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23 - 114
STRUCTURAL ADHESIVE LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.20FRONTFENDER
DR STRUCTURAL ADHESIVE LOCATIONS (Continued)
BODY STRUCTURE
23 - 115
Fig.21FLOORPAN
23 - 116
STRUCTURAL ADHESIVE LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.22INNERWHEELHOUSE
Fig.23INNERBOXSIDEPANEL
DR STRUCTURAL ADHESIVE LOCATIONS (Continued)
BODY STRUCTURE
23 - 117
Fig.24INNERWHEELHOUSE
Fig.25INNERBOXSIDEPANEL
23 - 118
STRUCTURAL ADHESIVE LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.26INNERDOORPANEL
Fig.27INNERDOORPANEL
DR STRUCTURAL ADHESIVE LOCATIONS (Continued)
BODY STRUCTURE
23 - 119
Fig.28REARDOORINNERPANEL
23 - 120
STRUCTURAL ADHESIVE LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.29SILLRAIL-STDCAB
DR STRUCTURAL ADHESIVE LOCATIONS (Continued)
BODY STRUCTURE
23 - 121
Fig.30SILLRAIL-QUADCAB
23 - 122
BODY STRUCTURE
WELD LOCATIONS SPECIFICATIONS
DR
INDEX
DESCRIPTION
FIGURE
FENDER BRACE, CLOSURE TUBE AND FRAME MOUNTING BRACKET TO FRONT
FENDER SUPPORT, FRONT FENDER AND RADIATOR TUBE
STEERING COLUMN SUPPORT, CONNECTOR WIRING BRACKET AND WELD NUTS
TO LOWER PLENUM PANEL
WIPER ATTACHING WELD NUTS AND VACUUM RESERVOIR ATTACHING STUDS TO
COWL PAR PANEL
DASH PANEL TO FRONT FLOOR PAN
DASH PANEL TO LOWER PLENUM PANEL
LOWER PLENUM PANEL TO COWL BACK PANEL
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL MOUNTING BRACKET, AND WELD NUTS TO COWL SIDE PANEL - LEFT SIDE
DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PANEL - LEFT SIDE
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL MOUNTING BRACKET AND WELD NUTS TO COWL SIDE PANEL - RIGHT SIDE DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PANEL - RIGHT SIDE
REINFORCEMENT AND HEADLAMP MOUNTING PANEL TO OUTER FENDER PANEL SEAT MOUNTING FRONT BRACKETS TO SEAT MOUNTING FRONT CROSSMEMBER
TO FRONT FLOOR PAN
AIR BAG MODULE BRACKET SHIFTER MOUNTING PLATE AND REAR FLOOR PANE
TO FRONT FLOOR PAN
RIGHT TO LEFT REAR FLOOR CROSSMEMBER AND RIGHT TO LEFT SEAT
MOUNTING CROSSMEMBER
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL
SEAT MOUNTING FRONT CROSSMEMBER TO FRONT FLOOR PAN TO UNDERBODY
SUPPORT
FRONT SEAT MOUNTING CROSSMEMBERS TO FRONT SEAT MOUNTING BRACKET
TO FRONT FLOOR PAN
REAR FLOOR CROSSMEMBERS TO REAR FLOOR PAN
FLOOR SILL TO FRONT SEAT MOUNTING CROSSMEMBER, FRONT AND REAR
FLOOR PAN
AIR BAG MODULE BRACKET, SHIFTER MOUNTING PLATE AND FRONT SEAT
MOUNTING CROSSMEMBER TO FRONT FLOOR PAN
REAR SEAT MIDDLE MOUNTING PLATE TO REAR FLOOR PAN TO FRONT FLOOR
PAN
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL
LEFT REAR CROSSMEMBER TO RIGHT REAR CROSSMEMBER TO REAR FLOOR
PAN
31
32
33
34
35
36
3738
39
40
41
4243
44
45
46
47
48
4950
51
52
53
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 123
DESCRIPTION
FIGURE
STORAGE BIN TO RIGHT AND LEFT REAR FLOOR CROSSMEMBER TO REAR
FLOOR PAN
RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER TO LEFT REAR FRONT
SEAT MOUNTING CROSSMEMBER TO REAR FLOOR PAN
FRONT SEAT MOUNTING FRONT CROSSMEMBER AND STORAGE BIN TO FLOOR
SILL TO FRONT AND REAR FLOOR PAN
FRONT SEAT MOUNTING FRONT CROSSMEMBER TO UNDERBODY SUPPORT TO
FRONT FLOOR PAN
A-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
A-PILLAR REINFORCEMENT TO FRONT APERTURE EXTENSION TO INNER BODY
SIDE APERTURE TO OUTER BODY SIDE APERTURE
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
SHOULDER BELT REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE
FRONT PILLAR TAPPING PLATES TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
C-PILLAR BAFFLE AND OUTER BODY SIDE APERTURE TO INNER BODY SIDE
APERTURE
A-PILLER REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
FRONT EXTENSION PLATE TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE TO A-PILLAR REINFORCEMENT
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE
B-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
UPPER B-PILLAR TAPPING PLATE AND LOWER B-PILLAR TAPPING PLATE TO
OUTER BODY SIDE APERTURE
UPPER A-PILLAR TAPPING PLATE AND LOWER A-PILLAR TAPPING PLATE TO INNER
BODY SIDE APERTURE
SEAT BELT MOUNTING PLATES AND REINFORCEMENTS TO INNER BODY SIDE
APERTURE
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE
C-PILLAR REINFORCEMENTS AND SHOULDER BELT MOUNTING REINFORCEMENT
TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
SEAT BELT RETRACTOR PLATE TO FLOOR SILL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE
FLOOR SILL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE BACK REINFORCEMENT AND CAB BACK PANEL TO REAR FLOOR CROSSMEMBER
AND INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE CAB BACK REINFORCEMENT TO CAB BACK PANEL (CHILD TETHERS)
COWL SIDE PANEL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE
APERTURE
OUTER ROOF PANEL TO OUTER BODY SIDE APERTURE
ROOF HEADER TO OUTER ROOF PANEL TO A-PILLAR REINFORCEMENT TO INNER
BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
54
55
56
57
58
59
60
6162
63
6465
66
67
6869
70
71
72
7374
75
7677
7879
8023 - 124
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
DESCRIPTION
FIGURE
REAR ROOF HEADER TO OUTER ROOF PANEL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE
OUTER BODY SIDE APERTURE TO CAB BACK PANEL TO FLOOR SILL, INNER BODY
SIDE APERTURE TO FLOOR SILL
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE
CAB BACK REINFORCEMENT TO CAB BACK PANEL
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL FRONT CROSSMEMBER AND END SUPPORT BRACKET TO LONG CROSSMEMBER TO INNER BOX SIDE PANEL/STAKE POCKET REINFORCEMENT AND BOX FLOOR
SILL TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL
FRONT BOX PANEL TO OUTER BOX SIDE PANEL
81
82
83
8485
8687
88
89
90
91
92
9394
95
96
9798
99
100
101102
103
104
105106
107DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 125
DESCRIPTION
FIGURE
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/ FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL
BOX FRONT PANEL TO BOX FLOOR PANEL
BOX FLOOR PANEL TO INNER BOX SIDE PANEL
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER
BOX SIDE PANEL
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PANEL
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB)
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB)
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB)
108
109
110111
112
113
114
115
116
117118
119
120121
122123
124
125126
127
128
129
130
13123 - 126
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.31FENDERBRACE
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 127
Fig.32STEERINGCOLUMNSUPPORT
23 - 128
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.33WIPERATTACHINGWELDNUTS
Fig.34DASHPANEL
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 129
Fig.35DASHPANEL
23 - 130
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.36LOWERPLENUMPANEL
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 131
Fig.37FRONTFENDER
Fig.38DASHPANEL
23 - 132
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.39FRONTFENDER
Fig.40DASHPANEL
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 133
Fig.41HEADLAMPMOUNTINGPANEL
23 - 134
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.42SEATMOUNTINGFRONTBRACKETS-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 135
Fig.43AIRBAGMODULEBRACKET-STANDARDCAB
23 - 136
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.44RIGHTTOLEFTREARFLOORCROSSMEMBER-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 137
Fig.45REARFLOORCROSSMEMBER-STANDARDCAB
23 - 138
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.46SEATMOUNTINGFRONTCROSSMEMBER-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 139
Fig.47FRONTSEATMOUNTINGCROSSMEMBERS-STANDARDCAB
23 - 140
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.48REARFLOORCROSSMEMBERS-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 141
Fig.49FLOORSILL-STANDARDCAB
23 - 142
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.50AIRBAGMODULEBRACKET-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 143
Fig.51REARSEATMIDDLEMOUNTINGPLATE-QUADCAB
23 - 144
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.52REARFLOORCROSSMEMBER-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 145
Fig.53LEFTREARCROSSMEMBER-QUADCAB
Fig.54STORAGEBIN-QUADCAB
23 - 146
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.55RIGHTREARFRONTSEATMOUNTINGCROSSMEMBER-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 147
Fig.56FRONTSEATMOUNTINGFRONTCROSSMEMBER-QUADCAB
23 - 148
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.57FRONTSEATMOUNTINGFRONTCROSSMEMBER
