Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2003 Freightliner Sprinter 2500 L5-2.7L DSL TurboFACTORY OEM SERVICE PROCEDURE
Control Module HVAC: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Remove the rear dome light from the rear roof duct panel.
3. Disconnect the dome light wire harness connector and remove the dome light from vehicle.
4. Remove the six push-pin roof duct panel fasteners and remove the duct panel from the vehicle.
5. Remove the five evaporator panel screws at the front of the panel.
6. If equipped, remove the interior motion sensor from the evaporator panel, disconnect the wire harness connector and remove the motion sensor from the vehicle.
7. Remove the three push-in evaporator panel fasteners at the rear of the panel.
8. Remove the rear evaporator panel from the vehicle.
9. Disconnect the wire harness connectors from the rear A/C control module.
10. Remove the rear A/C control module retainers and the control module from the vehicle.
INSTALLATION
1. Install the rear A/C control module and control module retainers.
2. Connect the wire harness connectors to the rear A/C control module.
3. Install the rear evaporator panel onto the rear evaporator housing and install the three push-pin fasteners.
4. If equipped, connect the wire harness connector to the interior motion sensor and install the sensor into the evaporator panel.
5. Install the five evaporator panel screws at the front of the panel. Tighten the screws to 2 N.m (17 in. lbs.).
6. Install the roof duct panel and the six push-pin fasteners.
7. Connect the dome light wire harness connector and install the dome light into the roof duct panel.
8. Reconnect the battery negative cable.
1. Disconnect and isolate the battery negative cable.
Rear Roof Duct Panel:
2. Remove the rear dome light from the rear roof duct panel.
3. Disconnect the dome light wire harness connector and remove the dome light from vehicle.
4. Remove the six push-pin roof duct panel fasteners and remove the duct panel from the vehicle.
5. Remove the five evaporator panel screws at the front of the panel.
Rear Evaporator Panel:
6. If equipped, remove the interior motion sensor from the evaporator panel, disconnect the wire harness connector and remove the motion sensor from the vehicle.
7. Remove the three push-in evaporator panel fasteners at the rear of the panel.
8. Remove the rear evaporator panel from the vehicle.
Rear A/C Control Module:
9. Disconnect the wire harness connectors from the rear A/C control module.
10. Remove the rear A/C control module retainers and the control module from the vehicle.
INSTALLATION
1. Install the rear A/C control module and control module retainers.
2. Connect the wire harness connectors to the rear A/C control module.
3. Install the rear evaporator panel onto the rear evaporator housing and install the three push-pin fasteners.
4. If equipped, connect the wire harness connector to the interior motion sensor and install the sensor into the evaporator panel.
5. Install the five evaporator panel screws at the front of the panel. Tighten the screws to 2 N.m (17 in. lbs.).
6. Install the roof duct panel and the six push-pin fasteners.
7. Connect the dome light wire harness connector and install the dome light into the roof duct panel.
8. Reconnect the battery negative cable.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.