HVAC Heating & Air Conditioning - Service Information - Ram Pickup

2014 RAM 3500 HD Laramie
2014 HVAC Heating & Air Conditioning - Service Information - Ram Pickup
2014 HVAC
Heating & Air Conditioning - Service Information - Ram Pickup
DESCRIPTION
DESCRIPTION
A Manual Temperature Control (MTC) single zone or an Automatic Temperature Control (ATC) dual zone
heating-air conditioning system is available on this model.
To maintain the performance level of the Heating, Ventilation and Air Conditioning (HVAC) system, the
engine cooling system must be properly maintained. The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser will reduce the performance of the A/C and engine
cooling systems.
The engine cooling system includes the radiator, thermostat, radiator hoses and the engine coolant pump. See
ENGINE COOLING SYSTEM - RAM PICKUP for more information before opening or attempting any
service to the engine cooling system.
Fig. 1: HVAC Housing Assembly

Courtesy of CHRYSLER GROUP, LLC
NOTE: Dual zone system shown in illustration. Single zone system similar.
All vehicles are equipped with a common HVAC housing (1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing mounted within the passenger compartment under the
instrument panel. The HVAC housing includes:
Blend-air door(s) and actuator(s) (2 and 10)
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19:49:20 Page 1
Heater core (3)

A/C evaporator (4)
Recirculation-air door and actuator (5)
Evaporator temperature sensor (6)
HVAC wire harness (7)
Blower motor (8)
Blower motor resistor or power module (9)
Mode-air doors and actuators (11)
Based upon the system and mode selected, conditioned air can exit the HVAC housing through one or a
combination of the three main housing outlets: defrost, panel or floor. The defrost and the panel outlets are
located on the top of the housing and, the floor outlet is located on the bottom of the housing. Once the
conditioned air exits the HVAC housing, it is further directed through molded plastic ducts to the various outlets
within the vehicle interior. These outlets and their locations are as follows:
Defroster Outlet - Four defroster outlets are located in the instrument panel top cover, near the base of
the windshield.
Side Window Demister Outlets - There are two side window demister outlets, one is located at each
outboard end of the instrument panel top cover, near the belt line at the A-pillars.
Panel Outlets - There are four panel outlets in the instrument panel, one located near each outboard end
of the instrument panel facing the rear of the vehicle and two located near the top of the instrument panel
center bezel.
Front Floor Outlets - There are two front floor outlets, one located above each side of the floor panel
center tunnel near the dash panel.
Rear Outlets - On Crew Cab models there are two outlets located at the rear of the center front seat.
OPERATION
OPERATION
Both the Manual Temperature Control (MTC) single zone heating-A/C system and the Automatic Temperature
Control (ATC) dual zone heating-A/C system are blend-air type systems. In a blend-air heating-A/C system, a
blend-air door controls the amount of conditioned air that is allowed to flow through, or around the heater core.
In the available dual zone system, two blend-air doors are used to provide completely independent side-to-side
temperature control of the discharge air. The temperature control(s) determines the discharge air temperature(s)
by operating the blend door actuator(s), which move the blend-air door(s). This design allows almost immediate
control of output air temperature(s).
Thursday, November 16, 2017 19:49:20 Page 2

Fig. 2: Blend Air System Schematic

NOTE: Typical blend-air type HVAC system shown in illustration.
The heating-A/C system pulls outside (ambient) air through the fresh air intake (4) located at the cowl panel at
the base of the windshield and into the air inlet housing above the Heating, Ventilation and Air Conditioning
(HVAC) housing and passes through the A/C evaporator (7). Air flow is then directed either through or around
the heater core (2). This is done by adjusting the position of the blend-air door(s) (3) with the temperature
control(s) located on the A/C-heater control in the instrument panel. Air flow is then directed out the floor outlet
(8), instrument panel outlet (10) or the defroster outlet (1) in various combinations by adjusting the position of
the mode-air doors (9 and 11) using the mode control located on the A/C-heater control. The temperature and
mode control uses electrical actuators to operate the air doors.
The velocity of the air flow out of the outlets can be adjusted with the blower speed control located on the A/C-
heater control.
The fresh air intake can be shut off by pressing the Recirculation button on the A/C-heater control. This will
operate the electrically actuated recirculation-air door (5), which closes off the fresh air intake. With the fresh
air intake closed, the conditioned air within the vehicle is pulled back into the HVAC housing through the
recirculation air intake (6) located within the passenger compartment.
The A/C compressor can be engaged by pressing the A/C (snowflake) button on the A/C-heater control. It will
automatically engage when the mode control is set in any Mix to Defrost position. This will remove heat and
humidity from the air before it is directed through or around the heater core. The mode control on the A/C-
heater control is used to direct the conditioned air to the selected system outlets.
The defroster outlet receives airflow from the HVAC housing through the molded plastic defroster duct, which
connects to the HVAC housing defroster outlet. The airflow from the defroster outlets is directed by fixed vanes
in the defroster outlet grilles and cannot be adjusted. The defroster outlet grilles are integral to the instrument

panel top cover.
The side window demister outlets receive airflow from the HVAC housing through the molded plastic defroster
duct and two molded plastic demister ducts. The airflow from the side window demister outlets is directed by
fixed vanes in the demister outlet grilles and cannot be adjusted. The side window demister outlet grilles are
integral to the instrument panel. The demisters direct air from the HVAC housing through the outlets located on
the top corners of the instrument panel. The demisters operate when the mode control knob is positioned in the
floor-defrost and defrost-only settings. Some air may be noticeable from the demister outlets when the mode
control is in the bi-level to floor positions.
The panel outlets receive airflow from the HVAC housing through a molded plastic main panel duct, center
panel duct and two end panel ducts. The two end panel ducts direct airflow to the left and right instrument panel
outlets, while the center panel duct directs airflow to the two center panel outlets. Each of these outlets can be
individually adjusted to direct the flow of air.
The floor outlets receive airflow from the HVAC housing through the floor distribution duct. The front floor
outlets are integral to the molded plastic floor distribution duct, which is secured to the bottom of the housing.
The floor outlets cannot be adjusted.
NOTE: It is important to keep the air intake opening clear of debris. Leaf particles and
other debris that is small enough to pass through the cowl opening screen can
accumulate within the HVAC housing. The closed, warm, damp and dark
environment created within the housing is ideal for the growth of certain molds,
mildews and other fungi. Any accumulation of decaying plant matter provides
an additional food source for fungal spores, which enter the housing with the
fresh intake-air. Excess debris, as well as objectionable odors created by
decaying plant matter and growing fungi can be discharged into the passenger
compartment during heater-A/C operation if the air intake opening is not kept
clear of debris.
The A/C system is designed for non-CFC, R-134a refrigerant and uses an A/C expansion valve to meter the
flow of refrigerant through the A/C evaporator. The A/C evaporator cools and dehumidifies the incoming air
prior to blending it with the heated air. An evaporator temperature sensor is used to supply evaporator
temperature input to the A/C-heater control to maintain minimum evaporator temperature and prevent
evaporator freezing. The Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on
engine application, cycles the A/C clutch off and on as necessary to protect the A/C system from evaporator
freezing and optimize A/C system performance.
DIAGNOSIS AND TESTING

A/C PERFORMANCE
The A/C system is designed to provide the passenger compartment with low temperature and low humidity air.
The A/C evaporator, located in the HVAC housing is cooled to temperatures near the freezing point. As warm
damp air passes over the fins of the A/C evaporator, the air transfers its heat to the refrigerant in the evaporator
coils and the moisture in the air condenses on the evaporator fins. During periods of high heat and humidity, an
A/C system will be more effective in the Recirculation mode (max-A/C). With the system in the Recirculation

mode, only air from the passenger compartment passes through the A/C evaporator. As the passenger
compartment air dehumidifies, the A/C system performance levels rise.
Humidity has an important bearing on the temperature of the air delivered to the interior of the vehicle. It is
important to understand the effect that humidity has on the performance of the A/C system. When humidity is
high, the A/C evaporator has to perform a double duty. It must lower the air temperature, and it must lower the
temperature of the moisture in the air that condenses on the evaporator fins. Condensing the moisture in the air
transfers heat energy into the evaporator fins and coils. This reduces the amount of heat the A/C evaporator can
absorb from the air. High humidity greatly reduces the ability of the A/C evaporator to lower the temperature of
the air.
However, evaporator capacity used to reduce the amount of moisture in the air is not wasted. Wringing some of
the moisture out of the air entering the vehicle adds to the comfort of the passengers. Although, an owner may
expect too much from their A/C system on humid days. A performance test is the best way to determine
whether the system is performing up to design standards. This test also provides valuable clues as to the
possible cause of trouble with the A/C system.
A/C PERFORMANCE TEST
WARNING: Review the warnings and cautions for this system before performing the
procedure. Failure to follow these instructions may result in serious injury
or death.
NOTE: When connecting the service equipment coupling to the line fitting, verify that
the valve of the coupling is fully closed. This will reduce the amount of effort
required to make the connection.
NOTE: The work area ambient temperature must be above 21° C (70° F) and the
evaporator temperature must be above 13° C (55° F) prior to conducting the A/C
Performance Test.
1. Conduct the A/C System Performance Test (Cooldown Test) found within the HVAC System Test. Refer
to STANDARD PROCEDURE . If no Diagnostic Trouble Codes (DTCs) are found in the A/C-heater
control, Body Control Module (BCM), Powertrain Control Module (PCM) or Engine Control Module
(ECM), depending on engine application, go to 2 . If any DTCs are found, repair as required, then
proceed to 3 .
2. Connect a tachometer and a manifold gauge set or an A/C recycling/charging station.
3. Operate the heating-A/C system under the following conditions.
Engine at 1, 000 RPM at operating temperature
Door and windows closed
Transmission in Park or Neutral with parking brake set (depending on transmission application)
A/C-heater controls set to recirculation mode (max A/C), full cool, panel mode, high blower and
with A/C compressor engaged. If the A/C compressor does not engage, see the A/C SYSTEM
DIAGNOSIS table.

4. Insert a thermometer in the driver side center panel air outlet and operate the A/C system until the
thermometer temperature stabilizes.
NOTE: This procedure requires the technician to know what the temperature and
relative humidity is at the time of the test. The temperature must be
combined with the relative humidity to calculate the apparent ambient
temperature ("feels like" temperature), when the temperatures are above
21° C (70° F). Use the current ambient temperature and the relative
humidity in your location. This information can be obtained from multiple
sources, such as the Internet or local news media.
5. With the A/C clutch engaged, compare the air temperature at the center panel outlet and the A/C
compressor discharge pressure (high side) to the A/C Performance Temperature and Pressure chart. The
A/C clutch may cycle, depending upon the ambient temperature and humidity. If the A/C clutch cycles,
use the readings obtained before the clutch disengaged (coldest temperature).
A/C PERFORMANCE TEMPERATURE AND PRESSURE

Ambient Air 21° C 27° C 32° C 38° C 43° C
Temperature (Apparent) (70° F) (80° F) (90° F) (100° F) (110° F)
Air Temperature at 7° C 7° C 13° C 13° C 18° C
Center Panel Outlet (45° F) (45° F) (55° F) (55° F) (64° F)
Compressor Inlet 138 to 207 172 to 241 207 to 276
241 to 310 kPa 276 to 345 kPa
Pressure at Service Port kPa kPa kPa
(35 to 45 psi) (40 to 50 psi)
(low Side) (20 to 30 psi) (25 to 35 psi) (30 to 40 psi)
1034 to 1724 1379 to 2068 1724 to 2413 1999 to 2689 2413 to 2965
Compressor Discharge
kPa kPa kPa kPa kPa
Pressure at Service Port
(150 to 250 (200 to 300 (250 to 350 (290 to 390 (350 to 430
(High Side)
psi) psi) psi) psi) psi)
6. See the A/C SYSTEM DIAGNOSIS table if the air outlet temperature fails to meet the specifications in
the A/C Performance Temperature and Pressure chart, or if the A/C compressor discharge pressure is
high.
A/C SYSTEM DIAGNOSIS

Condition Possible Causes Correction
1. See DIAGNOSIS AND TESTING -
Constant A/C compressor REFRIGERANT SYSTEM LEAKS. Test
1. Low refrigerant system
engagement and warm air the refrigerant system for leaks. Repair,
charge
from passenger vents evacuate and charge the refrigerant system as
required.
Equal A/C system pressures, REFRIGERANT SYSTEM LEAKS. Test
1. No refrigerant in the
but the A/C clutch does not the refrigerant system for leaks. Repair,
refrigerant system
engage evacuate and charge the refrigerant system as
required.

2. See appropriate Wiring Information.

Check the fuse in the junction block. Repair
2. Open fuse
the shorted circuit or component and replace
the fuse as required.
3. Inoperative A/C clutch 3. See COMPRESSOR, A/C. Test the A/C
coil clutch coil and replace as required.
4. Improperly installed or 4. See SENSOR, EVAPORATOR
inoperative Evaporator TEMPERATURE. Correctly install or test
Temperature Sensor and replace the sensor as required.
5. Improperly installed or 5. See TRANSDUCER, A/C PRESSURE.
inoperative A/C pressure Correctly install or test and replace the
transducer sensor as required.
6. See the appropriate Electrical Diagnostic
6. Inoperative A/C-heater
Procedures for testing of the A/C-heater
control, BCM, or
control, BCM or PCM/ECM. Test the
PCM/ECM
module and replace as required.
1. See OIL, REFRIGERANT. Recover the
Normal A/C system pressures,
refrigerant from the refrigerant system and
but A/C Performance Test air 1. Excessive refrigerant oil
inspect the refrigerant oil content. Restore
temperatures at center panel in system
the refrigerant oil to the proper level as
outlet are too high
required.
2. See ACTUATOR, BLEND DOOR.
2. Blend door inoperative or
Inspect the blend door for proper operation
sealing improperly
and sealing and correct as required.
3. See ACTUATOR, BLEND DOOR. See
3. Blend door actuator the appropriate Electrical Diagnostic
inoperative Procedures for blend door actuator diagnosis.
Repair or replace as required.
The low side A/C system
REFRIGERANT SYSTEM LEAKS. Test
pressure is normal or slightly 1. Low refrigerant system
the refrigerant system for leaks. Repair,
low, and the high side A/C charge
evacuate and charge the refrigerant system as
system pressure is too low
required.
2. Refrigerant flow through
2. See EVAPORATOR, A/C. Replace the
the A/C evaporator is
restricted evaporator as required.
restricted
3. Inoperative A/C 3. See COMPRESSOR, A/C. Replace the
compressor A/C compressor as required.
1. See CONDENSER, A/C. Check the A/C
The low side A/C system condenser for damaged fins, foreign objects
pressure is normal or slightly 1. A/C Condenser air flow obstructing air flow through the condenser
high, and the high side A/C restricted fins, and missing or improperly installed air
system pressure is too high seals. Clean, repair or replace components as
required.
2. Refrigerant flow through 2. See DRIER, A/C RECEIVER. Replace

the A/C receiver/drier is the restricted A/C receiver/drier as required.

restricted
3. See ENGINE COOLING SYSTEM -
3. Inoperative cooling fan RAM PICKUP . Test the cooling fan and
replace as required.
4. See REFRIGERANT SYSTEM
4. Refrigerant system CHARGE. Recover the refrigerant from the
overcharged refrigerant system. Charge the refrigerant
system to the proper level as required.
REFRIGERANT SYSTEM LEAKS. Test
5. Air in the refrigerant
the refrigerant system for leaks. Repair,
system
evacuate and charge the refrigerant system as
required.
6. See ENGINE COOLING SYSTEM -
6. Engine overheating RAM PICKUP . Test the cooling system
and repair as required.
The low side A/C system 1. See ENGINE COOLING SYSTEM -
pressure is too high, and the 1. Accessory drive belt RAM PICKUP . Inspect the accessory drive
high side A/C system pressure slipping belt condition and tension. Tighten or
is too low replace the accessory drive belt as required.
2. Inoperative A/C 2. See VALVE, A/C EXPANSION. Test
expansion valve and replace the valve as required.
3. Inoperative A/C 3. See COMPRESSOR, A/C. Replace the
compressor A/C compressor as required.
1. See LINE, A/C LIQUID, LINE, A/C
The low side A/C system SUCTION and LINE, A/C DISCHARGE.
1. Restricted refrigerant
pressure is too low, and the Inspect the refrigerant lines for kinks, tight
flow through the refrigerant
high side A/C system pressure bends or improper routing. Correct the
lines
is too high routing or replace the refrigerant line as
required.
2. Inoperative A/C 2. See VALVE, A/C EXPANSION. Test
expansion valve and replace the valve as required.
3. Restricted refrigerant
3. See CONDENSER, A/C. Replace the
flow through the A/C
restricted A/C condenser as required.
condenser
HEATER PERFORMANCE
Before performing the following tests, see ENGINE COOLING SYSTEM - RAM PICKUP for the
procedures to check the engine coolant level and flow, engine coolant reserve/recovery system operation,
accessory drive belt condition and tension, radiator air flow and the fan drive operation. Using a scan tool,
check for any Diagnostic Trouble Codes (DTCs) in the A/C-heater Module, Body Control Module (BCM),
Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on engine application. Repair
as necessary. Refer to DTC INDEX - RAM PICKUP .

MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system through two heater hoses. With the engine idling at normal
operating temperature, set the temperature control to maximum heat position, the mode control to the floor
position, and the blower motor control to the highest speed position. Using a test thermometer, check the
temperature of the air being discharged from the floor outlets. Compare the test thermometer reading to the
Heater Temperature Reference chart.
HEATER TEMPERATURE REFERENCE

16° C 21° C 26° C 32° C
Ambient Air Temperature
(60° F) (70° F) (80° F) (90° F)
Minimum Air Temperature at 62° C 64° C 65° C 67° C
Floor Outlet (144° F) (147° F) (150° F) (153° F)
See ENGINE COOLING SYSTEM - RAM PICKUP if the heater outlet air temperature is below the
minimum specification. Both of the heater hoses should be hot to the touch. The coolant return heater hose
should be slightly cooler than the coolant supply heater hose. If the return hose is much cooler than the supply
hose, locate and repair the engine coolant flow obstruction in the cooling system.
OBSTRUCTED COOLANT FLOW
Possible locations or causes of obstructed coolant flow are as follows:
Inoperative water pump.

Inoperative thermostat.
Pinched or kinked heater hoses.
Improper heater hose routing.
Plugged heater hoses or supply and return ports at the cooling system connections.
Plugged heater core.
If proper coolant flow through the cooling system is verified, and heater outlet air temperature is low, a
mechanical problem may exist.
MECHANICAL PROBLEMS
Possible locations or causes of insufficient heat due to mechanical problems are as follows:
Obstructed cowl air intake.

Obstructed heater system outlets.
Blend-air door(s) or actuator(s) not functioning properly.
Faulty blower motor system
Inoperative A/C-heater control
TEMPERATURE CONTROL

If the heater outlet air temperature cannot be adjusted with the temperature control on the A/C-heater control,
the following could require service:
Inoperative A/C-heater control.

Inoperative blend door actuator(s).
Inoperative, obstructed or improperly installed blend-air door.
Inoperative related wiring harness or connectors.
Inoperative A/C-heater module.
Improper engine coolant temperature.
STANDARD PROCEDURE
STANDARD PROCEDURE - A/C EVAPORATOR CLEANING
Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and
humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system
operation, condensation forms in and around the A/C cooling coil. When airborne pollutants mix with this
condensation, bacteria and fungi growth begins and odor may result.
If the vehicle operator experiences a musty odor when operating the A/C system, perform the following
procedure:
WARNING: Always use eye protection, rubber gloves and protective clothing when
performing the following procedure. Avoid continuous breathing of
vapors from evaporator coil cleaning and sealing fluids. Avoid contact
with skin and eyes. Failure to follow these instruction may result in
possible serious or fatal injury.
1. Remove the cowl panel cover refer to COVER, COWL PANEL for more information.
2. Clean any dirt and debris that may be present at the HVAC fresh air inlet screen and at the top of the cowl
panel.
3. Install the cowl panel cover.
4. Raise and support the vehicle.
5. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may be
blocking the drain and repair as necessary.
6. Once drain operation has been verified;
when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an
appropriate pair of heater hose pliers.
when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or
plug and temporarily cap or plug the drain tube.
7. Lower the vehicle.
8. Place a protective cover over the front passenger side floor and seat area.

