Heating & Air Conditioning Iii PDF

HEATING & AIR CONDITIONING
Air Conditioning System
Service Precautions
Safety is the most important factor when performing not only fuel system maintenance but also
any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may
result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system
components can be accomplished safely and effectively by adhering to the following rules and
guidelines:
To avoid the possibility of fire and personal injury, always disconnect the negative battery
cable unless the repair or test procedure requires that battery voltage be applied.
Handle the electronic throttle control components carefully. Use cleanliness in order to
prevent damage. Do not drop the electronic throttle control components. Do not roughly
handle the electronic throttle control components. Do not immerse the electronic throttle
control components in cleaning solvents of any type.
Always relieve the fuel system pressure prior to disconnecting any fuel system component
(injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme
caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to
fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part
of the body that it contacts.
Always place a shop towel or cloth around the fitting or connection prior to loosening to
absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is
quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are
deposited into a suitable waste container.
Always keep a dry chemical (Class B) fire extinguisher near the work area.
Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.
Wear eye protection when servicing the air conditioning refrigerant system. Serious eye
injury can result from eye contact with refrigerant. If eye contact is made, seek medical
attention immediately.
Do not expose refrigerant to open flame. Poisonous gas is created when refrigerant is
burned. An electronic type leak detector is recommended.
Large amounts of refrigerant released in a closed work area will displace the oxygen and
cause suffocation.
The evaporation rate of refrigerant at average temperature and altitude is extremely high.
As a result, anything that comes in contact with the refrigerant will freeze. Always protect
skin or delicate objects from direct contact with refrigerant. R-134a service equipment or
vehicle A/C system should not be pressure tested or leak tested with compressed air.
Some mixtures of air and R-134a have been shown to be combustible at elevated
pressures. These mixtures are potentially dangerous and may result in fire or explosion
causing injury or property damage.
Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. Seek
medical attention immediately if swallowed or inhaled. Do not store in open or unmarked
containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol.
Keep out of reach of children and pets.
Do not open a cooling system when the engine is at running temperature. Personal injury
can result.
Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly
reduce the capacity of the entire system.
High pressures are produced in the system when it is operating. Extreme care must be
exercised to make sure that all connections are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replacement of lines or components. The
refrigerant oil will absorb moisture readily out of the air. This moisture will convert into
acids within a closed system.
The system must be completely empty before opening any fitting or connection in the
refrigeration system. Open fittings with caution even after the system has been emptied. If
any pressure is noticed as a fitting is loosened, retighten fitting and evacuate the system
again.
A good rule for the flexible hose lines is to keep the radius of all bends at least 10 times
the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible
hose lines should be routed so they are at least 3 in. (80 mm) from the exhaust manifold.
Inspect all flexible hose lines to make sure they are in good condition and properly routed.
The use of correct wrenches when making connections is very important. Improper
wrenches or improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain stable as long as moisture-free refrigerant
and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the
chemical stability. This may cause operational troubles or even serious damage if present
in more than very small quantities.
When opening a refrigeration system, have everything you will need to repair the system
ready. This will minimize the amount of time the system must be opened. Cap or plug all
lines and fittings as soon as they are opened. This will help prevent the entrance of dirt
and moisture. All new lines and components should be capped or sealed until they are
ready to be used.
All tools, including the refrigerant dispensing manifold, the manifold gauge set, and test
hoses should be kept clean and dry.
A/C SPECIFICATIONS
A/C System Information
CAUTION
Eye and skin protection must always be worn while working with refrigerants.
CAUTION
DO NOT breathe any refrigerant vapor or mist. Make sure to work in an adequately ventilated
space.
Accumulator
Removal & Installation
To Remove:
1. Recover the refrigerant from the A/C system.

2. Disconnect A/C low pressure switch electrical connector.
3. Remove the compressor hose nut from the accumulator.
4. Remove the compressor hose from the accumulator.
5. Remove the nut from the evaporator fitting.
6. Remove the accumulator bracket nut from the retaining stud.
7. Remove the accumulator.
Accumulator removal
8. Remove the accumulator retaining bracket.

9. Discard the O-rings.
To Install:
1. Install
the new O-rings.
2. Install
the accumulator retaining bracket.
3. Install
the retaining bracket bolt.
4. Install
the accumulator and accumulator bracket bolt.
5. Install
the evaporator fitting nut.
Tighten the nut to 12 ft lb (16 Nm). Install the compressor hose to the accumulator.
Tighten the nut to 12 ft lb (16 Nm).
6. Connect the A/C low pressure switch electrical connector.

7. Evacuate and recharge the A/C system.
8. Leak test the fittings with an electronic leak detector.
Air Door Actuators
Air Temperature Actuator
Air Temperature Actuator Replacement
To Remove:
CAUTION
Do not apply power to the actuator when it is removed from the HVAC module.
1. Remove the instrument panel hush panel.

2. Disconnect the connector from the air temperature actuator.
3. Remove the air temperature actuator mounting screws.
4. Remove the actuator from the HVAC assembly.
To Install:
1. Position the air temperature actuator on the HVAC assembly.

2. Install the actuator mounting screws.
3. Install the electrical connect to the air temperature actuator.
4. Install the instrument panel hush panel.
Right Side Air Temperature Actuator (2003-2007)
Right Air Temperature Actuator Replacement
To Remove:
CAUTION
1. Remove the instrument panel carrier.

2. Disconnect the connector from the right air temperature actuator.
3. Remove the actuator mounting screws.
4. Remove the right air temperature actuator.
To Install:
1. Position the right air temperature actuator on the HVAC assembly.

3. Connect the electrical connector to the actuator.
4. Install the I/P carrier.
5. Calibrate the actuator.
Left Side Air Temperature Actuator (2003-2007)
Left Air Temperature Actuator Replacement
To Remove:
CAUTION
1. Remove the I/P insulator panel.

