    12.  
    13. Remove the center bezel.
    14.  
    15. Remove the air conditioning push-button control module.
    16.  
    17. Twist the cover lock 1/4 turn and remove Power Distribution Center (PDC) cover.
    18.  
    19. Remove the nut and screws and remove steering column shroud.
    20.  
    21. Remove the PDC bolt, nut and nut for ground wire.
    22.  
    23. Disconnect the PDC electrical connectors and remove.
    24.  
    25. Remove the screws and remove passenger side air nozzle cover.
    26.  
    27. Remove the screws and remove left side cover.
    28.  
    29. Remove the left outer and inner air nozzles.
    30.  
    31. Remove the right side cover.
    32.  
    33. Remove the right outer and inner air nozzles.
    34.  
    35. Remove the protective matting from cluster location.
    36.  
    37. Remove the instrument panel top cover screws and cover.

      Click image to see an enlarged view

      Fig. Remove the speaker covers (1), center nozzle cover (2), top screws (4) and lower screws (5,6) to remove the top cover (3)-2005-06 Models

    38.  
    39. Remove the vent hose.
    40.  
    41. Remove the brake pedal spring.
    42.  
    43. Remove the ignition transponder.
    44.  
    45. Turn the steering wheel and lock the steering wheel in the straight ahead position.
      CAUTION
      The position of the steering gear must not be altered again for the entire duration of the work procedure.

    46.  
    47. Remove the steering column support bolts.
    48.  
    49. Remove the screws and remove instrument panel.

      Click image to see an enlarged view

      Fig. Remove the upper (1), right (3), center (4) and left (5) screws to remove the instrument panel assembly (2)-2005-06 Models

    50.  

  32.  
  33. Remove the defroster, floor distribution and instrument panel ducts.
  34.  
  35. Disconnect the two bulkhead ground connections near instrument cluster area.
  36.  
  37. Remove the passenger airbag bracket.
  38.  
  39. Disconnect the wire harness connector from the evaporator temperature sensor and air outlet temperature sensor.
  40.  
  41. Remove the wire harness from the bracket located on the right side of the heater housing and position the wire harness out of the way.
  42.  
  43. Disconnect the A/C-heater control cables from the mode door levers.
  44.  
  45. Disconnect the evaporator drain tube from the HVAC housing.
  46.  
  47. Remove the five bolts securing the HVAC housing to the body.
    NOTE
    Make sure that the interior is protected in case of loss of residual fluids from the heater core and the A/C evaporator.

  48.  
  49. Remove the HVAC housing from the vehicle.
  50.  
  51. Disassemble the HVAC housing to access the heater core.
  52.  
  53. Lift the heater core out of the lower half of the HVAC housing.
  54.  
  55. If necessary, remove the three heater core tube retaining bolts and the heater core tube assembly from the heater core.
  56.  
  57. Remove the heater core tube seals and discard as required.
  58.  

To install:

  1. If the heater core tube assembly was removed from the heater core, lubricate two new rubber O-ring seals with clean engine coolant and install them onto the heater core fitting.
  2.  
  3. If required, connect the heater core tube assembly to the heater core and tighten the three retaining bolts to 45 inch lbs. (5 Nm).
  4.  
  5. Install the heater core into the bottom half of the HVAC housing.
  6.  
  7. Installation of the HVAC housing is the reverse order of removal.
  8.  
  9. Evacuate and charge the refrigerant system.
  10.  
  11. Refill the cooling system to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  