9. Remove the blower motor. Refer to MOTOR, BLOWER, REMOVAL.

10. Remove the blower motor resistor or power module, depending on application. Refer to RESISTOR,
BLOWER MOTOR, REMOVAL or MODULE, POWER, BLOWER MOTOR, REMOVAL.
11. Clean any dirt and debris that may be present inside the HVAC blower motor housing and all readily
accessible areas inside the HVAC housing. If necessary, use a vacuum with a small flexible hose, and
take caution not to damage the evaporator core fins.
12. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C
evaporator with three bottles of Mopar® Cooling Coil Cleaner through the blower motor and power
module or resistor openings. Be sure to use all of the coil cleaner in each container.
13. Allow the vehicle to sit for 30 minutes.
WARNING: Excess cooling coil cleaner will drain from the evaporator housing
when the clamp, cap or plug is removed from the evaporator drain
hose or tube. Always use eye protection, rubber gloves and
protective clothing. Avoid continuous breathing of vapors from
evaporator coil cleaning fluid. Avoid contact with skin and eyes.
Failure to follow these instruction may result in possible serious or
fatal injury.
15. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow
excess coil cleaner to drain from the HVAC housing.
17. Refill the three empty coil cleaner bottles with clean tap water.
18. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely rinse the entire surface of A/C
evaporator with the three bottles of clean tap water through the blower motor and power module or
resistor openings. Be sure to use all of the water in each container.
19. Install the blower motor. Refer to MOTOR, BLOWER, INSTALLATION.
20. Install the blower motor resistor or power module, depending on application. Refer to RESISTOR,
BLOWER MOTOR, INSTALLATION or MODULE, POWER, BLOWER MOTOR,
INSTALLATION.
21. Disconnect the wire harness connector from the A/C compressor to disable compressor operation. Refer
to COMPRESSOR, A/C, REMOVAL.
22. Start the engine
23. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
24. Set the A/C-heater controls to the following:
air distribution to Panel and Recirculation mode
temperature to full heat
25. Allow the vehicle to run for 20 minutes.
26. Turn the engine off.

28. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may have
blocked the drain during evaporator coil cleaning and repair as necessary.
29. Once drain operation has been verified;
when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an
appropriate pair of heater hose pliers.
when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or
plug and temporarily cap or plug the drain tube.
31. Remove the blower motor. Refer to MOTOR, BLOWER, REMOVAL.
32. Remove the blower motor resistor or power module, depending on application. Refer to RESISTOR,
BLOWER MOTOR, REMOVAL or MODULE, POWER, BLOWER MOTOR, REMOVAL.
33. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C
evaporator with one bottle of Mopar® Cooling Coil Coating through the blower motor and power module
or resistor openings. Be sure to use all of the coil coating in the container.
NOTE: Be sure to thoroughly clean out the spray delivery tool with warm water
once coil coating is complete to prevent damage to the tool.
34. Refill the empty bottles with clean warm tap water and completely rinse out the PSE Flex Spray Delivery
Tool 534-62637, or equivalent.
35. Allow the vehicle to sit for 30 minutes.
36. Install the blower motor. Refer to MOTOR, BLOWER, INSTALLATION.
37. Install the blower motor resistor or power module, depending on application. Refer to RESISTOR,
BLOWER MOTOR, INSTALLATION or MODULE, POWER, BLOWER MOTOR,
INSTALLATION.
WARNING: Excess cooling coil coating will drain from the evaporator housing
when the clamp, cap or plug is removed from the evaporator drain
hose or tube. Always use eye protection, rubber gloves and
protective clothing. Avoid continuous breathing of vapors from
evaporator coil sealing fluid. Avoid contact with skin and eyes.
Failure to follow these instruction may result in possible serious or
fatal injury.
39. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow
excess coil coating to drain from the HVAC housing.
41. Start the engine
42. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
43. Set the A/C-heater controls to the following:
air distribution to Panel and Recirculation mode

temperature to full heat

44. Allow the vehicle to run for 20 minutes.
45. Turn vehicle off.
46. Remove protective cover from front passenger side floor and seat area.
47. Connect the wire harness connector to the A/C compressor. Refer to COMPRESSOR, A/C,
INSTALLATION.
48. Verify proper A/C-heater system operation.
SPECIFICATIONS
A/C SYSTEM
Item Description Notes

A/C Clutch Air Gap 0.35 - 0.60 mm (0.014 - 0.024 in.)
A/C Clutch Coil Draw 3.2 - 3.3 amps @ 12V ± 0.5V @ 21° C (70° F)
When measured across coil lead
A/C Clutch Coil Resistance 3.6 ± 0.2 ohms
connector
Freeze-up Control Evaporator Temperature Sensor HVAC housing mounted
High psi Control A/C pressure transducer A/C discharge line mounted
R-134a Refrigerant Charge 3.6L/4.7L/5.7L engines - 0.624 kg
Use only ND-8 PAG oil
Capacity (1 lb. 6 oz.)
FASTENER TORQUE
Description N.m Ft. Lbs. In. Lbs.

All Screws NOT Listed
1.1 - 10
Below
Specific fastener placement and torque pattern is required. See
A/C Compressor to Engine
COMPRESSOR, A/C Installation for more information.
A/C Condenser Bolts 2.2 - 20
A/C Compressor Clutch Plate
19 - 168
Bolt
A/C Expansion Valve Bolts 11 - 97
A/C Heater Control Screws 2.2 - 20
Air Ducts to Instrument Panel
2.2 - 20
Screws
Blower Motor Screws 1.7 - 15
HVAC Housing to Engine
6.8 - 60
Side of Dash Panel Nuts
HVAC Housing to Floor
6.8 - 60
Bracket Bolt
HVAC Housing to Passenger

Side of Dash Panel Nuts 6.8 - 60

Refrigerant Lines Nuts/Bolts 23 17 -
SPECIAL TOOLS
SPECIAL TOOLS
6801 - Terminal Probe

(Originally Shipped In Kit Number(s)
10190.)


9764 - Pliers, A/C Snap Ring

9909.)
C-4755 - Trim Stick

9299, 9299CC, 9299CC, 9300A-CAN.)
CONTROLS
ACTUATOR, BLEND DOOR
DESCRIPTION
DESCRIPTION

Fig. 3: Locating Blend Door Actuator

The blend door actuators are reversible, 12-volt direct current (DC), servo motors. Models with the single zone
heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models
with the dual zone system have two blend-air doors, which are controlled by two blend door actuators.
The blend door actuator (1) for the single zone heating-A/C system is located near the center of the HVAC
housing (2), close to the instrument panel.
For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes
the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A
second separate blend door actuator (3) located at the front of the HVAC housing is mechanically connected to
the passenger side blend-air door.

Fig. 4: Actuator
All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black
molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output
shaft with splines (3) that connect it to the respective door linkage and three integral mounting tabs (4) that
allow the actuator to be secured to the HVAC housing. The blend door actuators do not require mechanical
indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control.
OPERATION
OPERATION
The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a
dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the
blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor
connection high and the other connection low, the blend-air door will move in one direction. When the A/C-
heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite
direction.
When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air
door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the
operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control
learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code
(DTC) for any problems it detects in the blend door actuator circuits.
The blend door actuators are diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The blend door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL
REMOVAL
WARNING: Disable the airbag system before attempting any steering wheel, steering
column or instrument panel component diagnosis or service. Disconnect
and isolate the negative battery (ground) cable and wait two minutes for
the airbag system capacitor to discharge before performing further
diagnosis or service. This is the only sure way to disable the airbag
system. Failure to follow these instructions may result in accidental
airbag deployment and possible serious or fatal injury.
NOTE: The single zone heating-A/C system is equipped with a single blend door
actuator. The dual zone system has two blend door actuators, one for the driver
side blend-air door and one for the passenger side blend-air door.
SINGLE ZONE/DUAL ZONE DRIVER SIDE

Fig. 5: Blend Door Actuator

1. Disconnect and isolate the negative battery cable.

2. Remove the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL .
3. Disconnect the HVAC wire harness connector (1) from the blend door actuator (2) located at the rear of
the HVAC housing (3).
4. Remove the two screws (4) that secure the blend door actuator to the HVAC housing and remove the
actuator.
DUAL ZONE PASSENGER SIDE


2. Remove the HVAC housing (1) from the vehicle and place it on a workbench. Refer to HOUSING,
HVAC, REMOVAL.
3. Disconnect the HVAC wire harness connector (2) from the blend door actuator (3) located at the front of

the HVAC housing.

4. Remove the two screws (4) that secure the blend door actuator to the HVAC housing and remove the
actuator.
INSTALLATION
INSTALLATION
NOTE: The single zone heating-A/C system is equipped with a single blend door
actuator. The dual zone system has two blend door actuators, one for the driver
side blend-air door and one for the passenger side blend-air door.
SINGLE ZONE/DUAL ZONE DRIVER SIDE

1. Position the blend door actuator (1) to the back of the HVAC housing (4). If necessary, rotate the actuator
slightly to align the splines on the actuator output shaft (2) with those on the actuator coupler (3).


2. Install the two screws (4) that secure the blend door actuator (2) to the HVAC housing (3). Tighten the
screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (1) to the blend door actuator.
4. Install the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, INSTALLATION .
5. Reconnect the negative battery cable.
6. Initiate the Actuator Calibration function using a scan tool. Refer to STANDARD PROCEDURE .
DUAL ZONE PASSENGER SIDE


1. Position the blend door actuator (1) to the front of the HVAC housing (4). If necessary, rotate the actuator
slightly to align the splines on the actuator output shaft (2) with those on the actuator coupler (3).

2. Install the two screws (4) that secure the blend door actuator (3) to the HVAC housing (1). Tighten the
4. Install the HVAC housing. Refer to HOUSING, HVAC, INSTALLATION.
ACTUATOR, MODE DOOR
DESCRIPTION
DESCRIPTION

Fig. 11: Mode Door Actuator

The mode door actuators are reversible, 12-volt direct current (DC) servo motors. The heating-A/C systems on
this vehicle use two mode door actuators. One for the defrost-air door and one for the panel/floor-air door.
Both the defrost door actuator (1) and the panel/floor door actuator (3) are located on the driver side end of the
HVAC housing (2), close to the instrument panel.
Fig. 12: Actuator


shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that
allow the actuator to be secured to the HVAC housing. The mode door actuators do not require mechanical
indexing to the mode-air doors, as they are electronically calibrated by the A/C-heater control.
OPERATION
OPERATION
The mode door actuators are connected to the A/C-heater control through the vehicle electrical system by
dedicated two-wire leads and connectors of the HVAC wire harness. The mode door actuators can move the
defrost-air door and the panel/floor-air door in two directions. When the A/C-heater control pulls the voltage on
one side of the motor connection high and the other connection low, the mode-air door will move in one
direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door
moves in the opposite direction.
When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air
door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the
operation and relative position of the mode door actuators and the mode-air doors. The A/C-heater control
learns the mode-air door stop positions during the Actuator Calibration procedure and will store a Diagnostic
Trouble Code (DTC) for any problems it detects in the mode door actuator circuits.
The mode door actuators are diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The mode door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL
REMOVAL
and isolate the negative battery (ground) cable. Wait two minutes for the
airbag system capacitor to discharge before performing further diagnosis
or service. This is the only sure way to disable the airbag system. Failure
to follow these instructions may result in possible serious or fatal injury.
NOTE: The heating-A/C system is equipped with two mode door actuators, one for the
panel/floor-air door and one for the defrost-air door.
NOTE: Illustrations shown with instrument panel removed for clarity.
PANEL/FLOOR DOOR ACTUATOR

Fig. 13: Panel/Floor Door Actuator


2. Remove the instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
REMOVAL .
3. When equipped with center floor console, remove radio. Refer to RADIO, REMOVAL .
4. When not equipped with center floor console, remove cupholder. Refer to CUPHOLDER,
INSTRUMENT PANEL, REMOVAL .
5. Disconnect the HVAC wire harness (2) from the panel/floor door actuator (3).
6. Remove the two screws (4) that secure the panel/floor door actuator to the back of the HVAC housing (1)
and remove the actuator.
DEFROST DOOR ACTUATOR

Fig. 14: Defrost Door Actuator


2. Remove the instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
REMOVAL .
3. When equipped with center floor console, remove radio. Refer to RADIO, REMOVAL .
4. When not equipped with center floor console, remove cupholder. Refer to CUPHOLDER,
INSTRUMENT PANEL, REMOVAL .
5. Disconnect the HVAC wire harness (1) from the defrost door actuator (2).
6. Remove the two screws (3) that secure the defrost door actuator to the back of the HVAC housing (4) and
remove the actuator.
INSTALLATION
INSTALLATION
NOTE: The heating-A/C system is equipped with two mode door actuators, one for the
panel/floor-air door and one for the defrost-air door.
NOTE: Illustrations shown with instrument panel removed for clarity.
PANEL/FLOOR DOOR ACTUATOR

1. Position the panel/floor door actuator (1) to the back of the HVAC housing (4). If necessary, rotate the
actuator slightly to align the splines on the actuator output shaft (3) with those on the panel/floor door
actuator coupler (2).


2. Install the two screws (4) that secure the panel/floor door actuator (3) to the HVAC housing (1). Tighten
the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (2) to the panel/floor door actuator.
4. When equipped with center floor console, install the radio. Refer to RADIO, INSTALLATION .
5. When not equipped with center floor console, install the cupholder. Refer to CUPHOLDER,
INSTRUMENT PANEL, INSTALLATION .
6. Install the instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
INSTALLATION .
8. Initiate the Actuator Calibration function using a scan tool. Refer to DIAGNOSIS AND TESTING .
DEFROST DOOR ACTUATOR


1. Position the defrost door actuator (1) to the back of the HVAC housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator output shaft (3) with those on the defrost door

2. Install the two screws (3) that secure the defrost door actuator (2) to the HVAC housing (4). Tighten the
3. Connect the HVAC wire harness connector (1) to the defrost door actuator.
4. When equipped with center floor console, install the radio. Refer to RADIO, INSTALLATION .
5. When not equipped with center floor console, install the cupholder. Refer to CUPHOLDER,

INSTRUMENT PANEL, INSTALLATION .

INSTALLATION .
8. Initiate the Actuator Calibration function using a scan tool. Refer to DIAGNOSIS AND TESTING .
ACTUATOR, RECIRCULATION DOOR
DESCRIPTION
DESCRIPTION
Fig. 19: Recirculation Door Actuator

The recirculation door actuator (1) is a reversible 12-volt direct current (DC) servo motor. The single
recirculation door actuator is located on the inboard side of the air inlet housing (2).

Fig. 20: Actuator

shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that
allow the actuator to be secured to the HVAC housing. The recirculation door actuator does not require
mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control.
OPERATION
OPERATION
The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical
system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator
can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side
of the motor connection high and the other connection low, the recirculation-air door will move in one
direction.
When the A/C-heater control makes the voltage to both connections high or both connections low, the
recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to
monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The
A/C-heater control learns the recirculation-air door stop positions during the Actuator Calibration procedure and
will store a Diagnostic Trouble Code (DTC) for any problems it detects in the recirculation door actuator
circuits.
The recirculation door actuator is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The recirculation door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL

REMOVAL
column, or instrument panel component diagnosis or service. Disconnect
and isolate the battery negative (ground) cable, then wait two minutes for

1. Remove the HVAC housing assembly. Refer to HOUSING, HVAC, REMOVAL.

2. Remove the air inlet housing (1) and place it on a workbench. Refer to HOUSING, HVAC,
REMOVAL.
3. Remove the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing and
INSTALLATION
INSTALLATION


1. Install the recirculation door actuator (1) onto the side of the air inlet housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator output shaft (4) with those in the recirculation door

2. Install the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing (1).
Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Install the air inlet housing. Refer to HOUSING, HVAC, INSTALLATION.
4. Install the HVAC housing assembly. Refer to HOUSING, HVAC, INSTALLATION.

CONTROL, A/C AND HEATER
DESCRIPTION
MANUAL SINGLE ZONE
Fig. 24: Manual Single Zone Controls

The A/C-heater control for the manual temperature control (MTC) single zone heating-A/C system allows one
temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols.
The A/C-heater control is located in the instrument panel and contains:
a rotary control for fan speed selection and turning the heating-A/C system off (1).
a rotary control for temperature control of the discharged air (2).
a rotary mode control of the discharged air (3).
a push button control for recirculation (4) an LED in the button will illuminate when you are in
recirculation mode.
a push button A/C on/off control (5). An LED in the button illuminates when the A/C system is in
operation.
a push button rear window/side mirror defogger on/off control (6) when equipped with optional rear
heated window and/or heated mirrors. An LED in the button illuminates when the rear window/mirror
defogger (EBL) system is in operation.
The A/C-heater control for the MTC system is diagnosed using a scan tool. Refer to DIAGNOSIS AND
TESTING .
The A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged.
AUTOMATIC SINGLE ZONE

Fig. 25: Automatic Single Zone Controls

The A/C-heater control for the Automatic Temperature Control (ATC) single zone system maintains the interior
comfort level desired by the vehicle operator. This is accomplished by use of an interior temperature sensor,
ambient temperature sensor, and sun load sensor, based on the sensor input, the system automatically adjusts the
air temperature, airflow volume, airflow distribution and amount of inside air recirculation to maintain front
seat occupant comfort, even under changing outside weather conditions. All controls are identified by ISO
graphic symbols.
This ATC system offers several manual override features such as fan speed, airflow distribution and when the
outside air contains smoke, odors, high humidity, or if rapid cooling is desired, the interior air can be
recirculated by pressing the recirculation button.
The heating-A/C system uses electrically operated controls. These controls provide the vehicle operator with a
number of setting options to help control the climate and comfort within the vehicle.
The A/C-heater control is located in the instrument panel and contains:
a push-button control with indicator lamp to manually turn the A/C system on and off (1).
a push-button control with indicator lamp for manual recirculation control of the discharged air (2).
a push-button control with indicator lamp to change the current setting to front defrost mode (3).
Performing this function will cause the ATC to switch to manual mode.
a push-button control with indicator lamp to turn on the rear window defroster (4) and the heated outside
mirrors if equipped. The rear window defroster automatically turns off after ten minutes.
a rotary control for manual and automatic blower motor speed selection (6).
a push-button control to turn climate control ON or OFF (7).
a push-button control to adjust temperature control down (8).
a push-button control to adjust temperature control up (9).
Mode functions are controlled through the Uconnect Media Center Touch Screen.
The A/C-heater control for the ATC heating and A/C system obtains vehicle speed, engine speed, engine
coolant temperature, ambient temperature and refrigerant system head pressure data from the CAN-B bus and is
diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .