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 149
Fig.58A-PILLARREINFORCEMENT-STANDARDCAB
23 - 150
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.59A-PILLARREINFORCEMENT-STANDARDCAB
Fig.60INNERBODYSIDEAPERTURE-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 151
Fig.61SHOULDERBELTREINFORCEMENT-STANDARDCAB
Fig.62FRONTPILLARTAPPINGPLATES-STANDARDCAB
23 - 152
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.63INNERBODYSIDEAPERTURE-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 153
Fig.64C-PILLARBAFFLE-QUADCAB
23 - 154
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.65A-PILLARREINFORCEMENT-QUADCAB
Fig.66FRONTEXTENSIONPLATE-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 155
Fig.67OUTERBODYSIDEAPERTURE-QUADCAB
Fig.68B-PILLARREINFORCEMENT-QUADCAB
23 - 156
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.69UPPERTAPPINGPLATE-QUADCAB
Fig.70UPPERA-PILLARTAPPINGPLATE-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 157
Fig.71SEATBELTMOUNTINGPLATES-QUADCAB
Fig.72OUTERBODYSIDEAPERTURE-QUADCAB
23 - 158
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.73C-PILLARREINFORCEMENT-QUADCAB
Fig.74SEATBELTRETRACTORPLATE-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 159
Fig.75FLOORSILL-STANDARDCAB
23 - 160
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.76BACKREINFORCEMENT-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 161
Fig.77CABBACKREINFORCEMENT-STANDARDCAB
23 - 162
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.78COWLSIDEPANEL-STANDARDCAB
Fig.79OUTERROOFPANEL-STANDARDCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 163
Fig.80FRONTROOFHEADER-STANDARDCAB
Fig.81REARROOFHEADER-STANDARDCAB
23 - 164
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.82OUTERBODYSIDEAPERTURE-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 165
Fig.83OUTERBODYSIDEAPERTURE-QUADCAB
23 - 166
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.84REARFLOORCROSSMEMBER-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 167
Fig.85CABBACKREINFORCEMENT-QUADCAB
23 - 168
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.86CENTERSHOULDERBELTREINFORCEMENT-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 169
Fig.87A-PILLARREINFORCEMENT-QUADCAB
23 - 170
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.88B-PILLARREINFORCEMENT-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 171
Fig.89FRONTROOFHEADER-QUADCAB
23 - 172
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.90INNERBODYSIDEAPERTURE-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 173
Fig.91FRONTCROSSMEMBER-SHORTCARGOBOXONLY
23 - 174
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.92LONGCROSSMEMBER-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 175
Fig.93TAPPINGPLATES-SHORTCARGOBOXONLY
23 - 176
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.94STAKEPOCKETREINFORCEMENTS-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 177
Fig.95OUTERBOXSIDEREINFORCEMENTBRACES-SHORTCARGOBOXONLY
Fig.96OUTERWHEELHOUSE-SHORTCARGOBOXONLY
23 - 178
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.97WELDNUT-SHORTCARGOBOXONLY-SHORTCARGOBOXONLY
Fig.98FRONTBOXPANEL-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 179
Fig.99FRONTCROSSMEMBER-SHORTCARGOBOXONLY
Fig.100BOXFLOORPANEL-SHORTCARGOBOXONLY
23 - 180
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.101FRONTCROSSMEMBER-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 181
Fig.102STAKEPOCKETREINFORCEMENT-SHORTCARGOBOXONLY
23 - 182
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.103INNERTAILGATEPILLARPANEL-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 183
Fig.104BOXFLOORSILLCROSSMEMBER-SHORTCARGOBOXONLY
Fig.105INNERTAILGATEPILLAR-SHORTCARGOBOXONLY
23 - 184
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.106BOXSIDEPANEL-SHORTCARGOBOXONLY
Fig.107FRONTBOXPANEL-SHORTCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 185
Fig.108INNERBOXSIDEPANEL-SHORTCARGOBOXONLY
Fig.109OUTERWHEELHOUSEPANEL-SHORTCARGOBOXONLY
23 - 186
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.110FRONTCROSSMEMBER-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 187
Fig.111WHEELHOUSECROSSMEMBER-LONGCARGOBOXONLY
23 - 188
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.112FRONTANDCENTERSTAKEPOCKETREINFORCEMENTS-LONGCARGOBOXONLY
