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DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22RECIRCULATION DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23OPERATION
When the clutch coil is energized, it magnetically draws the clutch into contact with the rotor and drives the compressor shaft. When the coil is not energized, the rotor freewheels on the clutch rotor bearing, which is part of the rotor. The compressor clutch and coil are the only serviced parts on the compressor.
The compressor clutch engagement is controlled by several components: the A/C Heater mode control switch, the A/C high pressure transducer, the com- pressor clutch relay, and the (JTEC). The JTEC may delay compressor clutch engagement for up to thirty
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A/C COMPRESSOR CLUTCH (Continued)DR
† JTEC (4) The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9
amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21° C (70° F). If system voltage is more than 12.5 volts, add electrical loads by turn- ing on electrical accessories until the system voltage drops below 12.5 volts.(a) If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
Fig.1COMPRESSORCLUTCH-TYPICAL
1 - CLUTCH PLATE 2 - SHAFT KEY (not used on KJ) 3 - ROTOR 4 - COIL 5 - CLUTCH SHIMS 6 - SNAP RING 7 - SNAP RING
seconds. Refer to Electronic Control Modules for more information on the JTEC controls.
DIAGNOSIS AND TESTING - A/C COMPRESSOR CLUTCH COIL
For circuit descriptions and diagrams, (Refer to Appropriate Wiring Information). The battery must be fully-charged before performing the following tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil.
(2) With the A/C Heater mode control switch in any A/C mode, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle.
(3) The compressor clutch coil voltage should read within 0.2 volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within 0.2 volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a DRB III t scan tool and (Refer to Appropriate Diagnostic Information) for testing of the compressor clutch circuit and PCM control. The fol- lowing components must be checked and repaired as required before you can complete testing of the clutch coil:† Fuses in the junction block and the Power Dis- tribution Center (PDC) † A/C heater mode control switch † Compressor clutch relay † A/C high pressure transducer switch
STANDARD PROCEDURE - A/C COMPRESSOR CLUTCH BREAK-IN
After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C Heater control to the Recirculation Mode, the blower motor switch in the highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.REMOVAL
The refrigerant system can remain fully-charged during compressor clutch, rotor, or coil replacement. The compressor clutch can be serviced in the vehicle. (1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(3) Unplug the compressor clutch coil wire harness
connector.
(4) Remove the bolts that secure the compressor to
the mounting bracket.
(5) Remove the compressor from the mounting bracket. Support the compressor in the engine com- partment while servicing the clutch.
(6) Insert the two pins of the spanner wrench (Special Tool C-4489 or equivalent) into the holes of the clutch plate. Hold the clutch plate stationary and remove the hex nut (Fig. 2).
(7) Remove the clutch plate. (8) Remove the compressor clutch shims. (9) Remove the external front housing snap ring
with snap ring pliers (Fig. 3).
(10) Install the lip of the rotor puller (Special Tool C-6141-1 or equivalent) into the snap ring groove exposed in the previous step, and install the shaft pro- tector (Special Tool C-6141-2 or equivalent) (Fig. 4).
DR A/C COMPRESSOR CLUTCH (Continued)
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24 - 11
(11) Install the puller through-bolts (Special Tool C-6461 or equivalent) through the puller flange and into the jaws of the rotor puller and tighten (Fig. 5). Turn the puller center bolt clockwise until the rotor is free.
CAUTION: DO NOT APPLY FORCE TO THE END OF THE COMPRESSOR SHAFT.
Fig.2CLUTCHNUTREMOVE-Typical
1 - CLUTCH PLATE 2 - SPANNER
Fig.3EXTERNALSNAPRINGREMOVE-Typical 1 - PULLEY 2 - SNAP RING PLIERS
Fig.5INSTALLPULLERPLATE-Typical
1 - PULLER JAW 2 - PULLER
(12) Remove the screw and retainer from the clutch coil lead wire harness on the compressor front housing (Fig. 6).
Fig.6CLUTCHCOILLEADWIREHARNESS-
Typical
1 - COIL 2 - COIL WIRE 3 - RETAINER SCREW
Fig.4SHAFTPROTECTORANDPULLER-Typical 1 - PULLER JAW 2 - SHAFT PROTECTOR
(13) Remove the snap ring from the compressor hub and remove the clutch field coil (Fig. 7). Slide the clutch field coil off of the compressor hub.