Prior to replacing an A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the heating-
A/C system and run the Actuator Calibration function using a scan tool to verify that the concern is not a system
issue. Refer to STANDARD PROCEDURE .
AUTOMATIC DUAL ZONE
Fig. 26: Automatic Dual Zone Controls

The A/C-heater control (1) for the automatic temperature control (ATC) dual zone heating-A/C system allows
both the driver and the front seat passenger the ability to individually regulate air temperature for their side of
the vehicle. All controls are identified by ISO graphic symbols.
a push-button control with indicator lamp to manually turn the A/C system on and off (1).
a push-button control with indicator lamp for manual recirculation control of the discharged air (2).
a push-button control with indicator lamp to change the current setting to front defrost mode (3).
Performing this function will cause the ATC to switch to manual mode.
a push-button control with indicator lamp to turn on the rear window defroster (4) and the heated outside
mirrors if equipped. The rear window defroster automatically turns off after ten minutes.
a rotary control for manual and automatic blower motor speed selection (6).
a push-button control to turn climate control OFF (7).
a push-button control to adjust temperature up and down on left side (11).
a push-button control to adjust temperature up and down on right side (10).
a push-button control to turn the Automatic Climate Control ON.
Mode functions are controlled through the Uconnect Media Center Touch Screen.
The A/C-heater control for the ATC heating and A/C system obtains vehicle speed, engine speed, engine
coolant temperature, ambient temperature and refrigerant system head pressure data from the CAN bus and is
diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The A/C-heater control for the ATC system is diagnosed using a scan tool. Refer to DIAGNOSIS AND

TESTING .
REMOVAL
REMOVAL
Fig. 27: A/C-Heater Control, Center Bezel & Harness Connectors

NOTE: Typical A/C-heater control shown in illustration.

2. Remove the center bezel (1) from the instrument panel and disconnect the wire harness connectors (4 and
5) from the back of the A/C-heater control (2). Refer to BEZEL, INSTRUMENT PANEL, CENTER,
REMOVAL .
NOTE: Take the proper precautions to protect the front face of the center bezel
from cosmetic damage.

3. Place the center bezel on a workbench and remove the four screws (3) that secure the A/C-heater control
to the center bezel and remove the control.
INSTALLATION
INSTALLATION
Fig. 28: A/C-Heater Control, Center Bezel & Harness Connectors

NOTE: Typical A/C-heater control shown in illustration.
1. Position the A/C-heater control (2) onto the back of the instrument panel center bezel (1).
2. Install the four screws (3) that secure the A/C-heater control to the center bezel. Tighten the screws to 2.2
N.m (20 in. lbs.).
3. Connect the wire harness connectors (4 and 5) to the back of the A/C-heater control and install the
instrument panel center bezel. Refer to BEZEL, INSTRUMENT PANEL, CENTER,
INSTALLATION .
MODULE, POWER, BLOWER MOTOR
DESCRIPTION
DESCRIPTION

Fig. 29: Blower Motor Power Module

A blower motor power module is used on this model when equipped with the automatic temperature control
(ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system
use a blower motor resistor, instead of the blower motor power module. Refer to RESISTOR, BLOWER
MOTOR, DESCRIPTION.
The blower motor power module is mounted to the bottom of the HVAC housing, on the passenger side of the
vehicle. The blower motor power module consists of a molded plastic mounting plate (1) with an integral
connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry (3) and
a finned aluminum heat sink (4). The blower motor power module is accessed for service from under the
instrument panel.
OPERATION
OPERATION
The blower motor power module is connected to the vehicle electrical system through a dedicated lead and
connector of the HVAC wire harness. A second lead and connector of the HVAC wire harness is connected to
the blower motor. The blower motor power module allows the microprocessor-based automatic temperature
control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon
either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit
strategy.
The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower
motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output
voltage to change or maintain the desired blower speed.
The blower motor power module is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged.

REMOVAL
REMOVAL
and isolate the negative battery (ground) cable, then wait two minutes for
WARNING: The heat sink for the blower motor power module may get very hot during
normal operation. If the blower motor was turned on prior to servicing the
blower motor power module, wait five minutes to allow the heat sink to
cool before performing diagnosis or service. Failure to follow these
instructions may result in possible serious injury.


2. Disconnect the wire harness connector (1) from the blower motor power module (2) located at the bottom
of the HVAC housing (3) on the passenger side of the vehicle.
3. Remove the two screws (4) that secure the blower motor power module to the HVAC housing and
remove the power module.
INSTALLATION
INSTALLATION


1. Position the blower motor power module (2) onto the bottom of the HVAC housing (3).
2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten the
3. Connect the wire harness connector (1) to the blower motor power module.
RESISTOR, BLOWER MOTOR
DESCRIPTION
DESCRIPTION

Fig. 32: Blower Motor Resistor

The blower motor resistor is mounted to the bottom of the HVAC housing, below the glove box. The blower
motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2).
Behind the mounting plate are resistors contained within a metal heat sink (3).
OPERATION
OPERATION
The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and
connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will
reduce the current flow through the blower motor to change the blower motor speed.
The blower motor control for the heating-A/C system directs the ground path for the blower motor through the
correct resistor wire to obtain the selected speed. With the blower motor control in the lowest speed position,
the ground path for the blower motor is applied through all of the resistor wires. Each higher speed selected
with the blower motor control applies the blower motor ground path through fewer of the resistor wires,
increasing the blower motor speed.
The blower motor resistor cannot be adjusted or repaired and must be replaced if inoperative or damaged.
DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR
system. Failure to take the proper precautions may result in accidental
NOTE: See appropriate Wiring Information for circuit descriptions and diagrams.
Wiring Information includes wiring diagrams, proper wire and connector repair
procedures, further details on wire harness routing and retention, as well as
pin-out and location views for the various wire harness connectors, splices and
grounds.

2. Disconnect the wire harness connector from the blower motor resistor. Refer to RESISTOR, BLOWER
MOTOR, REMOVAL.
3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case
there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control

and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower
motor resistor.
REMOVAL
REMOVAL
and isolate the negative battery (ground) cable. Wait two minutes for the
airbag system capacitor to discharge before performing further diagnosis
or service. This is the only sure way to disable the airbag system. Failure
to follow these instructions may result in possible serious or fatal injury.
WARNING: The blower motor resistor may get very hot during normal operation. If
the blower motor was turned on prior to servicing the blower motor
resistor, wait five minutes to allow the blower motor resistors to cool
before performing diagnosis or service. Failure to take this precaution
may result in possible serious injury.
Fig. 33: HVAC Wire Harness Connector To Blower Motor Resistor


2. Reach under the passenger side of the instrument panel and disconnect the HVAC wire harness connector
(4) from the blower motor resistor (3).
3. Remove the two screws (1) that secure the blower motor resistor to the HVAC housing (2) and remove
the resistor.
INSTALLATION

INSTALLATION
Fig. 34: HVAC Wire Harness Connector To Blower Motor Resistor

1. Position the blower motor resistor (3) into the HVAC housing (2).
2. Install the two screws (1) that secure the blower motor resistor to the HVAC housing. Tighten the screws
to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (4) to the blower motor resistor.
SENSOR, AMBIENT TEMPERATURE
DESCRIPTION
DESCRIPTION

Fig. 35: Ambient Air Temperature Sensor

The ambient air temperature sensor (3) is a variable resistor, constructed of molded black plastic, that monitors
the air temperature outside of the vehicle. It includes and integral connector (2) that encloses two terminal pins.
The Automatic Temperature Control (ATC) heating and A/C system uses the ambient temperature sensor data
to maintain optimum cabin temperature levels. The ambient air temperature sensor is mounted inside the left
outside rear view mirror and the sensor tip (1) protrudes out the bottom of the housing.
OPERATION
OPERATION
The ambient air temperature sensor is a variable resistor that operates on a 5 volt Direct Current (DC) reference
signal sent by the Body Control Module (BCM). The ambient air temperature sensor is connected to the BCM
through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes
its internal resistance in response to changes in the outside air temperature, which either increases or decreases
the reference signal voltage read by the BCM. The BCM converts and broadcasts the sensor data over the
Controller Area Network (CAN) data bus, where it is read by the Automatic Temperature Control (ATC) A/C
heater module and other vehicle control modules.
The ambient air temperature sensor is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or
damaged.
REMOVAL
REMOVAL

Fig. 36: Removing Panel Below Mirror

2. Using a flat blade screwdriver (3) or equivalent, insert blade into slot and gently pry upward to remove
the panel (2) located below the left rear view mirror (1).
Fig. 37: Removing/Installing Ambient Temperature Sensor

3. Disconnect the sensor electrical connector (3) and remove sensor (2) from vehicle.
4. Rotate the sensor one quarter turn counter clockwise to disengage the panel (4) from the retaining slot (1).
INSTALLATION
INSTALLATION

Fig. 38: Removing/Installing Ambient Temperature Sensor

1. Position the Ambient temperature sensor (2) into the panel (4) and rotate the sensor one quarter turn
clockwise to engage the panel to the sensor retaining slot (1).
2. Connect the electrical connector (3) to the ambient temperature sensor.
3. Insert panel with ambient temperature sensor into the lower left side rear view mirror and gently snap into
place.
4. Connect the negative battery cable.
SENSOR, EVAPORATOR TEMPERATURE
DESCRIPTION
DESCRIPTION

Fig. 39: Downstream EVAP Temperature Sensor

NOTE: Cutaway of HVAC housing shown for clarity.
The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is
inserted into the top of the HVAC housing (2) to measure the temperature of the conditioned air downstream of
the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle
electrical system through a wire lead and connector of the HVAC wire harness.
The external location of the evaporator temperature sensor allows the sensor to be removed or installed without
disturbing the refrigerant in the A/C system.
OPERATION
OPERATION
The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C
evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator
temperature sensor input signal to optimize A/C system performance and to protect the A/C system from
evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the
temperatures it monitors and is connected to the A/C-heater control through a sensor ground circuit and a 5-volt
reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the
evaporator temperature sensor decreases.
The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The
A/C-heater control is programmed to respond to this input by requesting the Powertrain Control Module (PCM)
or Engine Control Module (ECM), depending on engine application, to cycle the A/C clutch as necessary to
optimize A/C system performance and to protect the A/C system from evaporator freezing.

The evaporator temperature sensor is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or
damaged.
REMOVAL
REMOVAL
Fig. 40: Evaporator Temperature Sensor

NOTE: Illustration shown with instrument panel removed for clarity.

2. Remove the glove box from the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
REMOVAL .
3. Remove the storage bin from the instrument panel. Refer to BIN, INSTRUMENT PANEL,
REMOVAL .
4. Disconnect the HVAC wire harness (2) from the evaporator temperature sensor (1) located on top of the
HVAC housing (3).
5. Pull the evaporator temperature sensor upward and forward and remove the sensor from the HVAC
housing.
INSTALLATION
INSTALLATION

Fig. 41: Evaporator Temperature Sensor

NOTE: Illustration shown with instrument panel removed for clarity.
1. Install the evaporator temperature sensor (1) into the top of the HVAC housing (3). Make sure the sensor
is fully engage to the housing.
2. Connect the HVAC wire harness (2) to the evaporator temperature sensor.
3. Install the storage bin. Refer to BIN, INSTRUMENT PANEL, INSTALLATION .
4. Install the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, INSTALLATION .
SENSOR, INFRARED TEMPERATURE
DESCRIPTION
DESCRIPTION

Fig. 42: Infrared Sensor

NOTE: Typical infrared sensor shown in illustration.
The infrared temperature sensor is located in the overhead console and consists of an infrared transducer
concealed behind a clear lens (2) in a molded plastic housing with an integral mounting tab (3) and wire
connector receptacle (1).
The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heating-
A/C system.
OPERATION
OPERATION
The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and
surroundings and converts its data into a linear pulse width modulated (PWM) output signal which is read by
the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared
sensor data as one of the inputs necessary to automatically control the interior cabin temperature levels. By
using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the
ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows
the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or
evaporative heat loss.
The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow
temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of
the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store
diagnostic trouble codes (DTCs) for any problem it detects.
The infrared sensor is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .

The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL
REMOVAL


2. Remove the overhead console (1) and place it on a workbench. Refer to CONSOLE, OVERHEAD,
FRONT, REMOVAL .
3. Remove the screw (3) that secures the infrared sensor (2) to the overhead console and remove the sensor.
INSTALLATION
INSTALLATION


1. Position the infrared sensor (2) onto the overhead console (1).
2. Install the screw (3) that secures the infrared sensor to the overhead console. Tighten the screw to 1.1
N.m (10 in. lbs.).
3. Install the overhead console. Refer to CONSOLE, OVERHEAD, FRONT, INSTALLATION .
SENSOR, SUN
DESCRIPTION
DESCRIPTION
NOTE: Typical sun sensor assembly shown in illustration.

Fig. 45: Sun Sensor

The Automatic Temperature Control (ATC) heating-A/C system uses a sun sensor (1) to measure sun light
intensity. The sun sensor incorporates three sun load sensors (2) within a molded plastic case which is mounted
to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness
receptacle (4) connects the sun sensor to the vehicle electrical system.
OPERATION
OPERATION
The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side
variations in sun light intensity. Passengers in sun and shadow require different functional settings because they
experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help
determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not
thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity
rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic
headlight control, if equipped.
The sun sensor is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .
The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL
REMOVAL

Fig. 46: Locating Sun Sensor


2. Remove the trim panel (2) that contains the sun sensor (1) from the top of the instrument panel using
Trim Stick (special tool #C-4755, Trim Stick) or equivalent and disconnect the instrument panel wire
harness connector from the sensor.
3. Using Trim Stick (special tool #C-4755, Trim Stick) or equivalent, gently pry on both sides of the sun
sensor assembly and remove the sun sensor from the panel.
INSTALLATION
INSTALLATION

Fig. 47: Locating Sun Sensor

1. Align the tab on the sun sensor (1) with the opening in the panel (2).
2. Gently push the sun sensor into the panel until the sensor snap retainers are securely engaged.
3. Connect the instrument panel wire harness to the sun sensor and install the panel onto the instrument
panel. Make sure the panel snap retainers are fully engaged.
SENSOR, TEMPERATURE, IN-CAR
DESCRIPTION
DESCRIPTION

Fig. 48: In-Car Temperature Sensor, Aspirator Motor & Thermistor

The in-car temperature sensor is used in the Automatic Temperature Control (ATC) heating and A/C system.
The in-car temperature sensor consists of an aspirator motor (2) and a temperature thermistor (3). The in-car
temperature sensor sends a resistance signal to the HVAC module and is attached to the steering column cover,
by integral mounting tabs (1).
OPERATION
OPERATION
Air is drawn from the passenger compartment by the aspirator motor and flows over the temperature thermistor.
The thermistor changes resistance with air temperature. The A/C heater module for the Automatic Temperature
Control (ATC) system receives the resistance signal over hard-wired circuits and calculates the temperature of
the air in the passenger compartment. The ATC system then automatically makes adjustments to maintain the
optimum passenger compartment comfort.
The in-car temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged.
DIAGNOSIS AND TESTING - IN-CAR TEMPERATURE SENSOR
NOTE: For complete circuit diagrams, see appropriate Wiring Information. Wiring
Information includes wiring diagrams, connector pin-out and location views,
details of wire harness routing and retention, splice and ground locations and
proper wire and connector repair procedures.
Using a scan tool, check for Diagnostic Trouble Codes (DTCs) related to the in-car temperature sensor and the

A/C heater module. If any DTCs are found, repair as necessary. Refer to DIAGNOSIS AND TESTING . If no
DTCs are found, perform the two following tests. Replace the in-car temperature sensor if the sensor fails either
test.
ASPIRATOR MOTOR TEST
The in-car temperature sensor uses an aspirator motor to draw air from the passenger compartment and flow the
air over the temperature thermistor. Test the motor as follows.
Fig. 49: Opening Grille & Opening Cover

1. Place the ignition in the Run position.

2. Place a small piece of newspaper in front of the aspirator motor opening grille (1), located on the steering
column opening cover (2). If the paper sticks to the grille, the aspirator motor is operating properly. The
piece of paper should be only large enough to cover the opening.
3. If the paper does not stick to the grille, check the in-car temperature sensor electrical connections and
wiring. If connections and wiring are OK, replace the in-car temperature sensor.
TEMPERATURE THERMISTOR TEST
The in-car temperature sensor uses a temperature thermistor to provide resistance values that correlate with
temperature change. Test the thermistor as follows.
1. Remove the in-car temperature sensor and place it on a workbench. Refer to SENSOR,
TEMPERATURE, IN-CAR, REMOVAL.
2. Note the current ambient air temperature of the work area.
3. Use an ohm meter and check the resistance between pins 1 and 2 of the in-car temperature sensor.
Compare the temperature of the work area to the found resistance value. The resistance should be within
specifications as listed in the Resistance and Temperature chart. If not OK, replace the in-car temperature
sensor.

RESISTANCE AND TEMPERATURE

Air Temperature Range Low Resistance Range (kohm) High Resistance Range (kohm)
-21° to -15°C (-5° to 5°F) 292 ± 1.0 223 ± 0.9
-14° to -9°C (6° to 15°F) 198 ± 0.9 161 ± 0.8
-8° to -4°C (16° to 25°F) 144 ± 0.8 123 ± 0.8
-3° to 1°C (26° to 35°F) 111 ± 0.7 95 ± 0.7
2 to 7°C (36° to 45°F) 86 ± 0.7 70 ± 0.6
8 to 12°C (46° to 55°F) 64 ± 0.6 55 ± 0.5
13° to 18°C (56° to 65°F) 51 ± 0.5 42 ± 0.4
19° to 23°C (66° to 75°F) 39 ± 0.4 33 ± 0.3
24° to 29°C (76° to 85°F) 31 ± 0.3 26 ± 0.3
30° to 35°C (86° to 95°F) 24 ± 0.3 20 ± 0.3
36° to 40°C (96° to 105°F) 18 ± 0.3 16 ± 0.3
41° to 46°C (106° to 115°F) 15 ± 0.3 13 ± 0.3
REMOVAL
REMOVAL
NOTE: Take the proper precautions to protect the face of the steering column opening
cover from cosmetic damage while performing this procedure.

Fig. 50: Remove/Install Steering Column Cover

2. Remove the steering column opening cover (3). Refer to COVER, STEERING COLUMN OPENING,
REMOVAL .
3. Disconnect the electrical connector (1) from the temperature sensor (2) and place the steering column
opening cover on a workbench.
Fig. 51: Remove/Install In-Car Temperature Sensor

4. Remove the two screws (1) that secure the in-car temperature sensor (2) to the steering column opening
cover (3) and remove the sensor.

INSTALLATION
INSTALLATION
NOTE: Take the proper precautions to protect the face of the steering column opening
cover from cosmetic damage while performing this procedure.
Fig. 52: Remove/Install In-Car Temperature Sensor

1. Position the in-car temperature sensor (2) onto the steering column opening cover (3).
2. Install the two screws (1) that secure the in-car temperature sensor to the steering column opening cover.
Tighten the screws securely.

Fig. 53: Remove/Install Steering Column Cover

3. Connect the electrical connector (1) to the temperature sensor (2).

4. Install the steering column opening cover (3). Refer to COVER, STEERING COLUMN OPENING,
INSTALLATION .
TRANSDUCER, A/C PRESSURE
DESCRIPTION
DESCRIPTION

Fig. 54: A/C Pressure Transducer

The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An
internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type
fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and
the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded
plastic connector with three terminals.
OPERATION
OPERATION
The A/C pressure transducer monitors the pressures in the high side of the A/C refrigerant system through its
connection to a fitting on the A/C discharge line and its internal resistance changes in response to the pressures
it monitors. The Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on engine
application, provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then
monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The
PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C
clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system
components from damage. The PCM/ECM will disengage the A/C clutch when high side pressure rises above
3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C
pressure transducer will also disengage the A/C clutch if the high side pressure drops below 193 kPa (28 psi)
and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant
pressure rises above 1655 kPa (240 psi), the PCM/ECM will actuate the cooling fan. The A/C pressure
transducer signal to the PCM/ECM also prevents the A/C clutch from engaging when ambient temperatures are
below about 10° C (50° F), due to the pressure/temperature relationship of the refrigerant.
A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or
installed without disturbing the refrigerant in the A/C system.
The A/C pressure transducer is diagnosed using a scan tool or (Refer to DIAGNOSIS AND TESTING .
The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged.
REMOVAL
REMOVAL
NOTE: It is not necessary to discharge the refrigerant system to replace the A/C
pressure transducer.