Fig.113OUTERFRONTANDCENTERSTAKEPOCKETREINFORCEMENT-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 189
Fig.114OUTERWHEELHOUSE-LONGCARGOBOXONLY
23 - 190
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.115TAILGATEBOXSIDEPIVOTREINFORCEMENT-LONGCARGOBOXONLY
Fig.116FRONTBOXSIDEPANEL-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 191
Fig.117FRONTBOXSIDEPANEL-LONGCARGOBOXONLY
Fig.118BOXFRONTPANEL-LONGCARGOBOXONLY
23 - 192
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.119BOXFLOORPANEL-LONGCARGOBOXONLY
Fig.120LONGCROSSMEMBERS-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 193
Fig.121INNERWHEELHOUSEPANEL-LONGCARGOBOXONLY
Fig.122TAILGATEPILLAROUTERPANEL-LONGCARGOBOXONLY
23 - 194
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.123REARSILLCROSSBOX-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 195
Fig.124OUTERBOXSIDEPANEL-LONGCARGOBOXONLY
23 - 196
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.125STAKEPOCKETREINFORCEMENTS-LONGCARGOBOXONLY
Fig.126TAILGATEPIVOTREINFORCEMENT-LONGCARGOBOXONLY
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 197
Fig.127INNERWHEELHOUSE-LONGCARGOBOXONLY
Fig.128OUTERTAILGATEPILLAR-LONGCARGOBOXONLY
23 - 198
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.129INNERDOORPANEL-QUADCAB
DR WELD LOCATIONS (Continued)
BODY STRUCTURE
23 - 199
Fig.130INNERDOORPANEL-STANDARDCAB
23 - 200
WELD LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.131INNERDOORPANEL-QUADCAB
DR
HEATING & AIR CONDITIONING
24 - 1
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page
page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 2
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HEATER
DESCRIPTION - COOLING SYSTEM
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 5
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE - DIODE
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT . . . . . . . . . . . . . . . . . . . . . . . . 1
REPLACEMENT SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT . . . . . . . . . . . . . . . . . . . . . . . . 2
A/C APPLICATION TABLE . . . . . . . . . . . . . . . . 7
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 8
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR CONDITIONER
All vehicles are equipped with a common HVAC housing assembly (Fig. 1). The system combines air conditioning, heating, and ventilating capabilities in a single unit housing mounted under the instrument panel.
DESCRIPTION - COOLING SYSTEM REQUIREMENTS
To maintain the performance level of the HVAC system, the engine cooling system must be properly maintained. The use of a bug screen is not recom- mended. Any obstructions in front of the radiator or condenser will reduce the performance of the air con- ditioning and engine cooling systems.
The engine cooling system includes the heater core and the heater hoses. Refer to Engine Cooling for more information before the opening of, or attempt- ing any service to the engine cooling system.
DESCRIPTION - REFRIGERANT SYSTEM SERVICE PORT
The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system. Unique service port coupler sizes are used on the R-134a system, to
ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment.
OPERATION
OPERATION - HEATER AND AIR CONDITIONER The heater air conditioner are blend-air type sys- tems. In a blend-air system, a blend door controls the amount of unconditioned air (or cooled air from the evaporator on models with air conditioning) that is allowed to flow through, or around, the heater core. A temperature control knob on the A/C Heater control panel determines the discharge air temperature by controlling an electric actuator, which moves the blend door. This allows an almost immediate control of the output air temperature of the system.
The mode control knob on the A/C Heater control panel is used to direct the conditioned air to the selected system outlets. Both mode control switches use electric actuators to control the mode doors.
On all vehicles, the outside air intake can be shut off by selecting the Recirculation Mode with the mode control knob. This will operate a electric actu- ated recirculation door that closes off the outside fresh air intake and recirculates the air that is already inside the vehicle.