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A/C COMPRESSOR CLUTCH (Continued)DR
Fig.7CLUTCHFIELDCOILSNAPRINGREMOVE-
Fig.8CLUTCHPULLEYINSTALL-Typical
Typical
1 - ROTOR BEARING ASSEMBLY 2 - INSTALLER
1 - COIL 2 - SNAP RING PLIERS
INSPECTION
Examine the friction surfaces of the clutch rotor and the clutch plate for wear. The rotor 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 compressor for oil. Remove the felt from the front cover. If the felt is saturated with oil, the shaft seal is leaking and the compressor must be replaced.
Check the rotor bearing for roughness or excessive leakage of grease. Replace the rotor and clutch plate, if required.
INSTALLATION
(1) Install the clutch field coil and snap ring. (2) Install the screw and retainer on the clutch coil lead wire harness on the compressor front housing. Tighten screw to 2.2 N·m (20 in. lbs.).
(3) Align the rotor assembly squarely on the front
compressor housing hub.
(4) Install the rotor bearing assembly with the installer (Special Tool C-6871 or equivalent) (Fig. 8). Thread the installer on the shaft, then turn the nut until the rotor assembly is seated.
(5) Install the external front housing snap ring with snap ring pliers. The bevel side of the snap ring must be facing outward. Press the snap ring to make sure it is properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch fail- ure and severe damage to the front housing of the compressor.
(6) Install the original clutch shims on the com-
pressor shaft.
(7) Install the clutch plate. Install the shaft hex
nut and tighten to 15–20 N·m (11–15 ft. lbs.).
(8) Check the clutch air gap with a feeler gauge (Fig. 9). If the air gap does not meet the specification, add or subtract shims as required. The air gap spec- ification is 0.41 to 0.79 millimeter (0.016 to 0.031
inch).Fig.9CHECKCLUTCHAIRGAP-Typical
1 - FEELER GAUGE
DR A/C COMPRESSOR CLUTCH (Continued)
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NOTE: The air gap is determined by the spacer shims. When installing an original, or a new clutch assembly, try the original shims first. When install- ing a new clutch onto a compressor that previously did not have a clutch, use a 1.0, 0.50, and 0.13 mil- limeter (0.040, 0.020, and 0.005 inch) shims from the new clutch hardware package that is provided with the new clutch.
(2) Resistance between terminals 85 and 86 (elec- tromagnet) should be 67.5 to 82.5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test. If not OK, replace the faulty relay.
(9) To complete the procedure,
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
A/C COMPRESSOR CLUTCH RELAY DESCRIPTION
ISO relay. However,
The compressor clutch relay is a International Standards Organization (ISO) micro-relay. The termi- nal designations and functions are the same as a con- ventional the micro-relay terminal orientation (footprint) is different, the cur- rent capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compart- ment. Refer to the PDC label for relay identification and location.
OPERATION
The compressor clutch relay is a electromechanical device that switches battery current to the compres- sor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay. The PCM responds to inputs from the A/C Heater mode control switch, the A/C low pressure switch, and the A/C high pressure switch. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH RELAY - DIAGNOSIS AND TESTING)
The compressor clutch relay cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - COMPRESSOR CLUTCH RELAY
RELAY TEST
The compressor clutch relay (Fig. 10) is located in the Power Distribution Center (PDC). Refer to the PDC label relay identification and location. Remove the relay from the PDC to perform the fol- lowing tests:
for
(1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay.
Fig.10COMPRESSORCLUTCHRELAY
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
RELAY CIRCUIT TEST
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
(1) The relay common feed terminal cavity (30) is connected to fused battery feed. There should be bat- tery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C com- pressor clutch relay output circuit cavity of the com- pressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required.
(4) The relay coil battery terminal
is con- nected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity
(86)
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A/C COMPRESSOR CLUTCH RELAY (Continued)DR
for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required.
(5) The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cav- ity and the A/C compressor clutch relay control cir- cuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Center (PDC).
(2) Remove the cover from the Power Distribution
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place.
(2) Install the PDC cover. (3) Connect the battery negative cable. (4) Test the relay operation.
A/C HEATER CONTROL DESCRIPTION
The A/C heater system uses a seriers of electrical controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner’s manual in the vehicle glove box for more information on the features, use, and suggested oper- ation of these controls.
The A/C heater control - (Single Zone) or (Dual Zone) panel is located to the right of the instrument cluster on the instrument panel.