Fig. 55: A/C Pressure Transducer, Connector, Discharge Line & O-Ring
NOTE: Typical A/C pressure transducer and refrigerant line shown.

2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C
discharge line (3).
3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard
the O-ring seal.
INSTALLATION
INSTALLATION
NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use
only refrigerant oil of the type required for the A/C compressor.

Fig. 56: A/C Pressure Transducer, Connector, Discharge Line & O-Ring
NOTE: Typical A/C pressure transducer and refrigerant line shown in the illustration.
1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line
fitting (3).
2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer
to 5.1 N.m (45 in. lbs.).
3. Connect the wire harness connector (1) to the A/C pressure transducer.
DISTRIBUTION
DUCT, DEFROSTER
REMOVAL
REMOVAL

NOTE: Take the proper precautions to protect the instrument panel from cosmetic
damage.
Fig. 57: Defroster Duct

1. Remove the instrument panel and place it on a workbench. Refer to PANEL, INSTRUMENT,
REMOVAL .
2. Remove the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL .
3. Remove the instrument panel ducts and place the center distribution duct on a workbench. Refer to
DUCT, INSTRUMENT PANEL, REMOVAL.
4. Remove the three retainers (3 and 4) that secure the defroster duct (1) to the center distribution duct (2)
and remove the defroster duct.
INSTALLATION
INSTALLATION

Fig. 58: Defroster Duct

1. Position the defroster duct (1) onto the center distribution duct (2).
2. Install the three retainers (3 and 4) that secure the defroster duct to the center distribution duct.
3. Install the instrument panel ducts onto the instrument panel support. Refer to DUCT, INSTRUMENT
PANEL, INSTALLATION.
4. Install the instrument panel cover Refer to COVER, INSTRUMENT PANEL, INSTALLATION .
5. Install the instrument panel. Refer to PANEL, INSTRUMENT, INSTALLATION .
DUCT, FLOOR CONSOLE
REMOVAL
REMOVAL

Fig. 59: Floor Console Duct

NOTE: Illustration shown with seat cushions removed for clarity.
NOTE: Automatic transmission model shown in illustration. Manual transmission

model similar.
1. Remove the floor console. Refer to CONSOLE, FLOOR, REMOVAL .

2. Disengage the floor console duct (1) from the rear duct adapter (3) and slide the adapter rearward into the
rear duct (2).
3. Disengage the floor console duct from the stud (4) on the floor panel.
4. Disengage the floor console duct from the rear floor distribution duct (5) and remove the console duct.

Fig. 60: Identifying Rear Duct, Push-Pin Retainers, And Center Seat Support
NOTE: Illustration shown with center front seat removed for clarity.
5. If required, remove the front seat. Refer to SEAT, FRONT, REMOVAL and/or SEAT, FRONT
CENTER, REMOVAL .
6. Remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat
support (3).
7. Disengage the rear duct from the rear outlet (4) and remove the rear duct.
INSTALLATION
INSTALLATION

Fig. 61: Identifying Rear Duct, Push-Pin Retainers, And Center Seat Support
NOTE: Illustration shown with center front seat removed for clarity.
1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the
outlet.
2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the
front seat. Refer to SEAT, FRONT, INSTALLATION and/or SEAT, FRONT CENTER,
INSTALLATION .
Fig. 62: Floor Console Duct


NOTE: Illustration shown with seat cushions removed for clarity.
NOTE: Automatic transmission models shown in illustration. Manual

transmission model similar.
3. Install the floor console duct (1) onto the rear floor distribution duct (5). Make sure the ducts are fully
engaged to each other.
4. Engage the floor console duct onto the stud (4).
5. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure
the ducts are fully engaged to each other.
6. Install the floor console. Refer to CONSOLE, FLOOR, INSTALLATION .
DUCT, FLOOR DISTRIBUTION, REAR
REMOVAL
REMOVAL
Fig. 63: Rear Floor Ducts

1. Remove the front seats. Refer to SEAT, FRONT, REMOVAL and/or SEAT, FRONT CENTER,
REMOVAL .
2. Roll back the front carpet from under the instrument panel toward the rear of the vehicle. Refer to
CARPET, FLOOR, REMOVAL .
3. Disengage the rear floor ducts (2 and 5) from the floor support bracket (3) and from the studs (4) located
on the floor panel.
4. Disconnect the rear floor ducts from the HVAC housing (1) and remove the ducts.

INSTALLATION
INSTALLATION
Fig. 64: Rear Floor Ducts

1. Connect the rear floor ducts (2 and 5) to the HVAC housing (1).
2. Engage the rear floor ducts to the studs (4) and the floor support bracket (3).
3. Reposition the front carpet. Refer to CARPET, FLOOR, INSTALLATION .
4. Install the front seats. Refer to SEAT, FRONT, INSTALLATION and/or SEAT, FRONT CENTER,
INSTALLATION .
DUCT, INSTRUMENT PANEL
REMOVAL
REMOVAL
damage.

Fig. 65: Center Distribution & Driver Side Demister Duct

REMOVAL .
3. Remove the retainer (1) that secures the driver side demister duct (2) to the end of the instrument panel
support (4).
4. Disconnect the driver side demister duct from the center distribution duct (3) and remove the demister
duct.
Fig. 66: Passenger Side Demister Duct & Passenger Side Instrument Panel Duct
5. Remove the retainer (1) that secures the passenger side demister duct (5) to the end instrument panel

support (6).
6. Remove the retainer (2) that secures the passenger side demister duct to the passenger side instrument
panel duct (3).
7. Disconnect the passenger side demister duct from the center distribution duct (4) and remove the demister
duct.
Fig. 67: Passenger Side Instrument Panel Duct

8. Remove the retainer (3) that secures the passenger side instrument panel duct (2) to the end of the
instrument panel support (1).
Fig. 68: Middle Of The Instrument Panel Support


9. Remove the retainer (2) that secures the passenger side instrument panel duct (3) to the middle of the

10. Remove the retainer (1) that secures the driver side instrument panel duct (3) to the middle of the
11. Remove the retainer (4) that secures the passenger side instrument panel duct (6) to the middle of the
center distribution duct (5).
Fig. 70: Driver Side Instrument Panel Duct

12. Remove the retainer (3) that secures the driver side instrument panel duct (1) to the end of the instrument

panel support (2).
Fig. 71: Passenger & Driver Side Instrument Panel Duct

13. Remove the two retainers (1) that secure the passenger side instrument panel duct (2) and the driver side
instrument panel duct (4) to the middle of the instrument panel support (3).
14. Remove the passenger side instrument panel duct.
Fig. 72: Center Distribution Duct

15. Remove the two retainers (1 and 3) that secure the center distribution duct (4) to the middle of the
16. Remove the driver side instrument panel duct (2) and the center distribution duct.

INSTALLATION
INSTALLATION
Fig. 73: Center Distribution Duct

1. Position the driver side instrument panel duct (2) and the center distribution duct (4) to the instrument
panel support (5).
2. Install the two retainers (1 and 3) that secure the center distribution duct (4) to the middle of the
instrument panel support.
Fig. 74: Passenger & Driver Side Instrument Panel Duct

3. Position the passenger side instrument panel duct (2) the instrument panel support (3) and connect it to

the center distribution duct.

4. Install the two retainers (1) that secure the passenger side instrument panel duct and the driver side
instrument panel duct (4) to the middle of the instrument panel support.
Fig. 75: Driver Side Instrument Panel Duct

5. Install the retainer (3) that secures the driver side instrument panel duct (1) to the end of the instrument
panel support (2).

6. Install the retainer (1) that secures the driver side instrument panel duct (3) to the middle of the

7. Install the retainer (4) that secures the passenger side instrument panel duct (6) to the middle of the center
distribution duct (5).
Fig. 77: Middle Of The Instrument Panel Support

8. Install the retainer (2) that secures the passenger side instrument panel duct (3) to the middle of the

9. Install the retainer (3) that secures the passenger side instrument panel duct (2) to the end of the


10. Position the driver side demister duct (2) to the instrument panel support (4) and connect it to the
11. Install the retainer (1) that secures the driver side demister duct to the instrument panel support.
12. Position the passenger side demister duct (5) to the instrument panel support (6) and connect it to the
13. Install the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel
duct (3).
14. Install the retainer (1) that secures the passenger side demister duct to the instrument panel support.

15. Install the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, INSTALLATION .
DUCT, INSTRUMENT PANEL DEMISTER
REMOVAL
REMOVAL
damage.

REMOVAL .
3. Remove the retainer (1) that secures the driver side demister duct (2) to the instrument panel support (4).
4. Disconnect the driver side demister duct from the center distribution duct (3) and remove the duct.

5. Remove the retainer (1) that secures the passenger side demister duct (5) to the instrument panel support
(6).
6. Remove the retainer (2) that secures the passenger side demister duct to the passenger side instrument
panel duct (3).
7. Disconnect the passenger side demister duct from the center distribution duct (4) and remove the demister
duct.
INSTALLATION
INSTALLATION


1. Position the driver side demister duct (2) to the instrument panel support (4) and connect it to the
2. Install the retainer (1) that secures the driver side demister duct to the instrument panel support.
3. Position the passenger side demister duct (5) to the instrument panel support (6) and connect it to the
4. Install the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel
duct (3).
5. Install the retainer (1) that secures the passenger side demister duct to the instrument panel support.
6. Install the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, INSTALLATION .
HOUSING, HVAC
DESCRIPTION
DESCRIPTION


All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities
into a single unit mounted behind the instrument panel in the passenger compartment. The HVAC housing
assembly consists of the following:
HVAC housing - The HVAC housing (1) consists of three pieces that are attached together by molded
plastic retaining clips and screws. The HVAC housing contains the heater core, A/C evaporator and
blend-air and mode-air doors, and has mounting provisions for the air-door actuators, floor console duct
(when equipped with center floor console), blower motor, blower motor resistor or power module
(depending on the control application), foam seals and the HVAC wire harness.
Air inlet housing - The air inlet housing (2) is mounted to the right end of the HVAC housing and
contains the recirculation-air door and has mounting provisions for the recirculation door actuator.
The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air
that is allowed to flow through or around the heater core. The dual zone heating A/C system uses two blend
door actuators while the single zone system uses only one blend door actuator.
The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an H-block type A/C
expansion valve, evaporator and evaporator temperature sensor to cool and dehumidify the incoming air prior to
blending it with the heated air. The temperature control(s) determines the discharge air temperature by operating
the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the
output air temperature of the system. The mode door actuators operate the mode-air doors which direct the flow
of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door
actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already
inside the vehicle. The blower motor controls the velocity of air flowing through the HVAC housing assembly
by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor
resistor or power module (depending on application), which is located at the bottom of the HVAC housing. The
electric door actuators, blower motor resistor or power module, blower motor and evaporator temperature
sensor are connected to the vehicle electrical system by the HVAC wire harness.

The HVAC housing must be removed from the vehicle for service of the air inlet housing and disassembled for
service of the heater core, A/C evaporator and the blend-air and mode-air doors.
REMOVAL
AIR INLET HOUSING
or death.
Fig. 86: Air Inlet Housing


2. Disconnect the HVAC wire harness (1) from the recirculation door actuator (2).
3. Carefully disengage the two retaining tabs (4) that secure the rear of the air inlet housing (3) to the top of
the HVAC housing (5).

Fig. 87: Front Of The Air Inlet Housing

4. Carefully disengage the two retaining tabs (3) that secure the front of the air inlet housing (1) to the top of
the HVAC housing (2) and remove the inlet housing.
NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must
be replaced.
5. If required, disassemble the air inlet housing. Refer to HOUSING, HVAC, DISASSEMBLY.
HVAC HOUSING ASSEMBLY
or death.
NOTE: The HVAC housing must be removed from the vehicle for service of the A/C
evaporator, heater core, mode-air and blend-air doors and air inlet housing.

Fig. 88: HVAC Housing To Engine Compartment Side Of The Dash Panel Nuts

2. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD
PROCEDURE.
3. Drain the engine cooling system. Refer to STANDARD PROCEDURE .
4. Disconnect the A/C liquid line and the A/C suction line from the A/C expansion valve. Refer to LINE,
A/C LIQUID, REMOVAL.
5. Disconnect the heater hoses from the heater core tubes.
6. If required, remove the Powertrain Control Module (PCM) to gain access to the two nuts (2) that secure
the HVAC housing to the engine compartment side of the dash panel. Refer to MODULE,
POWERTRAIN CONTROL, REMOVAL or MODULE, POWERTRAIN CONTROL, 6.7L
DIESEL, REMOVAL .
7. Remove the two nuts from the studs (1) that secure the HVAC housing to the engine compartment side of
the dash panel.

Fig. 89: HVAC Housing To Floor Bracket Nuts

8. If equipped with center floor console, remove the floor console duct. Refer to DUCT, FLOOR
CONSOLE, REMOVAL.
9. Remove the instrument panel from the passenger compartment. Refer to PANEL, INSTRUMENT,
REMOVAL .
10. If equipped, remove the rear floor ducts. Refer to DUCT, FLOOR DISTRIBUTION, REAR,
REMOVAL.
11. Remove the bolt (3) that secures the HVAC housing (2) to the floor bracket.
12. Remove the two nuts (1) that secure the HVAC housing to the passenger compartment side of the dash
panel.
13. Pull the HVAC housing assembly rearward and remove the housing assembly from the passenger
compartment.
DISASSEMBLY
AIR INLET HOUSING
and isolate the battery negative (ground) cable, then wait two minutes for



2. Remove the air inlet housing (1) and place it on a workbench. Refer to HOUSING, HVAC,
REMOVAL.
3. Remove the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing and

NOTE: If the seal on the air inlet is deformed or damaged, the seal must be
replaced.

4. Carefully disengage the four retaining tabs (1 and 2) that secure the air inlet (3) to the top of the air inlet
housing (4) and remove the air inlet.
Fig. 92: Recirculation-Air Door

5. To remove the recirculation-air door (2) from the air inlet housing (3), first carefully release the actuator
coupler retaining tab (1) located on the inside of the air inlet housing.
Fig. 93: Actuator Coupler

6. With the actuator coupler retaining tabs released, pull the actuator coupler (1) out of the recirculation-air
door (2).


NOTE: If the seals on the air door or air inlet housing are deformed or damaged,
the air door or housing seal must be replaced.
7. Disengage the door pivot shaft (3) from the air inlet housing (2) and carefully remove the recirculation-air
door (1) from the housing.
HVAC HOUSING
NOTE: The HVAC housing must be removed from the vehicle and disassembled for
service of the A/C evaporator and the mode and blend-air doors.
Fig. 95: HVAC Wiring Harness

1. Remove the HVAC housing and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL.
2. Disconnect the HVAC wiring harness (1) from the recirculation door actuator (2), power module or
blower resister (3) (depending on application) and the blower motor (4).
3. Disengage the HVAC wiring harness from the two retaining clips (5) and position the harness out of the
way.
Fig. 96: Foam Seal

NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
4. Remove the foam seal (1) from the front of the HVAC housing (2).
5. If required, remove the two bolts (4) that secure the A/C expansion valve (5) to the evaporator tube
tapping block (3) and remove the valve.

Fig. 97: Blower Motor & Evaporator Housing

6. Remove the three screws (2 and 5) that secure the blower motor and evaporator housing (6) to the HVAC
housing (3).
7. Carefully disengage the nine retaining tabs (1 and 4) that secure the blower motor and evaporator housing
the HVAC housing.
8. Carefully separate the blower motor and evaporator housing from the HVAC housing
Fig. 98: A/C Evaporator

NOTE: If the foam insulator around the A/C evaporator is deformed or damaged,
the insulator must be replaced.

9. If required, remove the A/C evaporator (1) from the blower motor and evaporator housing (2).
10. If the A/C evaporator is going to be reused, remove and discard the O-ring seals from the evaporator
fittings and install plugs into, or tape over the evaporator ports.

11. If equipped with dual zone system, disconnect the HVAC wire harness connector (2) and remove the two
screws (4) that secure the blend door actuator (3) to the front of the HVAC housing (1) and remove the
actuator.
Fig. 100: HVAC Housing Seal

12. Remove the seal (1) from the flange (2) at the front of the HVAC housing.

Fig. 101: HVAC Housing Flange

13. Remove the two screws (3) that secure the flange (1) to the front of the HVAC housing (2).
14. Carefully disengage the retaining tab that secures the flange to the HVAC housing and remove the flange.
15. Carefully pull the heater core (4) out of the HVAC housing.
16. Inspect all foam seals and replace as required.
Fig. 102: HVAC Wire Harness To Evaporator Temperature Sensor, Blend Door Actuator & Mode
Door Actuators

17. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2), blend door actuator
(3) and mode door actuators (4 and 6).
18. Remove the HVAC wire harness from the HVAC housing (5).
19. Remove the evaporator temperature sensor from the HVAC housing.
20. Remove the screws that secure the blend and mode door actuators to the HVAC housing and remove the
actuators.
Fig. 103: HVAC Housing

NOTE: If the foam seals on top of the HVAC housing are deformed or damaged,
they must be replaced.
21. Carefully cut the foam seals (1) along the parting line (5) of the two halves of the HVAC housing (2 and
4).
22. Release the fourteen retaining tabs (3) that secure the two halves of the HVAC housing together and
carefully separate the housing.

Fig. 104: Mode Air Doors

23. Carefully disengage the mode air doors (1 and 2) from the actuator couplers (5) by pulling the doors
straight upward.
NOTE: If a seal on an air door is deformed or damaged, the air door must be
replaced.
24. Remove the mode air doors and the center partition (3), if equipped, from the rear half of the HVAC
housing (4).
Fig. 105: Blend Air Doors


NOTE: Dual zone system with two blend doors shown in illustration. Single zone
system with one blend door similar.
25. Carefully disengage the blend air door(s) (2), as equipped, from the actuator coupler(s) (3) by pulling the
door(s) straight upward.
replaced.
26. Remove the blend air door(s) from the HVAC housing (1).

NOTE: Typical actuator coupler shown in illustration.
27. Remove the actuator coupler(s) (1) from the HVAC housing (2), as required. Carefully release the three
retaining tabs (3) on each actuator coupler from the inside surface of the HVAC housing and push the
coupler(s) out of the housing.
ASSEMBLY
AIR INLET HOUSING


NOTE: If the seals on the air door or air inlet housing are deformed or damaged, the air
door or housing seal must be replaced.
1. Position the recirculation-air door (1) into the air inlet housing (2).
2. Engage the door pivot shaft (3) to the opening in the air inlet housing.

CAUTION: Make sure that the recirculation-air door pivot shaft is properly
seated in the pivot seat located in the air inlet housing.

3. Align the actuator coupler (1) with the recirculation door pivot shaft (2) and install the coupler until the
coupler retaining tab is fully engaged to the recirculation door. Be sure to install the coupler with the
coupler arm located between the two stop tabs on the air inlet housing.

NOTE: If the seal on the air inlet is deformed or damaged, the seal must be
replaced.
4. Position the air inlet (3) to the top of the air inlet housing (4) and engage the four retaining tabs (1 and 2).
Make sure the retaining tabs are fully engaged.