2. Disconnect the connector from the left air temperature actuator.
3. Remove the actuator mounting screws.
4. Remove the left air temperature actuator.
To Install:
1. Position the left air temperature actuator on the HVAC assembly.

3. Connect the electrical connector to the actuator.
4. Install the I/P insulator panel.
Mode Actuator
Mode Actuator Replacement
To Remove:
CAUTION
1. Remove the floor air outlet from the floor duct.

2. Remove the center console and center console duct (if equipped).
3. Disconnect the electrical connection at the mode actuator.
4. Remove the mode actuator mounting screws from the HVAC module.
5. Remove the mode actuator with the actuator cam attached.
To Install:
1. Position the mode actuator with the actuator cam to the HVAC module.
Align the heater/defroster valve lever with the cam slot
Align the A/C valve lever with the cam
2. Install the mode actuator mounting screws.

3. Connect the mode actuator electrical connection.
4. Install the center console duct and the center console (if equipped).
5. Install the floor air outlet duct extension to the floor air duct.
Air Inlet Actuator/Recirculation Actuator

Delphi
Recirculation Actuator Replacement (Delphi)
To Remove:
CAUTION
1. Remove the instrument panel upper trim panel.

2. Remove the instrument panel lower trim panel and glove box assembly.
3. Remove the passenger side air bag.
4. Disconnect the connector from the recirculation actuator.
5. Remove the recirculation actuator mounting screws.
6. Remove the recirculation actuator from the HVAC assembly.
To Install:
1. Position the recirculation actuator on the HVAC assembly.

2. Install the recirculation actuator mounting screws.
3. Connect the electrical connector to the recirculation actuator.
4. Install the passenger side air bag.
5. Install the instrument panel lower trim panel and the glove box assembly.
6. Install the instrument panel upper trim panel.
Visteon
Recirculation Actuator Replacement (Visteon)
To Remove:
CAUTION
1. Remove the HVAC module assembly.

2. Remove the evaporator core cover from the HVAC module.
3. Remove the recirculation actuator from the HVAC module assembly.
To Install:
1. Position the recirculation actuator on the HVAC assembly.

2. Install the recirculation actuator mounting screws.
3. Install the evaporator core cover to the HVAC module.
4. Install the HVAC module assembly.
Ambient Air Temperature Sensor
Ambient air temperature sensor removal
To Remove:
1. Remove the right front park/turn signal housing.

2. Disconnect the ambient air temperature sensor electrical connector.
3. Remove the ambient air temperature sensor.
To Install:
1. Install the ambient air temperature sensor.

2. Connect the electrical connector to the ambient air temperature sensor.
3. Install the right front park/turn signal housing.
Blower Motor
Delphi
Blower Motor Replacement (Delphi)
To Remove:
1. Remove the instrument panel sound insulator panel (if equipped).

2. Disconnect the electrical connector from the blower motor.
3. Remove the blower motor insulating cover screws.
4. Remove the blower motor insulating cover.
5. Pull the retaining tab down and rotate blower motor counterclockwise to remove.
To Install:
1. Position the blower motor and turn assembly clockwise until tab locks in place.
2. Install the blower motor insulating cover.
3. Connect the electrical connector to the blower motor.
4. Install the instrument panel sound insulator panel (if equipped).
Visteon
Blower Motor Replacement (Visteon)
To Remove:
1. Remove the instrument panel sound insulator panel (if equipped).

2. Disconnect the electrical connector from the blower motor.
3. Remove the blower motor screws.
4. Remove the blower motor from the HVAC module.
To Install:
1. Position the blower motor and install mounting screws.

3. Install the instrument panel sound insulator panel (if equipped).
Blower Motor Control Processor
Blower motor control processor removal
To Remove:
1. Remove the sound insulator from the instrument panel.

2. Disconnect the connector from the blower motor.
3. Disconnect the connector from the blower motor control processor.
4. Remove the blower motor control processor.
To Install:
1. Install the blower motor control processor and screws.

2. Connect the electrical connector to the blower motor control processor.
4. Install the sound insulator under the instrument panel.
Calibration
To Calibrate:
1. Turn the ignition switch to the OFF position.

2. Remove the fuse from the HVAC control module positive circuit.
NOTE: The fuse must be removed for more than 60 seconds to clear the control module
memory.
3. Wait at least 60 seconds.

4. Install the fuse.
Compressor
4.3L Engine
To Remove:
1. Recover the refrigerant.

2. Release the drive belt tensioner.
3. Remove the drive belt from the A/C compressor.
4. Remove the hose assembly bolt from the compressor.
5. Remove the compressor hose assembly from the compressor.
6. Disconnect the electrical connector from the compressor.
7. Discard the sealing washers and cap hoses.
8. Remove the compressor mounting bolts.
9. Remove the compressor from bracket.
10. Drain and measure the amount of oil contained in the old compressor.
To Install:
NOTE: New compressor assemblies may be pre-filled with 8 oz. of refrigerant oil. If replacing the
compressor, refer to Compressor Oil Balancing .
1. Install the compressor.

Tighten the mounting bolts to 37 lb ft (50 Nm).
2. Install new sealing washers on the compressor ports.

3. Install the A/C compressor hose assembly on the compressor.
Tighten the bolts to 25 lb ft (34 Nm).
4. Connect the compressor clutch electrical connector.

5. Install the drive belt on the A/C compressor.
6. Evacuate and charge the refrigerant system.
7. Leak test the fittings of the reinstalled component using a commercially available leak
tester.
4.8L, 5.3L and 6.0L Engines
To Remove:
4. Remove the right front tire and wheel assembly.
5. Remove right front wheel house panel.
6. Remove the discharge hose assembly bolt from the compressor.
7. Remove the compressor discharge hose from the compressor.
8. Remove the suction hose assembly bolt from the compressor.
9. Remove the compressor suction hose from the compressor.
12. Disconnect the electrical connector.
NOTE: The lower right bolt is captured in the compressor due to lack of clearance.

