MERCEDES SPRINTER

2.8 T.D.

from '98

(FRONT EVAPORATOR)

WITH POWER STEERING

MER 40281

AIR CONDITIONER

AIR CONDITIONER

AIR CONDITIONER

INST

INST

INSTALLATION INSTRUCTIONS

ALLATION INSTRUCTIONS

ALLATION INSTRUCTIONS

MERCEDES SPRINTER
2.8 T.D. from '98

-1-

07.99

Auto Air

Conditioning

OR

IGINAL

REFRIGERANT CHARGE

FOR 134a

0.750

±

0.050 kg

MER 4001

FOR SERVICE USE

OIL SP-20

-2-

07.99

FIG. 1

MER 4002

MERCEDES SPRINTER from '98

EVAPORATOR INSTALLATION

Auto Air

Conditioning

OR

IGINAL

2

REMOVE PARTS IN SEQUENCE OF NUMBERS.

1

3

4

5

-3-

07.99

FIG. 2

MER 4003

EVAPORATOR INSTALLATION

DISCARD

Auto Air

Conditioning

OR

IGINAL

DRILL ¯10mm

CUT AWAY
AS SHOWN

MERCEDES SPRINTER from '98

FOR DRAIN HOSE

A

DRILL ¯6 mm

VIEW A

-4-

07.99

FIG. 3

MER 4004

EVAPORATOR COIL

Auto Air

Conditioning

OR

IGINAL

EVAPORATOR INSTALLATION

2 CLOOSE CELL TAPES
1/2"x3/4"x40cm

TERMISTOR

SCREW
4x12

DRAIN HOSE
16mmx16cm

ALUMINUM
DRAIN TUBE

MERCEDES SPRINTER from '98

SPONGE

INSERT TO
DRAIN HOLE

SEE FIG. 4

ELECTRONIC
CONTROL BOX

2 SCREWS
5x19

-5-

07.99

FIG. 4

DRAIN HOSE GROMMET

Auto Air

Conditioning

OR

IGINAL

MER 4005

EVAPORATOR INSTALLATION

¯ 27mm

30mm

25mm

120mm

32mm

DRILL ¯ 27mm

75mm

DRILL

MERCEDES SPRINTER from '98

07.99

A/C SWITCH

-6-

EVAPORATOR INSTALLATION

Auto Air

Conditioning

OR

IGINAL

FIG. 5

MER 4006

DISCARD

MERCEDES SPRINTER from '98

4 BOLTS M10x45
+8 WASHERS
+4 LOCKWASHERS
+4 NUTS

2 BOLTS M8x40
+WASHERS 8x2mm

COMPRESSOR

2 BOLTS M8x40
+WASHERS 8x2mm

COMPRESSOR
BRACKET

05.02

MER 4007

-7-

FIG. 6

I.

FAN.

P.S.

D.P.

ALT.

COMP.

FAN.

D.P.

I.

COMP.

P.S.

ALT.

BELT 6PK 2175

BELT 6PK 2160

MERCEDES SPRINTER 2.8 T.D from '98

ENGINE KIT INSTALLATION

Auto Air

Conditioning

OR

IGINAL

I.

FOR MODELS WITH ONE ORIGINAL IDLER

FOR MODELS WITH 2 ORIGINAL IDLER

-8-

07.99

FIG. 7

MER 4008

INTERCOOLER

Auto Air

Conditioning

OR

IGINAL

CONDENSER INSTALLATION

MERCEDES SPRINTER from '98

4 BOLTS M6x15
+WASHERS
+LOCKNUTS

4 BOLTS M6x15
+WASHERS
+LOCKNUTS

115mm

ELECTRIC FAN BRACKET (2068-301)

ELECTRIC FAN BRACKET (2068-302)

ELECTRIC FAN

2 BOLTS M6x10
+SQUARE NUTS

2 BOLTS M6x10
+SQUARE NUTS

-9-

07.99

FIG. 8

MER 4009

MERCEDES SPRINTER from '98

4 SPACERS
¯19x¯10.5x10mm

Auto Air

Conditioning

OR

IGINAL

CONDENSER INSTALLATION

4 BOLTS M6x15
+WASHERS
+LOCKWASHERS

2 ORIGINAL
BOLTS

2 SCREWS 4x10
+WASHERS

2 ORIGINAL BOLTS

2 OIL TUBE BRACKETS

CONDENSER

RADIATOR

4 BOLTS M6x35
+WASHERS 6x2mm

-10-

07.99

FIG. 9

MER 4010

BOLT M6x15
+WASHER
+LOCKWASHER

Auto Air

Conditioning

OR

IGINAL

RECEIVER
DRIER

TRINARY SWITCH

RECEIVER DRIER INSTALLATION

RECEIVER DRIER
BRACKET

BOLT M6x25
+LOCKNUT

BOLT M6x15
+LOCKWASHER

MERCEDES SPRINTER from '98

BATTERY

-11-

07.99

FIG. 10

MER 4011

HOSE 5/16"x 70cm

Auto Air

Conditioning

OR

IGINAL

HOSE 13/32"x 55cm

HOSE 1/2"x 70cm

SERVICE VALVE

SERVICE
VALVE

REFRIGERANT HOSES INSTALLATION

HOSE 5/16"x 90cm

BLOCK VALVE
(FLANGE)

CLAMPING PLATE
(0035)

SOCKET HEAD
BOLT M6x20

MERCEDES SPRINTER from '98

-12-

07.99

FIG. 11

MER 4012

ELECTRIC SYSTEM
PLASTIC COVER

Auto Air

Conditioning

OR

IGINAL

WIRE HARNESS INSTALLATION

2 SCREWS 5x12

2 ORIGINAL BOLTS

ELECTRIC SYSTEM
BRACKET

2 SCREWS 5x12

TO COMPRESSOR

TO ELECTRIC FANS

TO TRINARY
SWITCH

TO (+) BATTERY

RELAY

RELAY 2x15A

FUSE 10A

FUSE 20A

FIG. 12

MERCEDES SPRINTER from '98

SEE FIG.12

-13-

04.00

FIG. 13

MER 4013

WIRING DIAGRAM

Auto Air

Conditioning

OR

IGINAL

BATTERY

20A

FUSE

BROWN

87

86

85

30

87

86

85

30

87B

RELAY

BROWN

BLUE

BLACK

RED

ELECTRONIC
CONTROL BOX

TERMISTOR

D-3A

PINK

YELLOW

BROWN

RED

A/C SWITCH

PLUG

GREEN

BLUE

20A

FUSE

ORIGINAL SPEED

SWITCH PLUG

(WHITE)

BLUE

BLUE (+)

BROWN

RED

WHITE

WHITE

RELAY

2x15A

BROWN

ORIGINAL GREEN
(+) ILL

ORIGINAL BLACK/BLUE
(+) AFTER IGN.

ORIGINAL BROWN (Ð)

ORIGINAL PLUG
NEER SPEED SWITCH
PLUG (BLACK)

ORIGINAL YELLOW
FIRST SPEED

ORIGINAL WHITE/BLACK

ORIGINAL RED/BLUE

II

ORIGINAL BLACK/YELLOW III

ORIGINAL WHITE IV

ORIGINAL RED
(+) FLAP

(Ð)

(+)

4 BLUE WIRE CONNECTORS

MERCEDES SPRINTER from '98

BLACK

COMPRESSOR

ELECTRIC FAN

BROWN

YELLOW

ELECTRIC FAN

YELLOW

BROWN

BLUE

TRINARY
SWITCH

BLUE

BLACK

BLACK

BLUE

3 RED CONNECTORS