5. Install the recirculation door actuator (1) onto the side of the air inlet housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator output shaft (4) with those in the recirculation door

6. Install the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing (1).
Tighten the screws to 1.1 N.m (10 in. lbs.).
7. Install the air inlet housing. Refer to HOUSING, HVAC, INSTALLATION.
HVAC HOUSING
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.
NOTE: 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. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE.
NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of
refrigerant oil to the refrigerant system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
NOTE: Replacement of the O-ring seals is required anytime the A/C expansion valve is

removed from the A/C evaporator. Failure to replace the rubber O-ring seals
may result in a refrigerant system leak.

NOTE: Typical actuator coupler shown in illustration.
1. Install the actuator coupler(s) (1) into the HVAC housing (3), as required. Make sure the arm (2) on the
coupler is positioned between the two stops (4) on the HVAC housing. Make sure the three retaining tabs
on each actuator coupler are fully engaged to the inside surface of the HVAC housing.
Fig. 113: Blend Air Doors


NOTE: Dual zone system with two blend doors shown in illustration. Single zone
system with one blend door similar.
replaced.
2. Install the blend air door(s) (2), as equipped, onto the actuator coupler(s) (3). Align the keyway in the
blend air door pivot shaft with the key on the actuator coupler.
Fig. 114: Mode Air Doors

replaced.
3. Install the mode air doors (1 and 2) and the center partition (3), if equipped, to the rear half of the HVAC
housing (4). Align the keyways in the mode air door pivot shafts with the keys on the actuator couplers
(5). Align the dowel pins on the center partition to the holes in the HVAC housing.


4. Align the pivot shafts of the air doors to the holes in the HVAC housing halves (2 and 4).
5. Align the dowel pins on the rear half of the HVAC housing to the holes in the front half of the HVAC
housing and install the two halves of the housing together.
6. Carefully engage the fourteen retaining tabs (3). Make sure the retaining tabs are fully engaged.
NOTE: If the foam seals on top of the HVAC housing are deformed or damaged,
they must be replaced.
7. Inspect the foam seals (1), especially along the parting line (5) and replace as required.
Fig. 116: HVAC Wire Harness To Evaporator Temperature Sensor, Blend Door Actuator & Mode
Door Actuators

8. Install the blend and mode door actuators (3, 4 and 6) onto the HVAC housing (5). If necessary, rotate the
actuators slightly to align the splines on the actuator output shaft with those on the actuator coupler.
9. Install the screws that secure the blend and mode door actuators to the HVAC housing. Tighten the
10. Install the evaporator temperature sensor (2) onto the HVAC housing.
11. Connect the HVAC wire harness (1) to the evaporator temperature sensor and the blend and mode door
actuators.
12. Install the HVAC wire harness onto the HVAC housing. Make sure the wiring harness is routed correctly
and is fully engaged to the retaining clips.
Fig. 117: HVAC Housing Flange

NOTE: If the foam seals on the heater core are deformed or damaged, they must
be replaced.
13. Inspect the foam seals on the heater core (4) and replace as required.
14. Carefully install the heater core into the front of the HVAC housing (2).
15. Position the flange (1) onto the front of the HVAC housing. Make sure the retaining tab is fully engaged.
16. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 1.1 N.m (10
in. lbs.).

Fig. 118: HVAC Housing Seal

17. Install the foam seal (1) onto the flange (2) at the front of the HVAC housing.

18. If equipped with dual zone system, install the blend door actuator (3) onto the front of the HVAC housing
(1). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on
the actuator coupler.
19. Install the screws (4) that secure the blend door actuator to the HVAC housing. Tighten the screws to 1.1
N.m (10 in. lbs.).


21. Inspect the foam insulator on the A/C evaporator (1) and replace as required.
22. Carefully install the A/C evaporator into the blower motor and evaporator housing (2).

23. Carefully install the blower motor and evaporator housing (6) onto the HVAC housing (3). Align the
dowel pins to the holes in the housing.
24. Carefully engage the nine retaining tabs (1 and 4). Make sure the retaining tabs are fully engaged.

25. Install the three screws (2 and 5) that secure the blower motor and evaporator housing to the HVAC
housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
Fig. 122: Foam Seal

26. Remove the tape or plugs from the evaporator tube fittings.
27. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings.
Use only the specified O-ring seals 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.
28. Install the A/C expansion valve (5) onto the evaporator tube tapping block (3).
29. Install the two bolts (4) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten
the bolts to 11 N.m (97 in. lbs.).
30. Install the foam seal (1) onto the HVAC housing (2).


31. Connect the HVAC wiring harness (1) to the recirculation door actuator (2), power module or blower
resister (3) (depending on application) and the blower motor (4).
32. Engage the HVAC wiring harness to the two retaining clips (5). Make sure the wire harness is fully
engaged to the retaining clips.
NOTE: If the heater core is being replaced, flush the cooling system. Refer to
STANDARD PROCEDURE .
34. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. 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. Refer to OIL,
REFRIGERANT, STANDARD PROCEDURE. Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
INSTALLATION
AIR INLET HOUSING

Fig. 124: Front Of The Air Inlet Housing

NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be
replaced.
1. Position the air inlet housing (1) onto the top of the HVAC housing (2).
2. Engage the two retaining tabs (3) that secure the front of the air inlet housing to the HVAC housing.

3. Engage the two retaining tabs (4) that secure the rear of the air inlet housing (3) to the HVAC housing
(5).
4. Connect the HVAC wire harness (1) to the recirculation door actuator (2).

HVAC HOUSING ASSEMBLY
NOTE: When replacing multiple A/C system components, see the Refrigerant Oil
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime
a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and
metal gaskets could result in a refrigerant system leak.
Fig. 126: HVAC Housing To Floor Bracket Nuts

1. Position the HVAC housing assembly (2) into the passenger compartment and over the studs on the dash
panel, with the condensate drain tube in its proper location.
2. Install the two nuts (1) that secure the HVAC housing to the passenger compartment side of the dash
panel. Tighten the nuts to 6.8 N.m (60 in. lbs.).

3. Install the bolt (3) that secures the HVAC housing to the floor bracket. Tighten the bolt to 6.8 N.m (60 in.
lbs.).
4. If equipped, install the rear floor ducts. Refer to DUCT, FLOOR DISTRIBUTION, REAR,
INSTALLATION.
5. Install the instrument panel assembly. Refer to PANEL, INSTRUMENT, INSTALLATION .
6. If equipped with center floor console, install the floor console duct. Refer to DUCT, FLOOR
CONSOLE, INSTALLATION.
Fig. 127: HVAC Housing To Engine Compartment Side Of The Dash Panel Nuts
7. Install the two nuts (2) onto the two studs (1) that secure the HVAC housing to the engine compartment
side of the dash panel. Tighten the nuts to 6.8 N.m (60 in. lbs.).
8. If removed, install the powertrain control module (PCM). Refer to MODULE, POWERTRAIN
CONTROL, INSTALLATION or MODULE, POWERTRAIN CONTROL, 6.7L DIESEL,
INSTALLATION .
9. Connect the heater hoses to the heater core tubes.
10. Connect the A/C liquid line and the A/C suction line to the A/C expansion valve. Refer to LINE, A/C
LIQUID, INSTALLATION.
12. If the heater core is being replaced, flush the cooling system. Refer to STANDARD PROCEDURE .
13. Refill the engine cooling system. Refer to STANDARD PROCEDURE .
14. Evacuate the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.
refrigerant system. When replacing multiple A/C system components, see the Refrigerant Oil Capacities
chart to determine how much oil should be added to the refrigerant system. Refer to OIL,


16. Charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.
MOTOR, BLOWER
DESCRIPTION
DESCRIPTION
Fig. 128: Blower Motor, Blower Wheel, Harness Connector & Mounting Tabs
The blower motor (1) is used to control the velocity of air moving through the HVAC housing assembly by
spinning the blower wheel (2) at the selected or programmed speed (depending on control system application).
The blower motor is a 12-volt, direct current (DC) motor that is mounted within a plastic housing that has
integral wire harness connector (3), integral mounting tabs (4) and the squirrel cage-type blower wheel secured
to the blower motor shaft. The blower wheel is positioned within the air inlet housing on the passenger side end
of the HVAC housing assembly.
OPERATION
OPERATION
The blower motor is used to control the velocity of air moving through the HVAC housing assembly by
spinning the blower wheel within the air inlet housing at the selected or programmed speed (depending on
control system application).
On the Manual Temperature Control (MTC) heating-A/C system, blower motor speed is controlled by
regulating the path to ground through the blower control switch and the blower motor resistor. With the

Automatic Temperature Control (ATC) heating-A/C system, blower motor speed is controlled by an electronic
blower motor power module, which uses a pulse width modulated input from the A/C-heater control and a
feedback signal from the blower motor to regulate the blower motor ground path. On both systems, the blower
motor will operate whenever the ignition switch is in RUN and the blower motor control is in any position
except Off. The blower motor receives battery current through the Power Distribution Center (PDC) whenever
the ignition switch is in RUN.
The blower motor can be accessed for service from underneath the instrument panel.
NOTE: The blower motor is supplied with a 12V feed from the BCM whenever the
ignition switch is in RUN. Due to an open circuit condition within the blower
motor control switch the BCM is UNABLE to detect an OPEN circuit for the
blower motor.
The blower motor control system is diagnosed using a scan tool Refer to STANDARD PROCEDURE .
The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or
repaired and must be replaced if inoperative or damaged.
DIAGNOSIS AND TESTING - BLOWER MOTOR
NOTE: The blower motor is supplied with a 12V fused feed from the Power Distribution
Center (PDC), whenever the ignition switch is in the RUN position. Due to an
open circuit condition within the blower motor control switch the Body Control
Module (BCM) is UNABLE to detect an OPEN circuit for the blower motor.
To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the
negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. See
appropriate Wiring Information for circuit descriptions and diagrams.
OPERATION
Possible causes of an inoperative blower motor include:
Open fuse
Inoperative blower motor resistor

Inoperative blower motor switch

Inoperative blower motor
Inoperative blower motor circuit wiring or wire harness connectors
NOISE
To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To
verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and
operate the heater-A/C system. If the noise goes away, possible causes include:
Foreign material on fresh air inlet screen

Foreign material in blower wheel
Foreign material in HVAC housing
Improper blower motor mounting
Deformed or damaged blower wheel
Worn blower motor bearings or brushes
VIBRATION
Possible causes of a blower motor vibration include:
Improper blower motor mounting

Foreign material in blower wheel
Deformed or damaged blower wheel
Worn blower motor bearings
REMOVAL
REMOVAL
NOTE: The blower motor is located on the passenger side of the vehicle under the
instrument panel. The blower motor can be removed from the vehicle without
having to remove the HVAC housing assembly.

Fig. 129: Blower Motor


2. Disconnect the HVAC wire harness lead (3) from the blower motor (2).
3. Remove the three screws (1) that secure the blower motor to the bottom of the HVAC housing (4) and
remove the blower motor.
INSTALLATION
INSTALLATION
Fig. 130: Blower Motor

1. Position the blower motor (2) into the bottom of the HVAC housing (4).

2. Install the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7
N.m (15 in. lbs.).
3. Connect the HVAC wire harness lead (3) to the blower motor.
OUTLET, AIR
REMOVAL
FRONT CENTER AIR OUTLETS
NOTE: Take the proper precautions to protect the front face of the center bezel from
cosmetic damage during this procedure.
Fig. 131: Plastic Retaining Clips To Air Outlet


2. Remove the center bezel (1) from the instrument panel and place it on a workbench. Refer to BEZEL,
INSTRUMENT PANEL, CENTER, REMOVAL .
3. Using Trim Stick (special tool #C-4755, Trim Stick) (2) or equivalent, carefully disengage the eight
plastic retaining clips (4) that secure each air outlet (3) to the center bezel.

Fig. 132: Air Outlet

4. Lift the top of each air outlet (1) rearward and upward to disengage the bottom of each outlet from the
center bezel (2) and remove the outlet(s).
FRONT OUTER AIR OUTLETS
NOTE: The front outer instrument panel air outlets can be serviced separately. The
center instrument panel air outlets are serviced with the instrument panel
center bezel Refer to BEZEL, INSTRUMENT PANEL, CENTER, REMOVAL .

Fig. 133: Instrument Panel Air Outlet

NOTE: Driver side air outlet shown in illustration. Passenger side outlet similar.
1. Using Trim Stick (special tool #C-4755, Trim Stick) (1) or equivalent, carefully disengage the retaining
tabs that secure each outer instrument panel air outlet (2) to the instrument panel cover (3) and remove the
outlet.
2. If servicing the driver side air outlet, disconnect the head lamp switch wiring harness from the head lamp
switch (4) and if required, remove the switch from the outlet bezel. Refer to SWITCH, HEADLAMP,
REMOVAL .
REAR SEAT AIR OUTLETS

Fig. 134: Identifying Rear Air Outlet Housing

NOTE: Illustration shown with front seat cushions removed for clarity.
1. Remove the two screws (1) that secure the rear air outlet housing (2) to the rear of the front center seat
support (3).
2. Remove the rear air outlet housing and place it on a workbench.
Fig. 135: Identifying Rear Air Outlets

3. Using Tim Stick (special tool #C-4755, Trim Stick) or equivalent (1), disengage the retaining tabs that
secure the rear air outlets (2) to the rear air outlet housing (3) and gently pry the outlets from the housing
(3).
INSTALLATION
FRONT CENTER AIR OUTLETS
NOTE: Take the proper precautions to protect the front face of the center bezel from
cosmetic damage during this procedure.

Fig. 136: Center Air Outlet

1. Position the center air outlets (1) to the back of the instrument panel center bezel (2) and engage the
bottom of each outlet to the center bezel.
Fig. 137: Air Outlet

2. Carefully engage the eight plastic retaining clips (2) that secure each air outlet (1) to the center bezel (3).
Make sure the retaining clips are fully engaged.
INSTALLATION .
FRONT OUTER AIR OUTLETS

Fig. 138: Side Air Outlet

NOTE: Driver side air outlet shown in illustration. Passenger side outlet similar.
1. If required, install the head lamp switch (1) onto the air outlet (2). Refer to SWITCH, HEADLAMP,
INSTALLATION .
2. If servicing the driver side air outlet, connect the head lamp switch wiring harness to the head lamp
switch. Refer to SWITCH, HEADLAMP, INSTALLATION .
3. Position the air outlet to the opening in the instrument panel cover (3) and align the outlet to the
instrument panel duct.
4. Engage the retaining tabs that secure each air outlet to the instrument panel cover. Make sure the retaining
tabs are fully engaged.
REAR SEAT AIR OUTLETS
NOTE: The air outlets are retained into the air outlet housing by eight retaining tabs.
The air outlets must be first installed onto the bottom set of retaining tabs, then
the upper set of tabs can be engaged.

Fig. 139: Identifying Rear Air Outlets, Retaining Tabs, And Housing
1. Position the rear air outlets (1) to the back of the rear air outlet housing (2) and engage the lower set of
retaining tabs (3).
2. Gently engage the upper set of retaining tabs (4). Make sure all of the retaining tabs are fully seated.
Fig. 140: Identifying Rear Air Outlet Housing

NOTE: Illustration shown with front seat cushions removed for clarity.
3. Position the rear air outlet housing (2) to the rear of the front center seat support (3).

4. Install the two screws (1) that secure the rear air outlet housing to the center seat support. Tighten the
PLUMBING
WARNING
WARNING
WARNING: The A/C system contains refrigerant under high pressure. Repairs should
only be performed by qualified service personnel. Serious or fatal injury
may result from improper service procedures.
WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure
may irritate the eyes, nose, and/or throat. Wear eye protection when
servicing the A/C refrigerant system. Serious eye injury can result from
direct contact with the refrigerant. If eye contact occurs, seek medical
attention immediately.
WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created
when refrigerant is burned. An electronic leak detector is recommended.
Serious or fatal injury may result from improper service procedures.
WARNING: If accidental A/C system discharge occurs, ventilate the work area before
resuming service. Large amounts of refrigerant released in a closed work
area will displace the oxygen and cause suffocation and serious or fatal
injury.
WARNING: The evaporation rate of R-134a refrigerant at average temperature and

altitude is extremely high. As a result, anything that comes in contact with
the refrigerant will freeze. Always protect the skin or delicate objects from
direct contact with the refrigerant.
WARNING: The R-134a service equipment or the vehicle refrigerant 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 property damage and serious or fatal injury.
WARNING: The engine cooling system is designed to develop internal pressures up

to 145 kPa (21 psi). Do not remove or loosen the coolant pressure cap,
cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or
hose clamps while the engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 minutes before opening the

cooling system for service. Failure to observe this warning can result in
serious burns from the heated engine coolant.
CAUTION
CAUTION
CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use
R-12 equipment or parts on an R-134a A/C system. These refrigerants are
not compatible and damage to the A/C system will result.
CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a
refrigerant oil. These refrigerant oils are not compatible and damage to the
A/C system will result.
CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or A/C system. Many
federal, state/provincial and local regulations prohibit the recharge of A/C
systems with known leaks. Chrysler LLC recommends the detection of A/C
system leaks through the use of approved leak detectors and fluorescent
leak detection dyes. Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the entire A/C refrigerant
system is recommended. A/C systems found to be contaminated with A/C
system sealers, A/C stop-leak products or seal conditioners voids the
warranty for the A/C system.
CAUTION: Recover the refrigerant before opening any fitting or connection. Open the
fittings with caution, even after the system has been discharged. Never
open or loosen a connection before recovering the refrigerant.
CAUTION: If equipped, do not remove the secondary retention clip from any spring-
lock coupler connection while the refrigerant system is under pressure.
Recover the refrigerant before removing the secondary retention clip.
Open the fittings with caution, even after the system has been discharged.
Never open or loosen a connection before recovering the refrigerant.
CAUTION: 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. Before disconnecting a component, clean the outside of
the fittings thoroughly to prevent contamination from entering the
refrigerant system. Keep service tools and the work area clean. Do not
open the refrigerant system or uncap a replacement component until you
are ready to service the system. Immediately after disconnecting a

component from the refrigerant system, seal the open fittings with a cap or
plug. This will prevent contamination from entering the A/C system.
CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped.
Do not open a container of refrigerant oil until you are ready to use it.
Replace the cap on the oil container immediately after using. Store
refrigerant oil only in a clean, airtight, and moisture-free container.
CAUTION: Do not overcharge the refrigerant system. Overcharging will cause

excessive compressor head pressure and can cause compressor noise
and A/C system failure.
DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS
WARNING: Review the safety precautions and warnings before performing this
or death.
WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created
when refrigerant is burned. An electronic leak detector is recommended.
Serious or fatal injury may result from improper service procedures.
WARNING: Use extreme care when working around a running engine. Keep hands
and fingers clear of the radiator fan, accessory drive belt and all other
moving components. Keep away when wearing loose clothing, jewelry or
long hair that is not properly secured. Underhood components may
become hot to the touch. Be careful not to come into contact with hot
engine, A/C and engine cooling system components. Failure to follow
these instructions may result in serious or fatal injury.
NOTE: Always conduct the A/C Performance Test as outlined in this test prior to
searching for an A/C refrigerant leak. Refer to DIAGNOSIS AND TESTING.
NOTE: The A/C system in this vehicle comes equipped from the factory with
fluorescent refrigerant leak detection dye installed in the refrigerant system.
When searching for a refrigerant leak in the A/C system, use an Ultra Violet (UV) light and an electronic leak
detector that is designed for refrigerant used on this vehicle. It is important to use only high-quality refrigerant
leak detection equipment to properly locate refrigerant system leaks, such as the equipment listed in the team
PSE Service Equipment Catalog. When the use of additional leak detection dye is required, use only Chrysler
LLC approved refrigerant leak detection dye, available through Mopar®.
LEAK TEST