To Install:


3. Install the A/C compressor hoses on the compressor.

5. Install the wheel house panel.
6. Install the tire and wheel assembly.
tester.
6.6L Engine
Denso
To Remove:
4. Remove the discharge hose assembly bolt from the compressor.
5. Remove the compressor discharge hose from the compressor.
6. Remove the suction hose assembly bolt from the compressor.
7. Remove the compressor suction hose from the compressor.
To Install:


3. Install the A/C compressor hoses on the compressor.

tester.
Delphi/Harrison
To Remove:

4. Remove the compressor hose assembly bolt from the compressor.
To Install:
compressor, refer to Compressor Oil Balancing.


Tighten the bolt to 25 lb ft (34 Nm).

tester.
8.1L Engine
To Remove:

4. Remove the right front tire and wheel assembly.
5. Remove right front wheel house panel.
6. Remove the compressor hose assembly bolt from the compressor.
NOTE: The lower right bolt is captured in the compressor due to lack of clearance.

To Install:


Tighten the bolt to 25 lb ft (34 Nm).

5. Install the wheel house panel.
6. Install the tire and wheel assembly.
tester.
Compressor Clutch
Delphi/Harrison
To Remove:
1. Clamp a J 34992 or appropriate holding fixture in a vise.

2. Use thumb screws in order to attach the compressor to the holding fixture.
NOTE: Do not drive or pound on the clutch hub or shaft. Internal damage to the
compressor may result.
Compressor clutch plate and hub assembly
3. Ensure that the center screw forces the tip to thrust against the end of the shaft.
4. Thread a J 33013-B remover/installer tool or equivalent onto the hub.
5. While holding the body of the remover with a wrench, turn the center screw into the
remover body in order to remove the clutch plate and hub assembly (1).
6. Remove the shaft key.
7. Retain the shaft key for reassembly.
8. Remove the rotor and bearing assembly retaining ring.
9. Install the J 33023-A to the front head.
Use the pulley puller J33020 to remove the rotor and bearing
assembly
10. Install the J 33020 into the inner circle of slots in the rotor.
11. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the
segments between the slots in the rotor.
12. Hold the J 33020 in place. Tighten the puller screw against the guide to remove the puller
rotor and bearing assembly.
13. Mark the location of the clutch coil terminal on the compressor front head.
14. Install the J 33023-A on the front head of the compressor.
15. Install the J 8433-1 and J 8433-3 with J 33025 on the compressor.
16. Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil.
A/C compressor clutch coil removal
To Install:
1. Place the clutch coil assembly on the compressor with the terminals positioned at the
marked location.
2. Place the J 33024 over the internal opening of the clutch coil housing.
3. Align the J 33024 with the compressor front head.
4. Center the J 8433-1 on the countersunk center hole of the J 33024.
5. Install the through bolts and washers of the J 34992 through the slots in the J 8433-1.
6. Thread the through bolts into the J 33025 in order to achieve full fixture thickness.
NOTE: Make sure that the clutch coil and the J 33024 stay in-line during the installation.
7. Turn the J 8433-3 of the J 8433-1 in order to force the clutch coil onto the head.
8. With the compressor still mounted to the J 34992 and the coil seated on the front head,
stake the front head using a drift punch with a diameter of 0.125 in (3.175 mm).
9. Stake the front head at 3 places 120 degrees apart in order to ensure that the clutch coil
remains in position. Ensure that the stake size is only one half of the area of the punch tip
and only 0.010-0.015 in (0.28-0.35 mm) in depth.
10. With the compressor mounted to the holding fixture, position the rotor and bearing
assembly on the front head.
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A.
13. Assemble the 2 through bolts and the washers of the holding fixture through the slots of
the J 8433-1.
14. Thread the bolts into the holding fixture. Make sure that the thread of the through bolts
engages the full thickness of the J 34992.
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing
assembly onto the front of the compressor.
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, perform the
following:
17. Loosen the J 8433-3
18. Realign the J 33017 and the J 33023-A to ensure that the installer clears the front head.
19. Install the rotor and bearing assembly retainer ring.
20. Install the shaft key into the hub key groove.
21. Allow the key to project approximately 3.2 mm (0.125 in) out of the keyway. The shaft key
curves slightly in order to provide interference fit in the hub key groove.
22. Clean the clutch plate and clutch rotor.
23. Align the shaft key with the shaft keyway.
24. Place the clutch plate and the hub assembly (1) onto the compressor shaft.
25. Remove the forcing tip on the J 33013 remover or equivalent.
26. Reverse the body direction on the center screw.
27. Install the J 33013 remover/installer tool or equivalent with the bearing.
28. Back off the body of the J 33013 remover/installer tool or equivalent as necessary in order
to permit the center screw to be threaded onto the end of the compressor shaft.
29. Hold the center screw with a wrench.
30. Tighten the hex portion of the J 33013 remover/installer tool or equivalent in order to
press the hub onto the shaft.
31. Tighten the body several turns.
32. Remove the installer. Ensure that the shaft key remains in place in the keyway.
33. Install the clutch plate and hub assembly to the final position. Ensure that the air gap
between frictional surfaces of the clutch plate and clutch rotor measures within 0.50-0.76
mm (0.020-0.030 in).
34. Remove the J 33013 remover/installer tool or equivalent.
35. Verify proper positioning of the shaft key. Ensure that the shaft key is even with or slightly
above the clutch hub.
36. Spin the pulley rotor by hand in order to verify that the rotor does not rub against the
clutch drive plate.
Denso
To Remove:
1. Remove the clutch plate retaining bolt.
2. Remove the clutch plate assembly.
3. Remove the clutch hub/bearing snap ring.
4. Remove the clutch hub/bearing assembly.
5. Remove the clutch coil connector bracket screw.
6. Remove the clutch coli snap ring.
7. Remove the clutch coil assembly.
To Install:
1. Install the clutch coil to the compressor.