The control panel contains a rotary-type tempera- ture control, a rotary-type mode control switch knob, and a rotary-type blower motor speed switch knob. The control also has a push button to activate the Optional side view mirrors defroster elements and to turn the A/C on.
The Dual Zone HVAC control panel contains a pair of slider-type temperature controls, a rotary-type mode control switch knob and a rotary-type blower motor speed switch knob. The control also has but- tons to turn the A/C ON, Set it on Max A/C and for the Optional Heated Sideview Mirrors.
The A/C heater control panel cannot be repaired. If faulty or damaged, the entire unit must be replaced. The illumination lamps are available for service replacement.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the center bezel from the instrument panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL CENTER BEZEL - REMOVAL). (3) Remove the screws that secure the A/C Heater control to the instrument panel (Fig. 11) or (Fig. 12). (4) Pull the A/C Heater control assembly away from the instrument panel far enough to access the connections on the back of the control.
Fig.11SingleZoneHVACControl
1 - Mounting Tab (4) 2 - A/C Button 3 - Sideview Mirror Defroster Button (if equiped) 4 - Mode Control 5 - Blend Air Control 6 - Blower Motor Speed Control
(5) Unplug the wire harness connectors from the
back of the A/C Heater control (Fig. 13).
DR A/C HEATER CONTROL (Continued)
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A/C PRESSURE TRANSDUCER DESCRIPTION - A/C PRESSURE TRANSDUCER The A/C pressure transducer is a switch that is installed on a fitting located on the refrigerant dis- charge line between the compressor and the conden- sor in the front corner of the engine compartment. An internally threaded hex fitting on the transducer con- nects it to the externally threaded Schrader-type fit- ting on the liquid line. A rubber O-ring seals the connection between the transducer and the discharge line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer con- nect it to the vehicle electrical system through a take out and connector of the headlamp and dash wire harness.
The A/C pressure transducer cannot be adjusted or it must be
faulty or damaged,
if
repaired and, replaced.
OPERATION
The A/C pressure transducer monitors the pres- sures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The transducer will change its internal resis- tance in response to the pressures it monitors. The Powertrain Control Module (PCM) provides a five volt reference signal and a sensor ground to the transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pres- sure transducer input to the PCM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 10° C due to the pressure/temperature relationship of the refrigerant. The Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refriger- ant in the system. The A/C pressure transducer is diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING - A/C PRESSURE TRANSDUCER
The A/C pressure transducer is tested using a DRBIIIt scan tool. Refer to the appropriate diagnos- tic information. Before testing the A/C pressure transducer, be certain that the transducer wire har- ness connection is clean of corrosion and properly connected. For the air conditioning system to operate,
Fig.12DualZoneA/CControl
1 - A/C Button 2 - Max. A/C Button 3 - Sideview Mirror Defrost Button (if equiped) 4 - Mounting Tabs (4) 5 - Driverside Temperature Control 6 - Passengerside Temperature Control 7 - Mode Control 8 - Blower Motor Speed Control
Fig.13HVACControl-(RearView-typical)
1 - Mounting Tabs (4) 2 - Mounting Screws (4) 3 - HVAC Control Connector 4 - Heated Sideview Mirror Connector 5 - HVAC Control Assembly
INSTALLATION
(1) Plug the two wire harness connectors into the
back of the A/C Heater control.
(2) Position the A/C Heater control in the instru- ment panel bezel and secure it with four screws. Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Reinstall the center bezel onto the instrument panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL CENTER BEZEL - INSTALLA- TION).
(4) Connect the battery negative cable.
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A/C PRESSURE TRANSDUCER (Continued)an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. Refer to the A/C Pres- sure Transducer Voltage table for the possible condi- tion indicated by the transducer voltage readings.
A/C PRESSURE TRANSDUCER VOLTAGE POSSIBLE INDICATION
VOLTAGE
0.0
0.150 TO 0.450
0.451 TO 4.519
4.520 TO 4.850
5.0
REMOVAL
1. NO SENSOR SUPPLY VOLTAGE FROM PCM. 2. SHORTED SENSOR CIRCUIT. 3. FAULTY TRANSDUCER. 1. AMBIENT TEMPERATURE BELOW 10° C (50° F). 2. LOW REFRIGERANT SYSTEM PRESSURE. 1. NORMAL REFRIGERANT SYSTEM PRESSURE. 1. HIGH REFRIGERANT SYSTEM PRESSURE. 1. OPEN SENSOR CIRCUIT. 2. FAULTY TRANSDUCER.