1. Begin searching for refrigerant leaks using a high quality UV light to detect the fluorescent refrigerant
leak detection dye.
Inspect all connections, plumbing fittings, brazed joints, hoses, hose crimps, service ports,
compressor housing, pressure relief valve and A/C condenser for dye
Inspect the evaporator drain tube and condensate for presence of dye, which indicates a leak from
the A/C evaporator
If equipped with rear A/C, inspect the underbody refrigerant lines, fittings, rear evaporator drain
tube and condensate for presence of dye, which indicates a leak from the rear evaporator
If no leaks are found using a UV light, proceed to step 2 .
2. If a leak is not found with the leak detection dye, operate the heating and A/C system with the engine at
idle under the following conditions for at least 15 minutes, then proceed to step 3 .
Doors or windows open
Transmission in Park or Neutral with the parking brake set (depending on transmission application)
A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C compressor
engaged (If the A/C compressor does not engage, go to LOW OR EMPTY REFRIGERANT
SYSTEM.
If equipped with rear A/C, set rear controls to full cool and high blower
3. Shut the vehicle off and wait at least 5 minutes.
4. Insert the leak detector into the evaporator drain tube and the instrument panel air outlets, to check for
evaporator leaks. Check the evaporator tubes at the A/C expansion valve, for leaks not visible behind the
expansion valve. Check around the front of the A/C compressor, for compressor shaft seal leaks. Check
between the A/C condenser and radiator for condenser leaks not previously visible.
5. If equipped with rear A/C, insert the leak detector into the rear evaporator drain tube and rear air outlets.
Check the underbody A/C lines and fittings, evaporator tubes and rear A/C expansion valve.
LOW OR EMPTY REFRIGERANT SYSTEM
NOTE: This procedure should only be done after an A/C Performance Test has been
conducted and a refrigerant system leak has NOT been found using the factory
installed leak detection dye.
Do the following if the A/C compressor will not engage and a refrigerant leak in the A/C system is suspected.
but cannot be found using the factory installed leak detection dye.
1. Recover, evacuate and recharge the refrigerant system. Refer to PLUMBING, STANDARD
PROCEDURE.
2. Operate the heating and A/C system with the engine at idle under the following conditions for at least 15
minutes.
Doors or windows open
Transmission in Park or Neutral with the parking brake set (depending on transmission application)
A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C compressor
engaged

If equipped with rear A/C, set rear controls to full cool and high blower
3. Shut the vehicle off and return to. Refer to LEAK TEST.
STANDARD PROCEDURE
REFRIGERANT SYSTEM RECOVERY
Fig. 141: Identifying R-134a Refrigerant Recovery/Recycling/Charging Station

The R-134a refrigerant must be recovered from the A/C system prior to performing any repairs that require
disconnection of an A/C refrigerant line.
When recovering the A/C refrigerant system, use an R-134a refrigerant recovery/recycling/charging station (1)
that meets SAE standard J2788. Per SAE standard J2788, refrigerant recovery stations must recover 95% of the
refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant
removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the
equipment manufacturer for proper care and use of this equipment.
NOTE: A/C system should be tested prior to refrigerant recovery if the use of A/C
system sealants are suspected. These sealants have the potential to clog
refrigerant recovery equipment and cause vehicle A/C component damage.
Various tool manufacturers make tool kits that detect A/C system sealants. See
the operating instructions supplied by the equipment manufacturer for proper
care and use of this equipment.
If sealants are detected in an A/C system, the system should be treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers,
A/C stop-leak products or seal conditioners void the warranty for the A/C system.
RECOVERY PROCEDURE

WARNING: Review the safety precautions and warnings in this test before performing
this procedure. Failure to follow these instructions may result in serious
injury or death.
CAUTION: Various aftermarket manufacturers produce A/C system sealants that are
designed to stop A/C refrigerant system leaks. The use of A/C system
sealants may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or the vehicle A/C system
and are not recommended for use by Chrysler LLC.
CAUTION: A small amount of refrigerant oil is removed from the A/C system each
time the refrigerant system is recovered and evacuated. Before charging
the A/C system, you MUST replenish any oil lost during the recovery
process. See the equipment manufacturer instructions for more
information.
1. If use of aftermarket A/C system sealant is suspected, the A/C system should be tested for sealant prior to
refrigerant system recovery. See the operating instructions supplied by the equipment manufacturer for
proper use and care of this equipment.
2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the
refrigerant system.
3. Recover the A/C refrigerant system following the operating instructions supplied by the
recovery/recycling/charging station manufacturer.
4. Disconnect the refrigerant recovery/recycling/charging station from the refrigerant system service ports.
5. Reinstall the caps onto the refrigerant system service ports.
REFRIGERANT SYSTEM EVACUATE


If the A/C refrigerant system has been open to the atmosphere, it must be evacuated before the A/C system can
be recharged with R-134a refrigerant.
NOTE: Special effort must be used to prevent moisture from entering the A/C system
oil. Moisture in the oil is very difficult to remove and will cause a reliability
problem with the A/C compressor.
Moisture and air in the A/C refrigerant system will raise the compressor head pressure above acceptable
operating levels. This will reduce the performance of the A/C system and damage the A/C compressor.
Moisture will boil at near room temperature when exposed to vacuum. Always use an R-134a refrigerant
recovery/recycling/charging station with a vacuum pump (1) that meets SAE standard J2788, or an R-134a
compatible manifold gauge set and a stand-alone vacuum pump.
If an A/C compressor is left open to the atmosphere for an extended period of time, it is recommended that the
refrigerant oil in the compressor be drained and replaced with new refrigerant oil to reduce the possibility of
contaminating the refrigerant system. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE.
EVACUATION PROCEDURE
injury or death.
information.
1. Recover the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.
NOTE: When connecting service equipment couplers to refrigerant line service

ports, verify that the valve of each coupler is fully closed prior to
connecting. This will reduce the amount of effort required to make the
connections.
2. Connect an R-134a refrigerant recovery/recycling/charging station with a vacuum pump that meets SAE
standard J2788 to the refrigerant system, or an R-134a compatible manifold gauge set and a stand-alone
vacuum pump (depending on available equipment).
3. Open the refrigerant recovery/recycling/charging station or manifold gauge set valves and start the
vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to recharge to eliminate all
moisture in system. When the low-side gauge reads to the lowest degree of vacuum possible
(approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum
pump. If the refrigerant system fails to reach specified vacuum, the refrigerant system likely has a leak
that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start
the vacuum pump, open the valves and allow the refrigerant system to evacuate an additional 10 minutes.

4. Close the refrigerant recovery/recycling/charging station or manifold gauge set valves. Turn off and
disconnect the vacuum pump.
5. Disconnect the refrigerant recovery/recycling/charging station or manifold gauge set from the refrigerant
system service ports.
6. Install the caps onto the refrigerant system service ports.
REFRIGERANT SYSTEM CHARGE

After all A/C refrigerant system repairs have been completed and the refrigerant system has been evacuated, the
A/C system can be recharged with R-134a refrigerant.
When charging the A/C system, use an R-134a refrigerant recovery/recycling/charging station (1) that meets
SAE standard J2788. Per SAE standard J2788, refrigerant recovery stations must charge the system to an
accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment manufacturer for
proper care and use of this equipment.
CHARGING PROCEDURE
injury or death.
information.
1. Recover and evacuate the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.

2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the
refrigerant system.
3. When required, adjust the refrigerant oil level. Refer to OIL, REFRIGERANT, STANDARD
PROCEDURE.
NOTE: A/C system refrigerant capacity can be found on the HVAC Specification
Label, located in the engine compartment.
4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. Refer to
REFRIGERANT, SPECIFICATIONS. See the operating instructions supplied by the equipment
manufacturer for proper use of this equipment.
5. Open both the low and high side valves, then open the charge valve to allow the heated refrigerant to flow
into the refrigerant system.
6. When the transfer of refrigerant has stopped, close the valves.
WARNING: Take care not to open the high side (high pressure) valve while
performing Step 7. Failure to follow these instructions may result in
possible serious or fatal injury.
7. Perform the following if all of the refrigerant charge did not transfer from the dispensing device:
Open all of the windows in the vehicle.
Set the heating and A/C system so that the A/C compressor is operating and the blower motor is
operating at its lowest speed setting.
Run the engine at a steady high idle (about 1400 RPM).
If the A/C compressor does not operate, test the compressor control circuits and repair as required.
Open the low side valve and the charge valve to allow the remaining refrigerant to flow into the
refrigerant system.
When the transfer of refrigerant has stopped, close the valves.
8. Disconnect the refrigerant recovery/recycling/charging station from the refrigerant system service ports.
9. Reinstall the caps onto the refrigerant system service ports.
COMPRESSOR, A/C
DESCRIPTION
A/C CLUTCH

Fig. 144: A/C Compressor Clutch Components

NOTE: Typical A/C clutch assembly shown in illustration.
The A/C compressor clutch assembly consists of a stationary electromagnetic field coil (4), bearing and pulley
assembly (3), shims (7) and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1).
These components provide the means to engage and disengage the A/C compressor from the engine accessory
drive belt.
The A/C clutch bearing and pulley assembly is retained to the front of the compressor with a snap ring (6). The
A/C clutch field coil is also retained to the front of the compressor using a snap ring (5).
A/C COMPRESSOR

Fig. 145: A/C Compressor

The A/C system on models equipped with the 3.6L engine, use a Visteon RS-18 A/C compressor. This A/C
compressor has a fixed displacement of 180 cubic centimeters (11 cubic inches).
The A/C system on models equipped with the 4.7L engine, use the Denso 10SRE15 A/C compressor (1). This
A/C compressor has a fixed displacement of 150 cubic centimeters (9.2 cubic inches).
The A/C system on models equipped with the 5.7L engine, use the Denso 10SRE18 A/C compressor. This A/C
compressor has a fixed displacement of 180 cubic centimeters (11 cubic inches).
All A/C compressors are ten cylinder, reciprocating swash plate type compressors with the suction and
discharge ports (2) located on the compressor cylinder head (3) and have a label identifying the use of R-134a
refrigerant.
HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the A/C compressor. This mechanical valve is designed to vent
refrigerant from the A/C system to protect against damage to the A/C compressor and other A/C system
components, caused by condenser air flow restriction or an overcharge of refrigerant.
OPERATION
A/C CLUTCH
The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from
the engine accessory drive belt. When the electromagnetic A/C clutch coil is energized, it magnetically draws
the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the A/C clutch coil is
not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.

A/C clutch engagement is controlled by the Powertrain Control Module (PCM) or Engine Control Module
(ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a
request signal on the CAN-B bus to the Body Control Module (BCM), which then transfers the request on the
CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement.
When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit
back to the BCM to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side
driver provides battery current to the A/C clutch coil.
The A/C clutch control system is diagnosed using a scan tool or (Refer to DIAGNOSIS AND TESTING .
The A/C clutch components cannot be repaired and must be replaced if inoperative or damaged.
A/C CLUTCH
The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from
the engine accessory drive belt. When the electromagnetic A/C clutch coil is energized, it magnetically draws
the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the A/C clutch coil is
not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.
A/C clutch engagement is controlled by the Powertrain Control Module (PCM) or Engine Control Module
(ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a
request signal on the CAN-B bus to the Totally Integrated Power Module (TIPM), which then transfers the
request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C
clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated
hard-wired circuit back to the TIPM to energize the internal A/C clutch high side driver. When energized, the
A/C clutch high side driver provides battery current to the A/C clutch coil.
The A/C clutch control system is diagnosed using a scan tool or (Refer to DIAGNOSIS AND TESTING . .
The A/C clutch components cannot be repaired and must be replaced if inoperative or damaged.
A/C COMPRESSOR
The A/C compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. The
A/C compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the
refrigerant.
The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction port.
It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is then
pumped to the A/C condenser through the compressor discharge port.
CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C
compressor. Failure to properly adjust the refrigerant oil level can prevent
the A/C system from operating as designed and can cause serious A/C
compressor damage.
The A/C compressor cannot be repaired and must be replaced if inoperative or damaged. The compressor

clutch, pulley and bearing assembly, and clutch field coil are available for service. If an internal failure of the
A/C compressor has occurred, the A/C condenser must also be replaced. Refer to CONDENSER, A/C,
REMOVAL.
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135
kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge
pressure of 2756 kPa (400 psi) is reached.
The high pressure relief valve should not open when the A/C system is operating correctly. If the high pressure
relief valve vents refrigerant, there is most likely a problem within the A/C refrigerant system. The high
pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. If
the high pressure relief valve vents refrigerant, see the A/C System Diagnosis chart. Refer to DIAGNOSIS
AND TESTING.
The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed
or otherwise disturbed. The valve is only serviced as a part of the A/C compressor.
A/C CLUTCH COIL
The A/C clutch coil electrical circuit is controlled by the Powertrain Control Module (PCM) or Engine Control
Module (ECM), depending on engine application, through the Body Control Module (BCM). See SYSTEM
WIRING DIAGRAMS for complete HVAC wiring diagrams. Begin testing of a suspected A/C clutch coil
problem by performing the preliminary checks.
PRELIMINARY CHECKS
1. Using a scan tool, check for Diagnostic Trouble Codes (DTCs) in the A/C-heater control, BCM and
PCM/ECM. If no DTCs are found, go to Step 2. If any DTCs are found, repair as required.
2. If the A/C clutch still will not engage, verify the refrigerant charge level by conducting the A/C
Performance test. Refer to DIAGNOSIS AND TESTING. If the refrigerant charge level is OK, go to
COIL RESISTANCE TEST and COIL CURRENT DRAW TEST If the refrigerant charge level is not
OK, adjust the refrigerant charge as required.
COIL RESISTANCE TEST

2. Disconnect the wire harness connector from the A/C clutch coil connector.
3. Use an ohm meter and Back Probe Tool (special tool #6801, Terminal Probe) and measure the resistance
of the A/C clutch coil at the coil connector terminals.
4. See A/C CLUTCH COIL SPECIFICATIONS for acceptable A/C clutch coil resistance. Specifications
apply for a work area temperature of 21° C (70° F).
a. If the A/C clutch coil reading is below specifications, the coil is shorted and must be replaced.

b. If the A/C clutch coil reading is above specifications, the coil is open and must be replaced.
COIL CURRENT DRAW TEST
1. Verify the battery state of charge.

2. Connect an ammeter (0 to 10 ampere scale selected) in series with the A/C clutch coil feed terminal using
Back Probe Tool (special tool #6801, Terminal Probe). Connect a voltmeter (0 to 20 volt scale selected)
to measure voltage across the battery and the A/C clutch coil.
3. With the A/C-heater control in the A/C mode and the blower motor at low speed, start the engine and
allow it to run at a normal idle speed.
4. The A/C clutch should engage immediately and the clutch coil supply voltage should be within two volts
of the battery voltage. If the clutch coil supply voltage is OK, go to 5 . If the coil supply voltage is not
within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as
necessary.
5. See A/C CLUTCH COIL SPECIFICATIONS for acceptable A/C clutch coil current draw.
Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add
electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.
a. If the A/C clutch coil current reading is zero, the coil is open and must be replaced.
b. If the A/C clutch coil current reading is above specifications, the coil is shorted and must be
replaced.
A/C CLUTCH COIL SPECIFICATIONS

Coil Resistance Coil Current Draw
3.6 ± 0.2 ohms 3.2 - 3.3 amps @ 12V ± 0.5V @ 21° C (70° F)
A/C SYSTEM NOISE
When investigating an A/C system related noise, you must first know the conditions under which the noise
occurs. These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed, engine
temperature, and any other special conditions. Noises that develop during A/C operation can often be
misleading. For example: What sounds like a failed front engine bearing or connecting rod, may be caused by
loose bolts, nuts, mounting brackets or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and depending upon drive belt tension, drive belts
can develop noises that are mistaken for an A/C compressor noise. Improper drive belt tension can cause a
misleading noise when the compressor clutch is engaged, which may not occur when the compressor clutch is
disengaged. Check the accessory drive belt condition and tension before beginning this procedure see ENGINE
COOLING SYSTEM - RAM PICKUP .
1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Turn the A/C
compressor On and Off several times to clearly identify the compressor noise. Listen to the A/C
compressor while the clutch is engaged and disengaged. Probe the A/C compressor with an engine
stethoscope or a long screwdriver with the handle held to your ear to better localize the source of the
noise.
2. Loosen all of the compressor mounting hardware and retighten. Check the compressor clutch retainer. Be

certain that the A/C clutch coil is mounted securely to the A/C compressor, and that the clutch plate and
pulley are properly aligned and have the correct air gap. Refer to COMPRESSOR, A/C, STANDARD
PROCEDURE.
3. To duplicate high-ambient temperature conditions (high head pressure), restrict the air flow through the
A/C condenser. Install a manifold gauge set or a scan tool to be certain that the discharge pressure does
not exceed 2760 kPa (400 psi).
4. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause
unusual noises. Also check the refrigerant lines and hoses for kinks or sharp bends that will restrict
refrigerant flow, which can cause noises.
5. If the noise is from opening and closing of the high pressure relief valve, recover, evacuate and recharge
the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.
6. If the high pressure relief valve still does not seat properly, replace the A/C compressor. Refer to
COMPRESSOR, A/C, REMOVAL.
STANDARD PROCEDURE
STANDARD PROCEDURE - A/C CLUTCH INSPECTION
NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can
remain fully-charged during compressor clutch, pulley and bearing assembly,
or coil replacement.
Fig. 146: Identifying Compressor Shaft, Clutch Plate & Shim

Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should

be replaced if there is excessive wear or scoring.
If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If
refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced.
Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing
assembly, if required.
REMOVAL
A/C CLUTCH
NOTE: The compressor clutch assembly can be serviced with the refrigerant system
fully-charged.
NOTE: Typical A/C compressor and clutch assembly shown in illustrations.
Fig. 147: Locating A/C Compressor Shaft Bolt


2. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .
3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top
of the A/C compressor (5).
4. Remove the fasteners that secure the A/C compressor to the engine and support the A/C compressor.
Refer to COMPRESSOR, A/C, REMOVAL.

5. Carefully remove the compressor clutch coil connector and wire lead from the connector bracket (2).
6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to
hold the clutch plate (4) from rotating during bolt removal.

CAUTION: Do not pry between the clutch plate and the pulley and bearing
assembly to remove the clutch plate from the compressor shaft as
this may damage the clutch plate.
NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate,
as they may be reused during the clutch plate installation process.
7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft
(1) and remove the clutch plate and shim(s) (3).

Fig. 149: Clutch Pulley & Snap Ring

8. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, remove the
snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and
remove the pulley and bearing assembly.
Fig. 150: Clutch Coil And Snap Ring

9. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, remove the
snap ring (4) that secures the compressor clutch coil (2) to the front of the A/C compressor (3) and
remove the field coil.

5.7L ENGINE
or death.
NOTE: The A/C compressor may be removed and repositioned without disconnecting
the refrigerant lines or discharging the refrigerant system.
Fig. 151: Accessory Drive Belt


PROCEDURE.
3. Remove the accessory drive belt (5). Refer to BELT, SERPENTINE, REMOVAL .
4. Disengage the plastic refrigerant line bracket from the upper front of the engine. Refer to LINE, A/C
DISCHARGE, REMOVAL.
6. Disconnect the engine wire harness connector from the A/C compressor (4).
7. Remove the nuts (2) that secure the A/C suction line (1) and the A/C discharge line (3) to the A/C
compressor.
8. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-
ring seals and gaskets.
9. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.


10. Remove the three bolt (1 and 2) that secure the A/C compressor (3) to the engine and remove the
compressor.
6.7L DIESEL ENGINE
or death.
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 engine.