2. Install the clutch coil snap ring.
3. Install the clutch hub/bearing assembly.
4. Install the clutch hub/bearing snap ring.
5. Oil the thinnest air gap shim and install inside the clutch plate.
6. Install the clutch plate assembly.
CAUTION
Make sure that the drive plate does not drag against the pulley when the pulley is rotated.
7. Ensure that the air gap between the pulley and the drive plate measures within 0.35-0.65
mm (0.014-0.026 in).
8. Install the clutch plate retaining bolt
Torque bolt to 13 ft lb (18 Nm).
Condenser
1999
To Remove:

2. Remove the grille.
3. Disconnect the refrigerant hose from the condenser.
4. Disconnect the evaporator tube from the condenser.
5. Remove the power steering cooler from the radiator support brackets.
6. Remove the upper fan shroud.
7. Remove the hood latch support to upper radiator support bolts.
8. Remove the condenser mounting bolts.
9. Tilt the top of the hood latch bracket forward and slide condenser out of vehicle.
10. Cap the open refrigerant lines to prevent moisture and dirt from entering.
To Install:
1. Install the condenser to the vehicle.

2. Install the condenser mounting bolts.
Tighten the bolts to 80 in lb (9 Nm).
3. Install the power steering cooler to the radiator support brackets.

4. Install the hood latch support to upper support bolts.
5. Install the upper fan shroud.

6. Connect the evaporator tube to the condenser using new sealing washers.
7. Install the refrigerant hose to the condenser.
8. Install grille.
10. Leak test the fittings.
2000-2007
To Remove:
2. Remove the grille.
3. Remove the tie bar to radiator brace bolts that are accessible from the rear of the upper
radiator support.
4. Remove the hood latch support bracket lower bolts.
5. Disconnect the compressor discharge hose from the condenser.
6. Disconnect the evaporator tube from the condenser.
7. Remove the insulator retainer bolts and upper insulator retainers.
8. Remove the condenser from the vehicle.
9. Cap the open refrigerant lines to prevent moisture and dirt from entering.
To Install:
1. If replacing the condenser, add new refrigerant oil to the condenser. Add 1 oz. or the
amount drained from the old condenser.
2. Install the condenser to the vehicle.
3. Install the upper insulator retainers and bolts.
4. Connect the evaporator tube to the condenser using new sealing washers.
5. Install the evaporator tube nut to the condenser.
6. Connect the A/C compressor discharge hose to the condenser using new sealing
washers.
Tighten the nut to 12 lb ft (16 Nm).
7. Install hood latch lower support bracket bolts.

8. Install grille.
10. Leak test the fittings.
Evaporator
Delphi
Evaporator core removal (Delphi)
To Remove:
1. Remove the HVAC housing assembly.

2. Remove heat stakes (if equipped) from the HVAC housing with a screwdriver and
hammer.
3. Remove the screws (if equipped) from the HVAC module assembly.
4. Remove the evaporator cowl gasket from the evaporator.
5. Separate the upper and lower HVAC module assemblies.
6. Remove the evaporator core.
To Install:
1. If replacing the evaporator, add refrigerant oil to the evaporator.
NOTE: Add 3 oz. of refrigerant oil or the amount drained from the evaporator if it is
greater then 3 oz.
2. Install the evaporator core into the HVAC module assembly.

3. Attach the upper and lower HVAC assembly cases.
4. Install the evaporator cowl gasket to the evaporator.
5. Install the screws to the HVAC module assembly.
6. Install the HVAC assembly.
Visteon
Evaporator core removal (Visteon)
To Remove:
1. Remove the HVAC housing assembly.

2. Disconnect the recirculation actuator electrical connector.
3. Remove the screws from the evaporator cover and remove cover.
4. Remove the evaporator cowl gasket from the evaporator.
5. Remove the evaporator core.
To Install:
1. If replacing the evaporator, add refrigerant oil to the evaporator.
NOTE: Add 3 oz. of refrigerant oil or the amount drained from the evaporator if it is
greater then 3 oz.
2. Install the evaporator core into the HVAC module assembly.
3. Install the evaporator cowl gasket to the evaporator.
4. Install the evaporator cover to the HVAC module assembly.
5. Connect the recirculation actuator electrical connector.
6. Install the HVAC assembly.
Expansion (Orifice) Tube
To Remove:

2. Loosen the evaporator tube fitting nut.
3. Remove the orifice tube from the evaporator tube.
NOTE: The open refrigerant lines should be capped to prevent contamination of the
refrigerant system.
4. Cap off the open refrigerant lines.
Expansion (Orifice) Tube Removal
To Install:
1. Uncap the evaporator tube.

2. Lubricate the new O-ring using new 525 viscosity refrigerant oil and install the seal.
3. Insert the long screen end of the new orifice into the evaporator tube.
4. Connect the evaporator tube at the fitting.
Tighten the fitting to 18 ft lb (25 Nm).