The air conditioner for all models is designed for the use of non-CFC, R-134a refrigerant. The air con- ditioning system has an evaporator to cool and dehu- midify the incoming air prior to blending it with the heated air. This air conditioning system uses a fixed orifice tube in the liquid line near the condenser out- let tube to meter refrigerant flow to the evaporator
HEATING & AIR CONDITIONING
24 - 2
HEATING & AIR CONDITIONING (Continued)DR
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C PERFORMANCE
The air conditioning system is designed to provide the passenger compartment with low temperature and low humidity air. The evaporator, located in the HVAC housing on the dash panel below the instru- ment panel, is cooled to temperatures near the freez- ing point. As warm damp air passes through the cooled evaporator, the air transfers its heat to the refrigerant in the evaporator and the moisture in the air condenses on the evaporator fins. During periods of high heat and humidity, an air conditioning sys- tem will be more effective in the Recirculation Mode. With the system in the Recirculation Mode, only air from the passenger compartment passes through the evaporator. As the passenger compartment air dehu- midifies, the air conditioning system performance levels improve.
Humidity has an important bearing on the temper- ature of the air delivered to the interior of the vehi- cle. It is important to understand the effect that humidity has on the performance of the air condition- ing system. When humidity is high, the 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 evapo- rator fins. Condensing the moisture in the air trans- fers heat energy into the evaporator fins and tubing. This reduces the amount of heat the evaporator can absorb from the air. High humidity greatly reduces the ability of the evaporator to lower the temperature of the air.
However, evaporator capacity used to reduce the amount of moisture in the air is not wasted. Remov- ing 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 the air conditioning system on humid days. A perfor- mance test is the best way to determine whether the system is performing up to standard. This test also provides valuable clues as to the possible cause of trouble with the air conditioning system.
Before proceeding, (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - CAUTION). The air temperature in the test room and in the vehicle must be a minimum of 21° C (70° F) for this test.
(1) Connect a tachometer and a manifold gauge set
or A/C recycling/charging station.
(2) Set the A/C Heater mode control switch knob in the Recirculation Mode position, the temperature control knob in the full cool position, and the blower motor switch knob in the highest speed position.
Fig.1HVACHousing-DualZoneShown(Typical-
SingleZone)
1 - Mounting Nut 2 - Passenger Blend Door Actuator (dual zone) 3 - Mounting Nut 4 - Air Intake Spacer 5 - Recirculation Door Actuator 6 - Recirculation Door Assembly 7 - Driver Side Blend Door Actuator 8 - HVAC Housing 9 - Mounting Screw 10 - Defroster Door Actuator 11 - Panel Actuator
coil. To maintain minimum evaporator temperature and prevent evaporator freezing, the A/C Fin Probe which is located in the evaporator cycles the com- pressor clutch by sending an A/C request to the JTEC which in turn processes this piece of informa- tion and if all conditions are met cycles the compres- sor clutch.
OPERATION - REFRIGERANT SYSTEM SERVICE PORT
The low pressure service port is located on the suc- tion refrigerant line, near the accumulator. The high pressure service port is located on the liquid line at the passenger side of the engine compartment, near the condenser.
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.
DR HEATING & AIR CONDITIONING (Continued)
HEATING & AIR CONDITIONING
24 - 3
(3) Start the engine and hold the idle at 1,000 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be closed.
(5) Insert a thermometer in the driver side center A/C (panel) outlet. Operate the engine for five min- utes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity.
(7) With the compressor clutch engaged, record the discharge air temperature and the compressor dis- charge pressure.
(8) Compare the discharge air temperature to the Performance Temperature and Pressure chart. If the discharge air temperature is high, (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - DIAGNOSIS AND TESTING - REFRIGERANT SYS- TEM LEAKS) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - SPECIFICATIONS - CHARGE CAPACITY).
Ambient Air Temperature Air Temperature at Center Panel Outlet Compressor Inlet Pressure at Service Port (low Side)
Condensor Out Pressuree at Service Port (High Side)
Performance Temperature and Pressure
21° C (70° F) 7° C (45° F)
27° C (80° F) 7° C (45° F)
32° C (90° F) 13° C (55° F)
38° C (100° F) 13° C (55° F)
43° C (110° F) 18° C (64° F)
138 to 207 kPa (20 to 30 psi)
1034 to 1724
kPa
172 to 241
207 to 276
241 to 310
kPa
(25 to 35 psi) 1379 to 2068
kPa
kPa
(30 to 40 psi) 1724 to 2413
kPa
kPa
(35 to 45 psi) 1999 to 2689
kPa
(150 to 250
(200 to 300
(250 to 350
(290 to 390
psi)
psi)
psi)
psi)
276 to 345 kPa (40 to 50 psi)
2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor discharge pressure to the Performance Temperature and Pressure chart. If
the compressor discharge pressure is high, see the Pressure Diagnosis chart.