Fig. 153: Nuts, A/C Compressor, A/C Suction Line & A/C Discharge Line
NOTE: Illustration shown with lower radiator hose removed for clarity.

PROCEDURE.
3. Remove the air filter housing.
4. Remove the turbocharger outlet tube.
5. Remove the nuts (1) that secure the A/C suction line (3) and the A/C discharge line (4) to the A/C
compressor (2).
6. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-
ring seals and gaskets.
7. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.

8. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL .

9. Disconnect the engine wire harness (1) from the A/C clutch coil connector (5).
10. Remove the three bolts (4) that secure the A/C compressor (3) to the mounting bracket (2) and remove the
compressor.
INSTALLATION
A/C CLUTCH

NOTE: Typical A/C compressor and clutch assembly shown in illustrations.
Fig. 155: Clutch Coil And Snap Ring

1. Align the dowel pin on the back of the compressor clutch coil (2) with the hole in the front of the A/C
compressor (3) and position the coil onto the compressor. Be certain that the compressor clutch coil wire
lead is properly routed so that it is not pinched between the A/C compressor and the coil.
CAUTION: The snap ring must be fully and properly seated in the groove or it
will vibrate out, resulting in a clutch failure and severe damage to the
A/C compressor.
NOTE: A new snap ring must be used to secure the compressor clutch field coil
to the A/C compressor. The bevel side of the snap ring must face outward
and both snap ring eyelets must be oriented to the right or to the left of the
field coil dowel pin location on the A/C compressor.
2. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, install the snap
ring (4) that secures the compressor clutch coil to the front of the A/C compressor. Be certain that the
snap ring is fully and properly seated in the groove and oriented correctly.

Fig. 156: Identifying Pulley & Bearing Assembly

CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not
damaged during A/C compressor pulley and bearing installation.
CAUTION: When installing the pulley and bearing assembly, DO NOT mar the
friction surfaces of the pulley or premature failure of the A/C clutch
will result.
3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the
pulley gently with a block of wood (2) placed on the pulley friction surface.

Fig. 157: Clutch Pulley & Snap Ring

CAUTION: The snap ring must be fully and properly seated in the groove or it
will vibrate out, resulting in a clutch failure and severe damage to the
A/C compressor.
NOTE: A new snap ring must be used to secure the pulley and bearing assembly
to the A/C compressor. The bevel side of the snap ring must face outward.
4. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, install the snap
ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain
that the snap ring is fully and properly seated in the groove.


5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim
(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being
used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.
Fig. 159: Locating A/C Compressor Shaft Bolt

6. Install the clutch plate (4) onto the front of the A/C compressor (5).
7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 in. lbs.).
NOTE: The shims may compress after tightening the shaft bolt. Check the air gap
in four or more places to verify the air gap is correct. Spin the pulley
before performing a final check of the air gap.
NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire
gap gauge to measure the clutch air gap. On other models, use a blade
type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate
and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If
the air gap is not between specifications, add or subtract shims as needed until the correct air gap is
obtained.
CAUTION: Be certain that the A/C clutch coil wire harness is properly routed so
that it is not pinched between the A/C compressor and the coil
connector bracket.
9. Carefully route the compressor clutch coil wire lead behind the connector bracket (2).
10. Install the compressor clutch coil connector (1) onto the connector bracket.
11. Position the A/C compressor to the engine and install the fasteners. Refer to COMPRESSOR, A/C,
INSTALLATION.
12. Connect the engine wire harness to the compressor clutch coil connector.
13. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
5.7L ENGINE
CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant
system oil level. Failure to properly adjust the refrigerant oil level will
CAUTION: The A/C condenser must be replaced if an internal failure of the A/C
compressor has occurred. Failure to replace the A/C condenser can cause
serious damage to the replacement A/C compressor.
Capacities chart to determine how much oil should be removed from the new

A/C compressor. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE.

1. If the A/C compressor (3) is being replaced, the refrigerant oil in the old compressor must be first drained
and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor
must be refilled with the same amount of new refrigerant oil that was drained out of the old 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. Refer to OIL, REFRIGERANT,
STANDARD PROCEDURE. Use only refrigerant oil of the type recommended for the A/C compressor
in the vehicle.
2. Position the A/C compressor to the engine.
3. If removed, install and securely tighten the two studs (3) that secure the A/C compressor to the engine.
4. Loosely install the three bolts (1 and 2) that secure the A/C compressor to the engine.
5. Tighten each of the bolts to 28 N.m (21 ft. lbs.) using the following sequence:
Upper bolt at front of compressor.
Lower bolt at front of compressor.
Bolt at rear of compressor.
6. Connect the engine wire harness connector to the A/C compressor.


7. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
8. Lubricate new O-rings with clean refrigerant oil and install them and new gaskets onto the refrigerant line
fittings. Use only the specified O-ring seals 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.
9. Install the A/C discharge line (3) and the A/C suction line (1) onto the A/C compressor (4).
10. Install the nuts (2) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the
nuts to 23 N.m (17 ft. lbs.).
12. Engage the plastic refrigerant line bracket to the upper front of the engine. Refer to LINE, A/C
DISCHARGE, INSTALLATION.
13. Install the accessory drive belt (5). Refer to BELT, SERPENTINE, INSTALLATION .
15. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE.
6.7L DIESEL ENGINE
CAUTION: If the A/C compressor is being replaced, be certain to adjust the refrigerant
system oil level. Failure to properly adjust the refrigerant oil level will

Capacities chart to determine how much oil should be removed from the new
A/C compressor. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE.

1. If the A/C compressor (2) is being replaced, the refrigerant oil in the old compressor must be first drained
and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor
must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor.
When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine
how much oil should be added to the refrigerant system. Refer to OIL, REFRIGERANT, STANDARD
PROCEDURE. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor (3) to the mounting bracket (2) and loosely install the three bolts (4) that
secure the compressor to the bracket.
3. Tighten each of the bolts to 28 N.m (21 ft. lbs.) using the following sequence:
Upper bolt at front of compressor.
Lower bolt at front of compressor.
Bolt at rear of compressor.
4. Connect the engine wire harness (1) to the A/C clutch coil connector (5).
5. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .

6. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
7. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant
line fittings. Use only the specified O-ring seals 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.
8. Connect the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (2).
9. Install the nuts (1) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the
nuts to 23 N.m (17 ft. lbs.).
10. Install the turbocharger outlet hose.
11. Install the air filter housing.
CONDENSER, A/C
DESCRIPTION
DESCRIPTION
NOTE: Gasoline engine model A/C condenser shown in illustration. Diesel engine
model similar.

Fig. 164: Identifying A/C Condenser

The A/C condenser (1) is located at the front of the engine compartment, behind the grille. The A/C condenser
is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to
give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a
liquid state.
The A/C condenser has an integral A/C receiver/drier (2), tapping blocks for the A/C refrigerant lines (3 and 4)
and connections for the integral automatic transmission cooler (5), when equipped.
OPERATION
OPERATION
When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C
condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-
pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance
of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille
openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow.
Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser
service.

The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on
the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and
gaskets must be replaced whenever a refrigerant line is disconnected from the A/C condenser.
The A/C condenser cannot be repaired and must be replaced if leaking or damaged.
REMOVAL
3.6L/4.7L/5.7L ENGINES
or death.
NOTE: Illustration shown with radiator removed for clarity.
Fig. 165: A/C Condenser/Transmission Combination Cooler, Lines, Bolts & Brackets

PROCEDURE.
3. Remove the radiator closure panel. Refer to PANEL, CLOSURE, RADIATOR, REMOVAL .
4. Remove the grille. Refer to GRILLE, REMOVAL .
5. If equipped, disconnect the automatic transmission cooler lines (11) from the transmission cooler. Refer
to TUBES AND HOSES, TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
6. Remove the bolt (8) that secures the condenser jumper line tapping block (7) to the right side of the
radiator (5).
7. Remove the bolts (4 and 9) that secure the refrigerant jumper lines to the A/C condenser (3).

8. Disconnect the jumper lines from the A/C condenser and remove and discard the dual plane seals.
9. Remove the three bolts that secure the condenser mounting brackets (1, 6 and 10) and remove the
brackets.
10. Disengage the lower left condenser mounting bracket (2) from the radiator and remove the A/C
condenser.
11. Install plugs in, or tape over the opened jumper line fittings and condenser ports.
6.7L DIESEL ENGINE
or death.
NOTE: A/C condenser for manual transmission model shown in illustration. Shown
with front fascia removed for clarity. Automatic transmission model similar.
PROCEDURE.
2. Remove the front bumper. Refer to BUMPER, FRONT, REMOVAL .
Fig. 166: Air Deflector, Hood Latch And Retainers Clips & Push Pins
3. If necessary, detach the hood cable from hood latch and retainers clips (2).
4. If necessary, remove push pins (3) and air deflector (1).
5. If equipped, disconnect the automatic transmission cooler lines from the transmission fluid cooler fittings
located at each end of the A/C condenser (1). Refer to TUBES AND HOSES, TRANSMISSION OIL
COOLER, STANDARD PROCEDURE .

Fig. 167: A/C Condenser Securing Bolts

6. Remove the bolts (6 and 8) that secure the A/C liquid line (5) and the A/C discharge line (9) from the A/C
condenser.
7. Disconnect the A/C liquid and discharge lines from the A/C condenser and remove and discard the O-ring
seals and gaskets.
8. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports.
9. Remove the four bolts (2, 7 and 10) that secure the A/C condenser to the charge air cooler.
10. Remove the A/C condenser from the engine compartment.
11. If required, remove the four bolts (4) that secure the four retaining brackets (3) to the A/C condenser and
remove the brackets. Replace the rubber isolators if necessary.
INSTALLATION
3.6L/4.7L/5.7L ENGINES

NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of
NOTE: Illustration shown with radiator removed for clarity.
Fig. 168: A/C Condenser/Transmission Combination Cooler, Lines, Bolts & Brackets
1. Position the A/C condenser (3) to the front of the radiator (5) and engage the lower left condenser
mounting bracket (2) to the radiator.
2. Install the condenser mounting brackets (1, 6 and 10) and retaining bolts. Tighten the bolts to 2.2 N.m (20
in. lbs.).
3. Remove the plugs or tape from the opened jumper line fittings and condenser ports.
4. Lubricate new dual plane seals with clean refrigerant oil and install them onto the jumper line fittings.
Use only the specified seals as they are made of a special material for the R-134a system. Use only
5. Connect the jumper lines to the A/C condenser and install the bolts (4 and 9). Tighten the bolts to 23 N.m
(17 ft. lbs.).
6. Install the bolt (8) that secures the condenser jumper line tapping block (7) to the radiator. Tighten the
bolt securely.
7. If equipped, connect the automatic transmission cooler lines (11) to the transmission cooler Refer to
TUBES AND HOSES, TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
8. Install the grille. Refer to GRILLE, INSTALLATION .
9. Install the radiator closure panel. Refer to PANEL, CLOSURE, RADIATOR, INSTALLATION .


11. If equipped, check and adjust the automatic transmission fluid level.
13. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
6.7L DIESEL ENGINE
NOTE: If only the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of
NOTE: A/C condenser for manual transmission model shown in illustration. Shown
with front fascia removed for clarity. Automatic transmission model similar.

Fig. 169: A/C Condenser Securing Bolts

1. If removed, install the four retaining brackets (3), isolators and bolts (4) onto the A/C condenser (1).
Tighten the bolts to 10.5 N.m (95 in. lbs.).
2. Position the A/C condenser into the engine compartment and install the four bolts (2, 7 and 10) that
secure the A/C condenser to the charge air cooler. Tighten the bolts to 10.5 N.m (95 in. lbs.).
3. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets 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.
5. Connect the A/C liquid line (5) and A/C discharge line (9) to the A/C condenser and install the bolts (6
and 8). Tighten the bolts to 23 N.m (17 ft. lbs.).

Fig. 170: Air Deflector, Hood Latch And Retainers Clips & Push Pins
6. If removed, install the air deflector (1) and push pins (3).
7. If removed, attach the hood cable to hood latch and retainers clips (2).
8. If equipped, connect the automatic transmission cooler lines to the transmission fluid cooler fittings
located at each end of the A/C condenser. Refer to TUBES AND HOSES, TRANSMISSION OIL
COOLER, STANDARD PROCEDURE .
9. Install the front bumper. Refer to BUMPER, FRONT, INSTALLATION .
11. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
CORE, HEATER
DESCRIPTION
DESCRIPTION
Fig. 171: Heater Core

The heater core (1) is a heat exchanger made of rows of tubes and fins and is located at the front of the HVAC
housing. The heater core tubes (2) are attached to the front of the heater core and are secured to the HVAC
housing by a flange.
The heater core can be serviced by removing the HVAC housing assembly from the vehicle.
OPERATION
OPERATION

Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows
through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air
directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control
of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower
motor speed controls the volume of air flowing through the HVAC housing.
The heater core cannot be repaired and must be replaced if restricted, leaking or damaged.
REMOVAL
REMOVAL
NOTE: Disassembly of the HVAC housing is not required to remove heater core.

1. Remove the HVAC housing (4) and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL.
2. Remove the foam seal (1) from the flange (2).
3. Remove the two screws (3) that secure the flange to the front of the HVAC housing.
4. Carefully disengage the retaining tab that secures the flange to the HVAC housing and remove the flange.

Fig. 173: Locating Heater Core

5. Carefully pull the heater core (2) out of the front of the HVAC housing (1).
6. Inspect all foam seals and replace as required.
INSTALLATION
INSTALLATION
Fig. 174: Locating Heater Core

NOTE: If the foam seals on the heater core are deformed or damaged, they must be
replaced.
1. Inspect the foam seals on the heater core (2) and replace as required.
2. Carefully install the heater core into the front of the HVAC housing (1).


3. Position the flange (2) onto the front of the HVAC housing (4). Make sure the retaining tab is fully
engaged.
4. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 1.1 N.m (10
in. lbs.).
5. Install the foam seal (1) onto the flange.
NOTE: If the heater core is being replaced, flush the cooling system. Refer to
STANDARD PROCEDURE .
CORE, SERVICE PORT VALVE
DESCRIPTION
DESCRIPTION
Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant
system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not
accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant.
The high side service port is located on the A/C liquid line. The low side service port is located on the A/C
suction line. Both the high side and low side A/C service port valve cores are serviceable.
Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing
the refrigerant system, always reinstall both of the service port caps.
An A/C pressure transducer is mounted on the A/C discharge line to monitor the high side A/C system
pressures. Refer to TRANSDUCER, A/C PRESSURE, DESCRIPTION.
REMOVAL

REMOVAL
or death.
Fig. 176: Identifying A/C Service Port Components

NOTE: Typical A/C service port shown in illustration.
1. Remove the protective cap (1) from the service port (2).
PROCEDURE.
3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port.
4. Install a plug in, or tape over the opened service port(s).
INSTALLATION
INSTALLATION

Fig. 177: Identifying A/C Service Port Components

NOTE: Typical A/C service port shown in illustration.
1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the
type recommended for the A/C compressor in the vehicle.
2. Remove the tape or plug from the service port (2).
CAUTION: Damage may result to a service port valve core if the valve core is not
fully seated in the A/C service port. Such damage can result in a loss
of refrigerant.
3. Install and tighten the valve core into the service port(s) using a Schrader type valve core tool.
NOTE: The protective cap helps aid in service port sealing and helps protect the
refrigerant system from contamination. Remember to always reinstall the
protective cap onto the service port when refrigerant system service is
complete.
5. Install the protective cap (1) onto the service port.
DRIER, A/C RECEIVER
DESCRIPTION
DESCRIPTION

NOTE: Gasoline engine model A/C condenser shown in illustration. Diesel engine
model similar.
Fig. 178: A/C Receiver/Drier & A/C Condenser

The A/C receiver/drier (1) stores unnecessary refrigerant, filters the refrigerant, helps remove moisture from the
refrigerant and retains any refrigerant vapor that may leave the A/C condenser (2) until it becomes a liquid. The
A/C receiver/drier is on the high-side of the A/C system and is located on the left side of the A/C condenser.
The A/C receiver/drier is integral to the A/C condenser and must be replaced with the condenser as an
assembly.
OPERATION
OPERATION
The A/C receiver/drier performs a filtering action to prevent foreign material that may be in the refrigerant from
contaminating the A/C expansion valve and the A/C compressor. Refrigerant enters the A/C receiver/drier as a
high-pressure, low temperature liquid. Desiccant inside the A/C receiver/drier absorbs any moisture which may
have entered and become trapped within the refrigerant system. In addition, during periods of high demand
operation of the A/C system, the A/C receiver/drier acts as a reservoir to store surplus refrigerant.
The A/C receiver/drier is integral to the A/C condenser and has no serviceable parts.
The A/C receiver/drier cannot be repaired and the A/C condenser must be replaced if the receiver/drier is
leaking or damaged, or if an internal failure of the A/C compressor has occurred. Refer to CONDENSER, A/C,

REMOVAL.
EVAPORATOR, A/C
DESCRIPTION
DESCRIPTION

The A/C evaporator (1) for the heating-A/C system is located within the HVAC housing, behind the instrument
panel. The A/C evaporator and insulator (2) are positioned in the HVAC housing so that all air entering the
housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and
outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is
engaged and circulating refrigerant through the A/C evaporator. The A/C expansion valve is attached directly to
the evaporator inlet and outlet ports (3) and the connections are sealed by O-rings.
The A/C evaporator can be serviced by removing and partially disassembling the HVAC housing.
OPERATION
OPERATION
Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on
the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil
and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.
a refrigerant line or expansion valve is disconnected. Failure to replace the
rubber O-ring seals and metal gaskets could result in a refrigerant system leak.
The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the
connections are made from a special type of rubber not affected by refrigerant. The O-ring seals must be
replaced whenever the A/C expansion valve is removed from the A/C evaporator.

The A/C evaporator cannot be repaired and must be replaced if leaking or damaged.
REMOVAL
REMOVAL

1. Remove the HVAC housing and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL.
2. Disconnect the HVAC wiring harness (1) from the recirculation door actuator (2), power module or
blower resister (3) (depending on application) and the blower motor (4).
3. Disengage the HVAC wiring harness from the two retaining clips (5) and position the harness out of the
way.
Fig. 181: Foam Seal

4. Remove the foam seal (1) from the front of the HVAC housing (2).
5. Remove the two bolts (4) that secure the A/C expansion valve (5) to the evaporator tube tapping block (3)
and remove the valve.

6. Remove the three screws (2 and 5) that secure the blower motor and evaporator housing (6) to the HVAC
housing (3).
7. Carefully disengage the nine retaining tabs (1 and 4) that secure the blower motor and evaporator housing
the HVAC housing.
8. Carefully separate the blower motor and evaporator housing from the HVAC housing


9. Remove the A/C evaporator (1) from the blower motor and evaporator housing (2).
10. If the A/C evaporator is going to be reused, remove and discard the O-ring seals from the evaporator
fittings and install plugs into, or tape over the evaporator ports.
INSTALLATION
INSTALLATION
NOTE: Replacement of the O-ring seals is required anytime the A/C expansion valve is
removed from the A/C evaporator. Failure to replace the rubber O-ring seals
may result in a refrigerant system leak.


NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the
insulator must be replaced.
1. Carefully install the A/C evaporator (1) into the blower motor and evaporator housing (2).