6. Leak test the fittings with an electronic leak detector.
General Troubleshooting
Leak Testing
WARNING
Never leak test the A/C system with compressed air. A mixture of air and R-134A can become
combustible at high pressure. This mixture may result in fire or explosion causing injury and/or
property damage.
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to
assist in refrigerant system leak diagnosis using a Rotunda approved ultraviolet black-light. It is
not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system.
A/C system service requires the use of a manifold gauge set with vacuum pump or a refrigerant
recovery/recycling station. The best way to determine if the system has a leak is to evacuate the
refrigerant from the vehicle into a refrigerant recovery/recycling station. Once the refrigerant has
been recovered the refrigerant recovery/recycling station will pull a vacuum on the system.
Isolate the A/C system by closing the valves when the vacuum reaches -26 in. Hg (-88 kPa). A
leak free system should be able to hold vacuum for at least 15 minutes or more. If you can not
reach the vacuum specified, air is leaking into the system, and the source must be located and
repaired.
Leaks will most likely occur at hose fittings and connections. A leak can also occur at the
compressor shaft seal at the front of the compressor. The A/C system contains refrigerant oil
mixed with refrigerant. Look for oily deposits at hose and pipe connections that indicate a leak.
Commercial electronic refrigerant leak detectors are available from tool suppliers. Follow the
manufactures instructions when using these tools.
Manifold gauge set components
Refrigerant recovery/recycling station
Heater System
Heater Core
Heater core removal
To Remove:
1. Remove the HVAC assembly.

2. Remove the heater core cover screws.
3. Remove the heater core cover from the HVAC assembly.
4. Remove the heater core gasket from the core.
5. Remove the heater core from the HVAC module assembly.
To Install:
1. Install the heater core to the HVAC module assembly.

2. Install the heater core cowl gasket to the HVAC module assembly.
3. Install the heater core cover and screws to the HVAC module assembly.
4. Install the HVAC module assembly to the vehicle.
HVAC Module
HVAC module removal
To Remove:
1. Remove the auxiliary battery (if equipped).

2. Recover the refrigerant from the refrigerant system (if equipped with A/C).
3. Drain the cooling system.
4. Disconnect the hoses from the heater core.
5. Remove the accumulator (if equipped with A/C).
6. Remove the instrument panel carrier.
7. Remove the evaporator drain hose (if equipped with A/C).
8. Disconnect the HVAC electrical connections and ground connections.
9. Remove the fasteners which secure the HVAC assembly to the firewall from the engine
compartment.
10. Remove the HVAC assembly.
To Install:
1. Install the HVAC assembly into the vehicle.

Tighten the nuts to 80 lb in (9 Nm) and the screws to 35 lb in (4 Nm).
2. Connect the electrical connections and ground connections.

3. Install the evaporator drain hose (If equipped with A/C).
4. Install the instrument panel carrier.
5. Install the accumulator (if equipped with A/C).
6. Connect the hoses to the heater core.
7. Refill the cooling system.
8. Evacuate and recharge the A/C system (if equipped with A/C).
9. Install the auxiliary battery (if equipped).
10. Inspect the system for leaks.
Instrument Panel Carrier
To Remove:
1. Disable the air bag system.

2. Set the parking brake.
3. Move the shift lever all the way down.
4. Disconnect the negative battery cable.
5. Tilt the steering wheel to the full down position.
6. Remove the I/P cluster trim plate bezel by gently pulling rearward at the corners.
7. Remove the end panels.
8. Remove the right side air outlets.
9. Remove the assist handle by releasing the tabs through the air outlet duct holes.
10. Remove the windshield pillar garnish moldings.
11. Remove the bolts securing the pad to the I/P assembly.
12. Lift the trim pad up to disconnect the ambient light sensor connector.
13. Remove the trim pad.
14. Remove the center console (if equipped).
15. Remove the I/P extension (if equipped).
16. Remove the driver side knee bolster.
17. Open the glove compartment door and remove bolts securing the lower trim panel to the I/
P assembly.
18. Disconnect electrical connectors and remove the lower trim panel.
19. Remove the passenger side air bag module.
20. Remove the radio.
21. Remove the HVAC control.
22. Remove the accessory switch housing.
23. Remove the left air louver housing.
24. Remove the steering column.
25. Remove the Vehicle Interface Unit (if equipped).
26. Remove the Vehicle Communication Unit (if equipped).
27. Remove the Remote Control Door Lock Receiver Unit (if equipped).
28. Disconnect the data link connector.
29. Remove the park brake release lever.
30. Remove the instrument cluster.
31. Remove both window air ducts from I/P assembly.
32. Remove the electrical harness from the I/P.
I/P assembly removal
33. Remove the I/P assembly retaining bolts and nuts.

34. Remove harness hold-down retainers from the I/P assembly.
35. Remove the instrument panel assembly from the vehicle.
I/P upper bracket removal
36. Remove the I/P upper brackets.

37. Disconnect all electrical connectors from the wiring harness junction block.
38. Remove the transfer case control module from the bracket (if equipped).
39. Remove the antenna cable from the cross car duct.
40. Remove the cross car duct.
41. Remove the amplifier (if equipped).
42. Separate the I/P harness from the I/P carrier.
NOTE: Do not remove the I/P harness from the vehicle.
43. Remove the right side of the carrier to gain access to the HVAC module.
44. Remove the I/P center support bracket bezel.
NOTE: Remove the I/P carrier assembly as one complete assembly.
45. Remove the I/P center support bracket bolt, side bolts and top bolts.
46. Remove the I/P carrier from the vehicle.
To Install:
1. Position the I/P carrier in the vehicle.

2. Install the I/P carrier top and side bolts.
Tighten the bolts to 37 ft lb (50 Nm).
3. Install the I/P center support bracket bolt.

Tighten the bolt to 18 ft lb (25 Nm).
4. Install the I/P center support bracket bezel.

5. Install the right side of the carrier to the vehicle (if the HVAC module was removed).
6. Tighten the bolts to 37 ft lb (50 Nm).
7. Attach the I/P harness to the carrier.
8. Install the amplifier (if equipped).
9. Install the cross car duct.
10. Install the antenna cable to the cross car duct.
11. Install the transfer case module (if equipped) to the bracket.
12. Connect the electrical connections to the wiring harness junction block.
13. Install the I/P upper brackets.
14. Position the I/P assembly to the vehicle.

15. Install the I/P assembly fasteners.
Tighten the nuts and bolts to 80 in lb (9 Nm).
16. Install the I/P upper brackets.