Condition
Possible Causes
Correction
Pressure Diagnosis
Constant compressor
engagement and warm air
from passenger vents.
1. Low refrigerant system
charge.
Equal pressures, but the compressor clutch does not engage.
1. No refrigerant in the refrigerant system.
2. Faulty fuse.
3. Faulty a/c compressor clutch coil.
1. See Plumbing/Diagnosis and Testing - Refrigerant System Leaks in this group. Test the refrigerant system for leaks. Repair, evacuate and charge the refrigerant system, if required.
1. See Plumbing/Diagnosis and Testing - Refrigerant System Leaks in this group. Test the refrigerant system for leaks. Repair, evacuate and charge the refrigerant system, if required. 2. Check the fuses in the Power Distribution Center and the junction block. Repair the shorted circuit or component and replace the fuses, if required. 3. See A/C Compressor/Diagnosis and Testing - Compressor Clutch Coil in this group. Test the compressor clutch coil and replace, if required.
HEATING & AIR CONDITIONING
24 - 4
HEATING & AIR CONDITIONING (Continued)DR
Condition
Possible Causes
Correction
Pressure Diagnosis
4. Faulty a/c compressor clutch relay.
5. Improperly installed or faulty Fin Sensor.
6. Faulty a/c high pressure transducer.
7. Faulty Powertrain Control Module (PCM).
1. Excessive refrigerant oil in system.
2. Blend door inoperative or sealing improperly.
3. Blend door actuator faulty or inoperative.
1. Low refrigerant system charge.
2. Refrigerant flow through the accumulator is restricted. 3. Refrigerant flow through the evaporator coil is restricted. 4. Faulty compressor.
Normal pressures, but A/C Performance Test air temperatures at center panel outlet are too high.
The low side pressure is normal or slightly low, and the high side pressure is too low.
The low side pressure is normal or slightly high, and the high side pressure is too high.
1. Condenser air flow restricted.
2. Inoperative cooling fan.
3. Refrigerant system overcharged.
4. See A/C Compressor Clutch Relay/Diagnosis and Testing - Compressor Clutch Relay in this group. Test the compressor clutch relay and relay circuits. Repair the circuits or replace the relay, if required. 5. See Fin Sensor/Diagnosis and Testing in this group. Reinstall or replace the Fin Sensor as required. 6. See A/C High Pressure Transducer/Diagnosis and Testing in this group. Test the a/c high pressure transducer and replace, if required. 7. (Refer to Appropriate Diagnostic Information). Test the PCM and replace, if required.
1. See Refrigerant Oil/Standard Procedure - Refrigerant Oil Level in this group. Recover the refrigerant from the refrigerant system and inspect the refrigerant oil content. Restore the refrigerant oil to the proper level, if required. 2. See Blend Door in this group. Inspect the blend door for proper operation and sealing and correct, if required. 3. Perform blend door actuator diagnosis, replace if faulty.
1. See Plumbing/Diagnosis and Testing - Refrigerant System Leaks in this group. Test the refrigerant system for leaks. Repair, evacuate and charge the refrigerant system, if required. 2. See Accumulator in this group. Replace the restricted accumulator, if required. 3. See A/C Evaporator in this group. Replace the restricted evaporator coil, if required.
4. See A/C Compressor in this group. Replace the compressor, if required.
1. Check the condenser for damaged fins, foreign objects obstructing air flow through the condenser fins, and missing or improperly installed air seals. Refer to Cooling for more information on air seals. Clean, repair, or replace components as required. 2. Refer to Cooling for more information. Test the cooling fan and replace, if required. 3. See Plumbing/Standard Procedure - Refrigerant System Charge in this group. Recover the refrigerant from the refrigerant system. Charge the refrigerant system to the proper level, if required.
DR HEATING & AIR CONDITIONING (Continued)
HEATING & AIR CONDITIONING
24 - 5
Condition
Possible Causes
Correction
Pressure Diagnosis
4. Air in the refrigerant system.
5. Engine overheating.
The low side pressure is too high, and the high side pressure is too low.
1. Accessory drive belt slipping.
2. Fixed orifice tube not installed. 3. Faulty compressor.
The low side pressure is too low, and the high side pressure is too high.