2. Carefully install the blower motor and evaporator housing (6) onto the HVAC housing (3). Align the
dowel pins to the holes in the housing.
3. Carefully engage the nine retaining tabs (1 and 4). Make sure the retaining tabs are fully engaged.
4. Install the three screws (2 and 5) that secure the blower motor and evaporator housing to the HVAC

housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
Fig. 186: Foam Seal

5. Remove the tape or plugs from the evaporator tube fittings.

9. Install the foam seal (1) onto the HVAC housing (2).


10. Connect the HVAC wiring harness (1) to the recirculation door actuator (2), power module or blower
resister (3) (depending on application) and the blower motor (4).
11. Engage the HVAC wiring harness to the two retaining clips (5). Make sure the wire harness is fully
engaged to the retaining clips.
refrigerant system. 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. Refer to OIL,
LINE, A/C DISCHARGE
REMOVAL
3.6L, 5.7L ENGINE
or death.

Fig. 188: A/C Discharge & Liquid Lines


PROCEDURE.
3. Remove the nut (2) that secures the A/C discharge line (3) to the condenser jumper line tapping block (1).
4. Disconnect the A/C discharge line from the condenser jumper line tapping block.

5. Remove the nut (2) that secures the A/C discharge line (3) to the A/C compressor (4).

6. Disconnect the A/C discharge line from the A/C compressor.

7. Disconnect the wire harness connector from the A/C pressure transducer.
8. Remove the plastic retaining brackets that secure the A/C discharge line to the A/C suction line and to the
upper front of the engine.
9. Remove the A/C discharge line from the engine compartment.
10. Remove and discard the O-ring seals and gaskets from the A/C discharge line and install plugs in, or tape
over the opened discharge line fittings and the jumper line and compressor ports.
11. If necessary, remove the A/C pressure transducer from the A/C discharge line. Refer to TRANSDUCER,
A/C PRESSURE, REMOVAL.
6.7L DIESEL ENGINE
or death.
Fig. 190: Identifying A/C Pressure Transducer & Discharge Line


PROCEDURE.
4. Disconnect the wire harness connector from the A/C pressure transducer (1).
5. Remove the nut (3) that secures the A/C discharge line (2) to the condenser jumper line tapping block (4).
6. Disconnect the A/C discharge line from the condenser jumper line tapping block and remove and discard
the O-ring seal and gasket.


8. Remove the nut (1) that secures the A/C discharge line (4) to the A/C compressor (2).
9. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and
gasket.
10. Install plugs in, or tape over the opened discharge line fittings and the compressor and jumper line ports.
11. If necessary, remove the A/C pressure transducer from the A/C discharge line. Refer to TRANSDUCER,
A/C PRESSURE, REMOVAL.
INSTALLATION
3.6L, 5.7L ENGINE

1. If removed, install the A/C pressure transducer onto the A/C discharge line. Refer to TRANSDUCER,
A/C PRESSURE, INSTALLATION.
2. Remove the plugs or tape from the opened discharge line fittings and compressor and jumper line ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge
4. Position the A/C discharge line (5) into the engine compartment.
5. Install the retaining brackets that secure the A/C discharge line to the A/C suction line and to the upper
front of the engine.
6. Connect the wire harness connector to the A/C pressure transducer.

7. Connect the A/C discharge line (3) to the A/C compressor (4).
8. Install the nut (2) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m
(17 ft. lbs.).

Fig. 193: A/C Discharge & Liquid Lines

9. Connect the A/C discharge line to the condenser jumper line tapping block (1) and install the nut (2).
Tighten the nut to 23 N.m (17 ft. lbs.).
12. Adjust the refrigerant oil level. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE.
6.7L DIESEL ENGINE

1. If removed, install the A/C pressure transducer onto the A/C discharge line (4). Refer to
TRANSDUCER, A/C PRESSURE, INSTALLATION.
2. Remove the tape or plugs from the discharge line fittings and the compressor and jumper line ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge
4. Connect the A/C discharge line to the A/C compressor (2).
5. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m
(17 ft. lbs.).

Fig. 195: Identifying A/C Pressure Transducer & Discharge Line

7. Connect the A/C discharge line (2) to the condenser jumper line tapping block (4) and install the nut (3).
Tighten the nut to 23 N.m (17 ft. lbs.).
8. Connect the wire harness connector to the A/C pressure transducer (1).
LINE, A/C LIQUID
REMOVAL
REMOVAL
or death.

PROCEDURE.
3. If equipped with a gasoline engine, remove the air filter housing and mounting bracket from the right side
of the engine compartment.
4. If equipped with the 6.7L diesel engine, remove the battery and battery tray from the right side of the
engine compartment.

Fig. 196: Remove/Install A/C Liquid Line

5. Remove the nut (2) that secures the A/C liquid line (1) to the condenser jumper line tapping block (3).
6. Disconnect the A/C liquid line from the condenser jumper line tapping block and remove and discard the
seals.
Fig. 197: Remove/Install A/C Liquid Line & Suction Line

7. Remove the nut (2) that secures the A/C liquid line and the A/C suction line to the A/C expansion valve

(1).
8. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the
seals.
Fig. 198: Remove/Install A/C Discharge Line

9. Remove the nut (1) securing the A/C discharge line (2) to the Internal Heat Exchanger (IHX) and remove
and discard the seal.
10. Install plugs in, or tape over the opened refrigerant line fittings and ports.
Fig. 199: Remove/Install Internal Heat Exchanger

11. Remove the bolt (3) securing the Internal Heat Exchanger (IHX) bracket, to the inner fender.
12. Remove the bolt (2) securing the liquid line to the inner fender.
13. Remove the bolt (4) securing the internal heat exchanger to the inner fender bracket.
14. Remove the line assembly (5) from the vehicle.
INSTALLATION
INSTALLATION
Fig. 200: Remove/Install Internal Heat Exchanger

1. Position the line assembly (5) into the engine compartment and install the mounting fasteners (3), (4), and
(5).
2. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve ports.

3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use
only the specified O-ring seals as they are made of a special material for the R-134a system. Use only
Fig. 201: Remove/Install A/C Liquid Line & Suction Line

4. Connect the A/C liquid line and A/C suction line to the A/C expansion valve (1).
5. Install the nut (2) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the
nut to 23 N.m (17 ft. lbs.).


6. Install the A/C discharge to the Internal Heat Exchanger using a new, lubricated seal.
7. Install the nut (1) that secures the A/C liquid discharge line (2) to the Internal Heat Exchanger. Tighten
the nut to 23 N.m (17 ft. lbs.).
Fig. 203: Remove/Install A/C Liquid Line

8. Lubricate a new seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting.

Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only
9. Connect the A/C liquid line (1) to the condenser jumper line tapping block (3).
10. Install the nut (2) that secures the A/C liquid line to the condenser jumper line tapping block. Tighten the
11. If equipped with the 6.7L diesel engine, install the battery tray and battery to the right side of the engine
compartment.
12. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing to
the right side of the engine compartment.
LINE, A/C SUCTION
REMOVAL
3.6L, 5.7L ENGINES
or death.

PROCEDURE.
3. Remove the air filter housing cover and engine air inlet tube. For CNG, refer to BODY, AIR
CLEANER, REMOVAL, 5.7L . For gas, refer to BODY, AIR CLEANER, REMOVAL, 5.7L or
BODY, AIR CLEANER, REMOVAL, 6.4L . For diesel, refer to BODY, AIR CLEANER,
REMOVAL, 6.7L .


4. Remove the nut (1) that secures the A/C suction line (2) to the Internal Heat Exchanger assembly.

5. Remove the nut (2) that secures the A/C suction line (1) to the A/C compressor (4).
6. Disconnect the A/C suction line from the A/C compressor.

7. Remove the plastic retaining brackets that secure the A/C suction line to the A/C discharge line and to the
8. Remove the A/C suction line from the engine compartment.
9. Remove and discard the O-ring seals and gaskets from the A/C suction line and install plugs in, or tape
over the opened suction line fittings and the expansion valve and compressor ports.
6.7L DIESEL ENGINE
or death.
Fig. 206: A/C Expansion Valve


PROCEDURE.
4. Remove the nut (1) that secures the A/C liquid line (2) and A/C suction line (3) to the A/C expansion
valve (4).
5. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-
ring seals.
6. Separate the A/C liquid line from the A/C suction line and install plugs in, or tape over the opened
refrigerant line fittings and expansion valve ports.


8. Remove the nut (1) that secures the A/C suction line (3) to the A/C compressor (2).
9. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seals and
gaskets.
10. Install plugs in, or tape over the opened suction line fittings and compressor port.
INSTALLATION
3.6L, 5.7L ENGINES
1. Remove the plugs or tape from the opened suction line fittings and the expansion valve and compressor
ports.

2. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction
3. Position the A/C suction line into the engine compartment.
4. Install the plastic retaining brackets that secure the A/C suction line to the A/C discharge line and to the

5. Connect the A/C suction line (1) to the A/C compressor (4).
6. Install the nut (2) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 N.m (17
ft. lbs.).


7. Connect the and the A/C suction line (2) to the Internal Heat Exchanger Assembly.
8. Install the nut (1) that secures the A/C suction line to the Internal Heat Exchanger. Tighten the nut to 23
N.m (17 ft. lbs.).
9. Install the air filter housing cover and engine air inlet tube. For CNG, refer to BODY, AIR CLEANER,
INSTALLATION, 5.7L . For gas, refer to BODY, AIR CLEANER, INSTALLATION, 5.7L or
BODY, AIR CLEANER, INSTALLATION . For diesel, refer to BODY, AIR CLEANER,
INSTALLATION, 6.7L .
6.7L DIESEL ENGINE


1. Position the A/C suction line (3) into the engine compartment.
2. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use
only the specified O-ring seals as they are made of a special material for the R-134a system. Use only
4. Connect the A/C liquid line (2) and A/C suction line of the A/C expansion valve (4).
5. Install the nut (1) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the

6. Remove the tape or plugs from the opened suction line fitting and compressor port.
7. Lubricate a new O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line
fitting. Use only the specified O-ring seal as it is 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.
8. Connect the A/C suction line (3) to the A/C compressor (2).
9. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 N.m (17
ft. lbs.).
OIL, REFRIGERANT
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT OIL CAPACITY
When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil
free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is
dispersed throughout the refrigerant system. The A/C compressor, A/C condenser, A/C evaporator and A/C
receiver/drier will each retain a significant amount of the needed refrigerant oil.

It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of
the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce
the cooling capacity of the A/C system and consequently result in higher discharge air temperatures.
CAUTION: Use only ND-8 PAG oil designed to work with R-134a refrigerant. The oil
container should be kept tightly capped until ready for use and then tightly
capped after use to prevent contamination from dirt and moisture.
Refrigerant oil quickly absorbs moisture it comes in contact with. Special
effort must be used to keep all R-134a system components moisture-free.
Moisture in the refrigerant oil is very difficult to remove and will cause a
reliability problem with the A/C compressor.
NOTE: Most reclaim/recycling equipment will measure the lubricant being removed
during recovery. This amount of lubricant should be added back into the
system. See the reclaim/recycling equipment manufacturers instructions.
It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a
component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system
after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet,
shiny surface around the leak.
Refrigerant oil must be added when an A/C compressor, A/C condenser or an A/C evaporator is replaced. See
the REFRIGERANT OIL CAPACITIES chart.
The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation refer to
COMPRESSOR OIL DRAIN PROCEDURE.
REFRIGERANT OIL CAPACITIES

Component Name ml. oz.
Total A/C System Fill 180 6
A/C Condenser 30 1
A/C Evaporator 60 2
A/C Compressor Drain and measure the oil from the old
compressor. See COMPRESSOR OIL
DRAIN PROCEDURE.
COMPRESSOR OIL DRAIN PROCEDURE
CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C
compressor. Failure to properly drain and measure the refrigerant oil from
the A/C compressor can prevent the A/C system from operating as
designed and cause serious compressor damage.
The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and

measure refrigerant oil from the A/C compressor.
1. Drain all of the refrigerant oil from the old A/C compressor into a clean measured container.
2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container.
3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of the old
compressor. Use only clean refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
4. Install the new A/C compressor onto the engine. Refer to COMPRESSOR, A/C, INSTALLATION.
REFRIGERANT
SPECIFICATIONS
REFRIGERANT CHARGE CAPACITY
REFRIGERANT CHARGE CAPACITY

Application Capacity
3.6L/4.7L/5.7L engines 0.624 kg (1 lb. 6 oz.)
6.7L engine w/auto trans 0.624 kg (1 lb. 6 oz.)
6.7L engine w/man trans 0.539 kg (1 lb. 3 oz.)
VALVE, A/C EXPANSION
DESCRIPTION
DESCRIPTION


The A/C expansion valve controls the amount of refrigerant entering the A/C evaporator. The A/C expansion
valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve type body (1)
with an inlet port (2), outlet port (3) and an integral thermal sensor (4).
The A/C expansion valve is located in the engine compartment at the dash panel, between the A/C refrigerant
lines and the A/C evaporator.
OPERATION
OPERATION
The A/C expansion valve controls the high-pressure, low temperature liquid refrigerant from the A/C liquid line
and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the A/C
evaporator. A mechanical sensor in the A/C expansion valve monitors the temperature and pressure of the
refrigerant leaving the A/C evaporator through the A/C suction line, and adjusts the orifice size at the liquid line
port to let the proper amount of refrigerant into the evaporator to meet the vehicle A/C cooling requirements.
Controlling the refrigerant flow through the A/C evaporator ensures that none of the refrigerant leaving the A/C
evaporator is still in a liquid state, which could damage the A/C compressor.
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant
line is disconnected from the expansion valve, or if the expansion valve is
removed. Failure to replace the rubber O-ring seals may result in a refrigerant
system leak.
The A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if
inoperative or damaged.
DIAGNOSIS AND TESTING - A/C EXPANSION VALVE
or death.
NOTE: The A/C expansion valve should only be tested following testing of the A/C
compressor.
NOTE: Liquid CO2 is required to test the A/C expansion valve. This material is available
from most welding supply facilities. Liquid CO2 is also available from
companies which service and sell fire extinguishers.
When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27°C (70° to
85°F). To test the expansion valve:
1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Refer to

PLUMBING, STANDARD PROCEDURE.

2. Verify the refrigerant system charge level by conducting the A/C Performance Test. Refer to
DIAGNOSIS AND TESTING.
3. Close all doors, windows and vents to the passenger compartment.
4. Set the A/C-heater controls so that the A/C compressor is operating, the temperature control is in the
highest temperature position, the mode-air doors is directing air output to the floor and the blower motor
operating is operating at the highest speed.
5. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the
passenger compartment to heat up. This will create the need for maximum refrigerant flow into the A/C
evaporator.
6. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 827 kPa to 1655
kPa (120 psi to 240 psi). The suction (low pressure) gauge should read 207 kPa to 345 kPa (30 psi to 50
psi). If OK, go to 7. If not OK, replace the inoperative A/C expansion valve.
WARNING: Protect the skin and eyes from exposure to liquid CO2 or personal
injury can result.
7. If the suction (low pressure) gauge reads within the specified range, freeze the A/C expansion valve for
30 seconds using liquid CO2 or another suitable super-cold material. Do not spray R-134a or R-12
refrigerant on the A/C expansion valve for this test. The suction (low pressure) gauge reading should
drop by 69 kPa (10 psi). If OK, go to 8. If not OK, replace the inoperative A/C expansion valve. Refer to
VALVE, A/C EXPANSION, REMOVAL.
8. Allow the A/C expansion valve to thaw. The suction (low pressure) gauge reading should stabilize at 207
kPa to 345 kPa (30 psi to 50 psi). If not OK, replace the inoperative A/C expansion valve. Refer to
VALVE, A/C EXPANSION, REMOVAL.
REMOVAL
REMOVAL
or death.



PROCEDURE.
3. Remove the nut (1) that secures the A/C liquid line (2) and A/C suction line (3) to the A/C expansion
valve (4).
4. Disconnect the A/C liquid and suction lines and from the A/C expansion valve and position the
refrigerant lines out of the way.
5. Remove the O-ring seals from the liquid and suction line fittings and discard.
6. Install plugs in, or tape over the opened liquid and suction line fittings.


7. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block
(3).
8. Remove the A/C expansion valve from the evaporator tube tapping block and remove and discard the O-
ring seals.
9. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports.
INSTALLATION
INSTALLATION

1. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.


5. Remove the tape or plugs from the liquid and suction line fittings.
6. Lubricate new O-ring seals with clean refrigerant oil and install them onto the liquid and suction line
fittings. Use only the specified O-ring seals 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.
7. Connect the A/C liquid line (2) and the A/C suction line (3) to the A/C expansion valve (4).
8. Install the nut (1) that secures the A/C liquid and suction lines the A/C expansion valve. Tighten the nut
to 23 N.m (17 ft. lbs.).

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2014 RAM 3500 HD Laramie

Heating & Air Conditioning - Service Information - Ram Pickup

Fig. 1: HVAC Housing Assembly

Blend-air door(s) and actuator(s) (2 and 10)

Thursday, November 16, 2017 19:50:02

Heater core (3)

Thursday, November 16, 2017 19:49:20 Page 2

Fig. 2: Blend Air System Schematic

NOTE: Typical blend-air type HVAC system shown in illustration.

Thursday, November 16, 2017 19:49:20 Page 3

panel top cover.

DIAGNOSIS AND TESTING

Thursday, November 16, 2017 19:49:20 Page 4

A/C PERFORMANCE TEST

Thursday, November 16, 2017 19:49:20 Page 5

A/C PERFORMANCE TEMPERATURE AND PRESSURE

A/C SYSTEM DIAGNOSIS

Thursday, November 16, 2017 19:49:20 Page 6

2. See appropriate Wiring Information.

2. Refrigerant flow through 2. See DRIER, A/C RECEIVER. Replace

Thursday, November 16, 2017 19:49:20 Page 7

the A/C receiver/drier is the restricted A/C receiver/drier as required.

Thursday, November 16, 2017 19:49:20 Page 8

MAXIMUM HEATER OUTPUT: TEST AND ACTION

HEATER TEMPERATURE REFERENCE

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow are as follows:

Inoperative water pump.

Obstructed cowl air intake.

Thursday, November 16, 2017 19:49:20 Page 9

Inoperative A/C-heater control.

Thursday, November 16, 2017 19:49:20 Page 10

9. Remove the blower motor. Refer to MOTOR, BLOWER, REMOVAL.

Thursday, November 16, 2017 19:49:20 Page 11

Thursday, November 16, 2017 19:49:20 Page 12

temperature to full heat

Item Description Notes

Description N.m Ft. Lbs. In. Lbs.

Thursday, November 16, 2017 19:49:20 Page 13

Side of Dash Panel Nuts 6.8 - 60

6801 - Terminal Probe

Thursday, November 16, 2017 19:49:20 Page 14

Thursday, November 16, 2017 19:49:20 Page 15

9764 - Pliers, A/C Snap Ring

C-4755 - Trim Stick

Thursday, November 16, 2017 19:49:20 Page 16

Fig. 3: Locating Blend Door Actuator

Thursday, November 16, 2017 19:49:20 Page 17

SINGLE ZONE/DUAL ZONE DRIVER SIDE

Thursday, November 16, 2017 19:49:20 Page 18

Fig. 5: Blend Door Actuator

1. Disconnect and isolate the negative battery cable.

DUAL ZONE PASSENGER SIDE

Fig. 6: Blend Door Actuator

1. Disconnect and isolate the negative battery cable.

Thursday, November 16, 2017 19:49:20 Page 19

the HVAC housing.

SINGLE ZONE/DUAL ZONE DRIVER SIDE

Fig. 7: Blend Door Actuator

Thursday, November 16, 2017 19:49:20 Page 20

Fig. 8: Blend Door Actuator

DUAL ZONE PASSENGER SIDE

Fig. 9: Blend Door Actuator

Thursday, November 16, 2017 19:49:20 Page 21

HVAC Heating & Air Conditioning - Service Information - Ram Pickup

HVAC Heating & Air Conditioning - Service Information - Ram Pickup