17. Install the harness hold-down retainers to the I/P assembly.
18. Install the harness to the I/P.
19. Install both front window air ducts to the I/P assembly.
20. Install the I/P cluster assembly.
21. Install the park brake release lever.
22. Install the data link connector.
23. Install the Remote Control Door Lock Receiver Module (if equipped).
24. Install the Vehicle Communication Unit (if equipped).
25. Install the Vehicle Interface Unit (if equipped).
26. Install the steering column.
27. Install the left air louver housing.
28. Install the accessory switch housing.
29. Install the HVAC control.
30. Install the radio.
31. Install the passenger side airbag module.
32. Connect all electrical connectors to the lower trim panel.
33. Install the lower trim panel to the I/P assembly.
34. Install the center console (if equipped).

35. Install the I/P cluster trim bezel.
36. Install the driver side knee bolster.
37. Install the I/P extension (if equipped).
38. Connect the ambient light sensor electrical connector to the underside of the instrument
panel upper trim pad.
39. Install the trim pad to the I/P assembly.
40. Install the trim pad retaining screws.
Tighten the screws to 18 in lb (2 Nm).
41. Install the windshield pillar garnish moldings.

42. Install the assist handle.
43. Install the right side air outlets.
44. Install the end panels.
45. Enable the air bag system.
46. Connect the negative battery cable.
Odor Correction
The air conditioning system may emit odors under certain conditions. This is usually due to the
growth of mold on the evaporator and in the evaporator case. Water vapor from the air
condenses on the fins of the evaporator as the A/C system is operating and collects in the
evaporator housing. A drain hole at the bottom of the evaporator case is used to allow the water
to drip out of the case and onto the ground. If the hole becomes clogged, it can be cleared with
compressed air.
In order to correct the odor problem, the mold must be neutralized by using chemicals.
Chemicals and cleaning systems have been specifically designed for disinfecting evaporator
cores and housings. Check with your auto parts store or car dealership parts department on the
availability of an evaporator core cleaning system.
The use of the cleaning system will vary slightly depending on how the A/C system is designed.
Cleaning the evaporator core and housing generally involves spraying a cleaning solution into
the housing and allowing the solution to soak for a period of time. The solution is then rinsed out
with water. On some vehicles, the blower resistor can be removed from the housing under the
hood and the solution can be sprayed in the resistor hole. On other vehicles, a hole must be
drilled on the housing and patched with silicone or putty when the cleaning operation is
completed. Evaporator cleaning systems vary. Always follow the instructions that come with the
kit.
Refrigerant Oil Level Check
Compressor Oil Balancing
Draining Procedure
1. Drain the compressor crankcase into a clean graduated container. Rotate the compressor
shaft to assist in draining the compressor.
2. Measure and record the amount of oil drained from the removed compressor. This
measurement will be used during installation of the replacement compressor.
3. Properly discard the used refrigerant oil.
Balancing Procedure
NOTE: The refrigerant oil in the A/C system must be balanced during compressor replacement.
Follow the balancing instructions provided with the compressor. The replacement compressor
may be shipped with 8.0 oz of refrigerant oil.
1. Refer to the amount of oil drained from the removed compressor.

2. Drain and measure the oil in the replacement compressor.
3. Fill the replacement compressor with the same amount of oil as was drained from the
removed compressor.
Refrigerant Recovery & Recharging
NOTE: It is not possible to determine the amount of refrigerant in an A/C system without
completely evacuating the system and recharging it. Always refer to the underhood heating and
air conditioning specification tag for the proper amount of refrigerant.
CAUTION
Do not add more refrigerant to the system than specified by the manufacturer. Excessive system
pressure may cause compressor failure.
CAUTION
A small amount of refrigerant oil is removed from the system each time the refrigerant is
recovered into a refrigerant recovery/recycling station. This amount of oil must be returned to the
system when the system is recharged. Follow the manufacturers instructions that came with the
equipment being used.
A refrigerant recovery/recycling station is needed to recover refrigerant from an A/C system.

Connect the equipment to the vehicles A/C system according to the manufacturers instructions.
Sensors, Switches & Valves
A/C Refrigerant Pressure Sensor/Pressure Cycling Switch/High Pressure

Recirculation Switch
To Remove:
NOTE: It is not necessary to recover the refrigerant from the system before removing the
sensor. The sensor is mounted in a service fitting.
1. Raise and support vehicle.

2. Disconnect the refrigerant pressure sensor electrical connector.
3. Remove the refrigerant pressure sensor from the evaporator tube.
To Install:
1. Install the pressure sensor to the evaporator tube fitting.

Tighten the sensor to 53 in lb (6 Nm).
2. Connect the electrical connector to the refrigerant pressure sensor.