1. Restricted refrigerant flow through the refrigerant lines.
2. Restricted refrigerant flow through the fixed orifice tube. 3. Restricted refrigerant flow through the condenser.
4. See Plumbing/Diagnosis and Testing - Refrigerant System Leaks in this group. Test the refrigerant system for leaks. Repair, evacuate and charge the refrigerant system, if required. 5. Refer to Cooling for more information. Test the cooling system and repair, if required.
1. Refer to Cooling for more information. Inspect the accessory drive belt condition and tension. Tighten or replace the accessory drive belt, if required. 2. See A/C Orifice Tube in this group. Replace the liquid line, if required. 3. See A/C Compressor in this group. Replace the compressor, if required.
1. See Liquid, Suction, and Discharge Line in this group. Inspect the refrigerant lines for kinks, tight bends or improper routing. Correct the routing or replace the refrigerant line, if required. 2. See A/C Orifice Tube in this group. Replace the liquid line, if required. 3. See A/C Condenser in this group. Replace the restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER PERFORMANCE
Before performing the following tests, refer to Cool- ing for the procedures to check the engine coolant level and flow, engine coolant reserve/recovery sys- tem operation, accessory drive belt condition and ten- sion, radiator air flow and the fan drive operation. Also be certain that the accessory vacuum supply line is connected at the engine vacuum source.
MAXIMUM HEATER OUTPUT
Engine coolant is delivered to the heater core through two heater hoses. With the engine idling at normal operating temperature, set the temperature control knob in the full hot position, the mode control switch knob in the floor position, and the blower motor switch knob in the highest speed position. Using a test thermometer, check the temperature of the air being discharged at the HVAC housing floor outlets. Compare the test thermometer reading to the Temperature Reference chart.
Ambient Air Temperature
Minimum Air Temperature at Floor Outlet
Temperature Reference 21.1° C (70° F) 63.8° C (147° F)
15.5° C (60° F) 62.2° C (144° F)
26.6° C (80° F) 65.5° C (150° F)
32.2° C (90° F) 67.2° C (153° F)
HEATING & AIR CONDITIONING
24 - 6
HEATING & AIR CONDITIONING (Continued)DR
If the floor outlet air temperature is too low, refer to Cooling to check the engine coolant temperature specifications. 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 sup- ply hose, locate and repair the engine coolant flow obstruction in the cooling system. Refer to Cooling for the procedures.
An alternate method of checking heater perfor- mance is to use a DRBIIIt scan tool to monitor the engine coolant temperature. The floor outlet air tem- perature reading should be no more than 4.5° C (40° F) lower than the engine coolant temperature read- ing.
OBSTRUCTED COOLANT FLOW Possible loca- tions or causes of obstructed coolant flow: † Faulty water pump. † Faulty thermostat. † Pinched or kinked heater hoses. † Improper heater hose routing. † Plugged heater hoses or supply and return ports † A plugged heater core.
at the cooling system connections.
If proper coolant flow through the cooling system is verified, and heater outlet air temperature is still low, a mechanical problem may exist.
causes of insufficient heat:
MECHANICAL PROBLEMS Possible locations or † An obstructed cowl air intake. † Obstructed heater system outlets. † A faulty, obstructed or † A faulty blower system. † A faulty a/c heater control.
improperly installed
blend door.
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be adjusted with the temperature control knob on the a/c heater control panel, the following could require service:
† A faulty a/c heater control. † A faulty blend door actuator. † A faulty, obstructed or † An obstructed cowl air intake. † The engine cooling system.
blend door.
improperly installed
CONDITION
POSSIBLE CAUSE
CORRECTION
Heater Diagnosis
INSUFFICIENT HEATER OUTPUT.
1. Incorrect engine coolant level. 2. Air trapped in engine cooling system. 3. Incorrect engine coolant temperature.
4. Blend door actuator inoperative or defective. 5. Blend door not operating properly.
6. Insufficient air flow through heater housing. 7. Improper blower motor operation.
1. Check the engine coolant level. Refer to Cooling for the procedures. 2. Check the operation of the coolant reserve/recovery system. Refer to Cooling for the procedures. 3. Check the performance and operation of the engine cooling system including: thermostat, water pump, fan drive, accessory drive belt, coolant flow (plugged radiator or heater core, plugged or kinked coolant hoses), air flow (missing or improperly installed radiator air seals or fan shroud). Refer to Cooling for the procedures. 4. (Refer to Controls/Blend Door Actuator) in this group.