  1. Remove the instrument panel and HVAC housing as an assembly as follows:
    1. Disconnect the negative battery cable.
    2.  
    3. Recover the refrigerant from the A/C system.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the air intake assembly.
    8.  
    9. Remove the nut and disconnect the A/C liquid line and the A/C suction line from the A/C expansion valve and remove and discard the O-ring seals.
    10.  
    11. Loosen the clamps and disconnect the heater hoses from the heater core.
    12.  
    13. Cap the expansion valve and heater core openings.
    14.  
    15. Remove the A-pillar trim.
    16.  
    17. Remove the sun visors and storage trays.
    18.  
    19. Remove the dome light.
    20.  
    21. Remove the headliner
    22.  
    23. Remove the steering column opening cover.
    24.  
    25. Remove the trim below the air outlet.
    26.  
    27. Open the glove box, push up on the two rear stops and fold the box down completely.
    28.  
    29. Remove the hinge screws and remove the glove box.
    30.  
    31. Remove the screws and remove the inner compartment liner.
    32.  
    33. Disconnect the glove box light electrical connector and remove the coolant air hose.
    34.  
    35. Using a trim stick C-4755 or equivalent, separate the clips and remove the center bezel.
    36.  
    37. Remove the air outlet covers from the instrument panel center section.
    38.  
    39. Remove the cover on the gearshift lever.
    40.  
    41. Remove the gear shifter assembly.
    42.  
    43. Remove the side air nozzles.
    44.  
    45. Turn the steering wheel to center position and lock steering.
    46.  
    47. Remove the airbag module from the steering wheel and remove the steering wheel.
      NOTE
      Matchmark the steering wheel to the steering column shaft for proper orientation during installation.

    48.  
    49. Disconnect all electrical connectors from wiring harness in area of A-pillar and roof and remove the wiring harness.
    50.  
    51. Disconnect all the electrical connectors from wiring harness in passenger footwell.
    52.  
    53. Disconnect all electrical connectors on instrument panel in driver footwell.
    54.  
    55. Disconnect the connections and lines of instrument panel in interior compartment.
    56.  
    57. Remove the air filter housing.
    58.  
    59. Disconnect the connections and lines of instrument panel in engine compartment.
    60.  
    61. Remove the bolts from firewall.
    62.  
    63. Remove the bolts.
    64.  
    65. Lift out the instrument panel support with instrument panel.

      Click image to see an enlarged view

      Fig. Disconnect all wiring harnesses (2, 3, 5) and remove the firewall bolts (1) and mounting bolts (4) to remove the instrument panel-2007-08 Models

    66.  

  2.  
  3. Remove the blower motor power module or blower motor resistor (depending on application).
  4.  
  5. Remove the two metal retaining clamps that secure the heater core tubes to the heater core.

    Click image to see an enlarged view

    Fig. Remove the retaining clamps (1) that secure the heater core tubes (2) to the heater core (3)-2007-08 Models

  6.  
  7. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
    CAUTION
    Make sure not to damage the stud mounting boss when removing the retaining bracket from the HVAC housing. Hold the end of the stud with vise grips or similar tool when removing the nut from the stud. Failure to follow this caution may result in damage to the HVAC housing.

  8.  
  9. Remove the nut (1) that secures the bracket (2) to the HVAC housing (3) near the blower motor. Hold the end of the stud with vise grips or similar tool when removing the nut from the stud.

    Click image to see an enlarged view

    Fig. Remove nut (1) securing bracket (2) to HVAC housing (3). )-2007-08 Models

  10.  
  11. Carefully position the blower motor portion of the HVAC housing (2) slightly forward for clearance and remove the heater core (1) from the HVAC housing (3) by pulling it straight out of the side of the housing.

    Click image to see an enlarged view

    Fig. Position the blower motor portion of the HVAC housing (2) slightly forward for clearance and remove the heater core (1) from the HVAC housing (3) )-2007-08 Models

  12.  

To install:

  1. Carefully position the blower motor portion of the HVAC housing slightly forward for clearance and install the heater core into the side of the HVAC housing.
  2.  
  3. Install the bracket to the HVAC housing.
  4.  
  5. Install the nut that secures the bracket to the HVAC housing. Tighten the nut securely.
  6.  
  7. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core fittings. Use only the specified O-rings as they are made of a special material compatible to engine coolant. Use only engine coolant of the type recommended for the engine in the vehicle.
  8.  
  9. Install the heater core tubes onto the heater core.
  10.  
  11. Install the two metal retaining clamps that secure the heater core tubes to the heater core.
  12.  
  13. Install the blower motor power module or blower motor resistor (depending on application).
  14.  
  15. The remainder of the installation is the reverse order of removal.
  16.  
  17. Evacuate and recharge the refrigerant system.
  18.  
  19. Refill the cooling system to the correct level.
  20.  
  21. Start the engine and check for leaks.
  22.  

 
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