3. Check for leaks.
System Flushing
After a catastrophic compressor failure, it is extremely important to eliminate and/or contain the
debris from the compressor that may have circulated through the A/C system. The debris
generated from a catastrophic compressor failure will be discharged into the compressor suction
line, discharge line, condenser and liquid line and may cause the new compressor to fail
prematurely. In addition to flushing, a liquid line filter should be installed in the system to stop
any remaining debris from circulating through the system.
Most refrigerant recovery/recycling stations have the ability to flush the system with cleaned and
dry refrigerant. Keep in mind that the refrigerant oil in the system will also be removed and must
be replaced when refrigerant is added to the system. Follow the instructions that came with the
equipment to properly flush the A/C system.
Troubleshooting by Symptom
Poor Heater System Performance
1. Start the engine. Allow the engine to idle. Does the engine reach normal operating
temperature? If yes, go to the next step. If no, go to step 8.
2. Allow the engine to idle. Select the FLOOR mode. Select the minimum blower speed and
the warmest temperature setting. Feel the temperature of the inlet and outlet heater hoses
at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose? If
yes, go to step 6. If no, go to the next step.
3. Install a thermometer into the center instrument panel air outlet. Secure a thermometer to
the heater core outlet heater hose. Select the PANEL mode. Select the maximum blower
speed. Select the warmest temperature setting. Record the temperature at the center
instrument panel air outlet and at the heater core outlet heater hose. Are the two
temperature readings about equal? If yes, go to the next step. If no, go to step 5.
4. Inspect and repair the cowl, recirculation door, and the HVAC module case for cold air
leaks. If problems are found and repaired, go to step 9.
5. Inspect the temperature door operation. Perform any necessary repairs. When repairs are
made, go to step 9.
6. Turn OFF the engine. Back flush the heater core. Start the engine. Select the FLOOR
mode and the lowest blower speed. Select the warmest temperature setting. Feel the
temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater
hose feel warmer than the outlet heater hose? If yes, go to the next step. If no, go to step
9.
7. Replace the heater core. When the repair is complete, go to step 9.
8. Repair the low engine temperature concern. When the repair is complete, go to step 9.
9. Operate the system in order to verify the repair. If the system operates properly, the repair
is complete. If the heater still does not work properly, repeat the entire procedure.
Insufficient Defrosting
1. Start the engine, select the DEFROST mode, and select the maximum blower speed.
Does sufficient air flow from the defroster outlets? If yes, go to the next step. If there is
insufficient airflow, go to step 9.
2. Measure the engine operating temperature. Does the engine reach normal operating
temperature? If yes, go to the next step. If the engine does not reach normal operating
temperature, go to step 7.
3. Select the minimum blower speed. Select the warmest temperature setting. Feel the
temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater
hose feel warmer than the outlet heater hose? If yes, go to step 10. If the hose
temperature is not right, go to the next step.
4. Test the operation of the A/C compressor clutch. Does the A/C compressor clutch
engage? If yes, go to the next step. If the compressor clutch does not engage, go to step
6.
5. Repair or replace the A/C compressor clutch. When the repair is complete, go to step 13.
6. Perform the "A/C System Performance Test" found in this section. Is the A/C system
operating within the specifications? If yes, go to step 8. If no, go to step 11.
7. Repair the low engine temperature concern. When the repair is complete, go to step 13.
8. Inspect for correct operation of the recirculation door. If the door is operating correctly, go
to step 13. If the door is not operating properly, go to step 12.
9. Repair the air delivery concern. When the repair is complete, go to step 13.
10. Repair the heating concern. When the repair is complete, go to step 13.
11. Repair the A/C performance concern. When the repair is complete, go to step 13.
12. Repair the recirculation door concern. When the repair is complete, go to step 13.
13. Operate the system in order to verify the repair. If the system is operating properly, the
procedure is complete. If the system is still not providing proper defrosting, repeat the
entire test.
Noise from Blower Motor
1. Inspect the air inlet grille for debris. If the grille has debris, go to step 7. If the grille is
clear, go to the next step.
2. Sit inside the vehicle, close the vehicle doors and windows, turn ON the ignition, with the
engine OFF, and cycle the blower motor through all of the speeds in order to determine
where and when the noise occurs. If there was noise during the blower operation, go to
the next step. If there is no noise, go to step 10.
3. Inspect for excessive vibration at each blower motor speed by feeling the blower case. If
there is vibration, go to step 6. If no vibration is present, go to the next step.
4. Listen to the blower motor at each blower speed. Is the blower motor making a squeaking
or chirping noise? If yes, go to step 8. If no noise exists, go to step 10.
5. Remove the blower motor, and inspect the blower motor and impeller for deposits of
foreign material. If there is debris, go to step 7. If there is no debris, go to the next step.
6. Inspect the blower motor for cracked blades, loose impeller retainer, or improper impeller
alignment. If any of these conditions exist, go to step 8. If none of these exist, go to step
9.
7. Remove the foreign material. When complete, go to the next step.
8. Replace the blower motor. When the repair is complete, go to step 10.
9. Install the blower motor. When the repair is complete, go to step 10.
10. Operate the system in order to verify the repair. If the condition has been corrected, the
repair is complete. If noise still exists, repeat the entire procedure.
Noise from A/C System