5. Check for a damaged, obstructed or improperly installed blend door or seals. (Refer to Controls/Blend Door Actuator) in this group. 6. Remove foreign material or obstructions from cowl air intake. 7. (Refer to Distribution/Blower Motor/ Diagnosis and Testing) in this group.
DR HEATING & AIR CONDITIONING (Continued) STANDARD PROCEDURE - DIODE REPLACEMENT
(1) Disconnect the battery negative cable and iso- late it. If vehicle has a dual batterys remove both negative cables.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 2).
Fig.2DIODEIDENTIFICATION
1 - CURRENT FLOW 2 - BAND AROUND DIODE INDICATES CURRENT FLOW 3 - DIODE AS SHOWN IN THE DIAGRAMS
(4) Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
(5) Install the new diode in the harness, making sure current flow is correct. If necessary refer to the appropriate wiring diagram for current flow.
(6) Solder the connections together using rosin core type solder only. Do not use acid core solder. (7) Tape the diode to the harness using electrical tape making, sure the diode is completely sealed from the elements.
(8) Re-connect the battery negative cable(s), and
test affected systems.
HEATING & AIR CONDITIONING
24 - 7
SPECIFICATIONS
A/C APPLICATION TABLE
Notes
SP-15 PAG oil Evaporator mounted discharge line
Software - J2190
resistor block
PCM ± 0.5V @ 70° F
Item Vehicle System
Compressor Freeze–up Control High psi Control
Control Head
Mode Door Blend Door Recirculation Door Blower Motor
Cooling Fan
Clutch
Control Draw
Gap DRB IIIT Reads
Actuators
Description DR- Ram Truck R134a w/ fixed orifice tube Saden SD-7
A/C Fin Sensor475 psi A/C cut out electronic
electric electric electric
hardwired to control head Viscous for cooling with a single speed electric for A/C for 3.7, 4.7 and 5.7L gas engines. Viscous for both cooling and A/C with 5.9L diesel engine and 8.0L gas engine. Electro- mechanical relay 2 - 3.7 amps @ 12V 0.0169 - 0.0319
TPS, RPM, A/C switch test clutch and fan relay
HEATING & AIR CONDITIONING
24 - 8
HEATING & AIR CONDITIONING (Continued) SPECIFICATIONSTORQUE SPECIFICATIONS
DR
DESCRIPTION
A/C COMPRESSOR CLUTCH PLATE NUT
A/C COMPRESOR LINE MANIFOLD FASTENER A/C COMPRESSOR TO MOUNTING BRACKET
BOLTS
ACCUMULATOR RETAINING BOLT
N·m
14.4
28 (±6)
27
BLEND DOOR ACTUATOR
2.4 (±.34)
SCREWS
HVAC HOUSING SCREWS HVAC HOUSING TO DASH
PANEL NUTS
SUCTION LINE TO
ACCUMULATOR FITTING
2.4 (±.34)
6.2
Ft. Lbs.
10.5
21 (±4)
20
3.7
1.8 (±.25)
1.8 (±.25)
4.6
6.6
In. Lbs.
127.4
250 (±50)
239
44
21 (±3)
21 (±3)
55
80
DR
CONTROLS
24 - 9
CONTROLS
TABLE OF CONTENTS
page
page
A/C COMPRESSOR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - A/C COMPRESSOR CLUTCH COIL STANDARD PROCEDURE - A/C. . . . . . . . . . . 10
COMPRESSOR CLUTCH BREAK-IN
. . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - COMPRESSORCLUTCH RELAY
. . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15A/C PRESSURE TRANSDUCER
DESCRIPTION - A/C PRESSURE
TRANSDUCER
. . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - A/C PRESSURETRANSDUCER
. . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16BLEND DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16A/C COMPRESSOR CLUTCH DESCRIPTION
The compressor clutch assembly consists of a sta- tionary electromagnetic coil, a rotor bearing and rotor assembly, and a clutch plate (Fig. 1). The elec- tromagnetic coil unit and the rotor bearing and rotor assembly are each retained on the nose of the com- pressor front housing with snap rings. The clutch plate is keyed to the compressor shaft and secured with a nut. These components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - BLOWERMOTOR RESISTOR . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - BLOWERMOTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19DEFROST DOOR ACTUATOR
REMOVAL - FLOOR - DEFROST DOOR
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MODE DOOR ACTUATOR