NOTE: Noise from the A/C system may be heard as squealing, chirping or moaning noises, or
as a vibration noise.
1. Start the engine and ensure the A/C system is ON. If any noise is heard when the system
engages, go to the next step. If no noises are heard at this point, go to step 8.
2. With the engine OFF, inspect the drive belt for excessive wear. If the belt is excessively
worn, go to step 17. If the belt is not worn, go to the next step.
3. Inspect the drive belt tension. If the tension is correct, go to the next step. If the tension is
not correct, go to step 18.
4. Inspect the drive belt for excessive oil coverage. If the belt is covered with oil, go to step
16. If there is no oil present, go to the next step.
5. Start the engine, ensure the A/C system is ON, and visually inspect the compressor and
the clutch. If the compressor appears locked up, go to step 23. If the compressor and
clutch appear okay, go to the next step.
6. If the compressor clutch is slipping, go to step 22. If the clutch is not slipping, go to the
next step.
7. Using a stethoscope, listen to the A/C compressor for any abnormal noise. If noise
appears to be caused by the compressor, go the step 14. If the compressor is not the
cause of the noise, go to step 9.
8. Does a moaning noise exist when the A/C clutch is engaged? If yes, go to the next step. If
no, go the step 11.
9. Listen to the A/C compressor components and mounting for noise concerns using a
stethoscope. Are any of these components loose, damaged or excessively worn? If yes,
go to step 19. If no, go to the next step.
10. Idle the engine and engage the A/C compressor clutch. Using a stethoscope, move
around the entire refrigerant plumbing system. Listening for any abnormal noises caused
by a component of the A/C system touching another component. Are any of the A/C
components grounding out and causing a vibration noise? If yes, go to step 21. If no, go
to step 12.
11. Does a vibration or rattle noise exist when the A/C clutch is engaged? If yes, go to the
next step. If no, go to step 13.
12. Does the noise stop when the A/C clutch is disengaged? If yes, go to step 14. If no, go to
step 24.
13. Idle the engine in PARK with the A/C compressor clutch engaged. Using a stethoscope,
move around the entire A/C system testing for any abnormal noises caused by a
component. Do any of the A/C components cause an abnormal noise? If yes, go to step
20. If no, go to step 24.
14. Verify that the A/C system is properly charged. If it is properly charged, go to step 25. If
not properly charged, go to the next step.
15. Recharge the A/C system to specification. Is the abnormal compressor noise still present?
If yes, go to step 23. If no, go to step 25.
16. Repair the oil leak. When the repair is complete, go to step 25.
17. Replace the drive belt. When the repair is complete, go to step 25.
18. Replace the drive belt tensioner. When the repair is complete, go to step 25.
19. Repair or replace the A/C compressor mounting component. When the repair is complete,
go to step 25.
20. Repair or replace the component that is causing the moaning concern as needed. When
the repair is complete, go to step 25.
21. Correctly route or insulate the A/C component. When the repair is complete, go to step
25.
22. Replace the A/C compressor clutch. When the repair is complete, go to step 25.
23. Replace the A/C compressor. When the repair is complete, go to step 25.
24. The concern may be caused by an engine related component. If the concern is found and
repaired, go to step 25.
25. Operate the system in order to verify the repair. If the system is okay, the repair is
complete. If not, repeat the entire procedure.
Noise from the HVAC Module
1. Start the engine. Cycle through all blower speeds, A/C mode settings and temperature
control settings. Determine the type of noise, whether it is a scraping, popping, ticking,
clicking, chirping or groaning, or an air rush or whistle. Is a scrape or pop noise evident
when selecting modes or temperature settings? If yes, go to step 5. If no, go to the next
step.
2. Is a tick/click, chirping, groaning or scraping noise present, but decreases as blower motor
speed is decreased? If yes, go to step 5. If no, go to the next step.
3. Is an air rush/whistle noise evident in all modes but not all temperature settings? If yes, go
to step 5. If no, go to the next step.
4. Is an air rush/whistle noise evident only in defrost or floor mode? If yes, go to step 5. If no,
examine for other sounds, repeat step 1.
5. Remove the instrument panel trim pad. When complete, go to the next step.
6. Inspect the airflow doors for proper operation and the ducts for obstructions or foreign
materials. Were any of these conditions found? If yes, go to step 9. If no, go to the next
step.
7. Inspect the mode and temperature doors and seals for warping or cracking. Are the doors
in normal condition? If yes, go to step 9. If no, go to the next step.
8. Replace the appropriate door and/or seals. When the repair is complete, go to step 10.
9. Remove any obstructions or foreign material found. When the repair is complete, go to
step 10.
10. Install the instrument panel trim pad. When complete, go to the next step.
11. Operate the system to verify the repair. If system operates without noise, the repair is
complete. If noise still exists, repeat the entire procedure.

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HEATING & AIR CONDITIONING

Air Conditioning System

Removal & Installation

1. Recover the refrigerant from the A/C system.

8. Remove the accumulator retaining bracket.

Tighten the nut to 12 ft lb (16 Nm).

6. Connect the A/C low pressure switch electrical connector.

Removal & Installation

Air Temperature Actuator

Air Temperature Actuator Replacement

1. Remove the instrument panel hush panel.

1. Position the air temperature actuator on the HVAC assembly.

Right Side Air Temperature Actuator (2003-2007)

Right Air Temperature Actuator Replacement

1. Remove the instrument panel carrier.

1. Position the right air temperature actuator on the HVAC assembly.

Left Air Temperature Actuator Replacement

1. Remove the I/P insulator panel.

1. Position the left air temperature actuator on the HVAC assembly.

1. Remove the floor air outlet from the floor duct.

Align the A/C valve lever with the cam

2. Install the mode actuator mounting screws.

Air Inlet Actuator/Recirculation Actuator

Recirculation Actuator Replacement (Delphi)

1. Remove the instrument panel upper trim panel.

1. Position the recirculation actuator on the HVAC assembly.

Recirculation Actuator Replacement (Visteon)

1. Remove the HVAC module assembly.

1. Position the recirculation actuator on the HVAC assembly.

Removal & Installation

Ambient air temperature sensor removal

1. Remove the right front park/turn signal housing.

1. Install the ambient air temperature sensor.

Removal & Installation

Blower Motor Replacement (Delphi)

1. Remove the instrument panel sound insulator panel (if equipped).

Blower Motor Replacement (Visteon)

1. Remove the instrument panel sound insulator panel (if equipped).

1. Position the blower motor and install mounting screws.

Removal & Installation

Blower motor control processor removal

1. Remove the sound insulator from the instrument panel.

1. Install the blower motor control processor and screws.

1. Turn the ignition switch to the OFF position.

3. Wait at least 60 seconds.

Removal & Installation

1. Recover the refrigerant.

1. Install the compressor.

2. Install new sealing washers on the compressor ports.

4. Connect the compressor clutch electrical connector.

4.8L, 5.3L and 6.0L Engines

14. Remove the compressor from bracket.

1. Install the compressor.

2. Install new sealing washers on the compressor ports.

4. Connect the compressor clutch electrical connector.

1. Install the compressor.

2. Install new sealing washers on the compressor ports.

4. Connect the compressor clutch electrical connector.

1. Recover the refrigerant.

1. Install the compressor.

2. Install new sealing washers on the compressor ports.

4. Connect the compressor clutch electrical connector.

1. Recover the refrigerant.