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connector for the A/C pressure transducer from the transducer connec- tor receptacle.
(3) Using an open end wrench, unscrew the A/C pressure transducer from the fitting on the discharge line between the compressor and the condenser.
(4) Remove the seal from the A/C pressure trans-
ducer fitting and discard.
INSTALLATION
(1) Lubricate a new rubber O-ring seal with clean it on the A/C pressure
refrigerant oil and install transducer fitting.
(2) Using an open end wrench, install and tighten the A/C pressure transducer onto the fitting on the discharge line between the compressor and the con- denser.
(3) Reconnect the wire harness connector for the A/C pressure transducer to the transducer connector receptacle.
(4) Reconnect the battery negative cable.
DR
BLEND DOOR ACTUATOR DESCRIPTION
The blend door actuators are reversible, 12-volt Direct Current (DC), servo motors. Models with the single zone heater and air conditioner system have a single blend air door, which is controlled by a single blend door actuator. Models with the optional dual zone front heater and air conditioner system have dual blend air doors, which are controlled by two blend door actuators. The single zone blend door actuator is located on the driver side end of the heat- er-A/C housing unit, close to the dash panel. In the dual zone system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, and is mechanically connected to only the driver side blend air door. In the dual zone system, a second separate blend door actuator is also located on the top of the heater-A/C housing unit and is mechanically connected to only the passenger side blend air door.
The blend door actuators are interchangeable with each other, as well as with the actuators for the mode door and the recirculation air door. Each actua- tor is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater- A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the link- age that drives the proper blend air door. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically cal- ibrated by the heater-A/C control module. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced.
OPERATION
Each blend door actuator is connected to the heat- er-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connec- tor of the HVAC wire harness. The blend door actua- tor can move the blend air door in two directions. When the heater-A/C control module pulls the volt- age on one side of the motor connection high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connec- tions low, the blend air door stops and will not move. These same motor connections also provide a feed- back signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The heater-A/C con-
DR BLEND DOOR ACTUATOR (Continued)
trol module 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 actuator can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
REMOVAL
The single zone heating and air conditioning sys- tem 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. The same service pro- cedures can be used for each of these actuators.
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly(Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the HVAC wire harness connector for the blend door actuator from the actuator connec- tor receptacle. (Fig. 14)
(4) Remove the screws that secure the blend door
actuator to the distribution housing.
(5) Remove the blend door actuator from the dis-
tribution housing.
INSTALLATION
(1) Position the blend door actuator into the heat- er/air conditioner housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. (2) Install and tighten the three screws that secure the blend door actuator to the distribution housing. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector for the blend door actuator to the actuator connector receptacle.
(4) Install the instrument panel assembly(Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).
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24 - 17
Fig.14HVACHousing-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
(5) Reconnect the battery negative cable. (6) Perform the heater-A/C control calibration pro- cedure. (Refer to 24 - HEATING & AIR CONDITION- ING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CON- TROL CALIBRATION).
BLOWER MOTOR RESISTOR BLOCK DESCRIPTION
The blower motor resistor is mounted to the rear side of the HVAC housing on the passenger side of the vehicle.
OPERATION
The resistor is a ceramic resistor that utilizes resistor circuit tracers to reduce current flow to the
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24 - 18
BLOWER MOTOR RESISTOR BLOCK (Continued)DR
blower. The blower motor switch directs the ground path through the correct resistor circuit to obtain the selected speed.
The blower motor resistor cannot be repaired and,
if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR RESISTOR
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the passenger side bottom of the HVAC unit and unplug the wire harness connector from the blower motor resistor.
(3) Check for continuity between each of
the blower motor switch input terminals of the resistor and the resistor output terminal. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor relay as required. If not OK, replace the faulty blower motor resistor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) The blower motor resistor is accessable from the passenger side of the HVAC unit and is located on the bottom of the HVAC unit.
(3) Pull out the lock on the blower motor resistor wire harness connector to unlock the connector latch. (4) Depress the latch on the blower motor resistor wire harness connector and unplug the connector from the resistor.
(5) Remove the two screws that secure the resistor
to the HVAC housing.
(6) Remove the resistor from the HVAC housing.
INSTALLATION
(1) Install the new resistor in the HVAC housing. (2) Install the two screws that secure the resistor to the HVAC housing and tighten to 2.2 N·m (20 in. lbs.).
(3) Plug in the blower motor harness connector. (4) Push in the lock on the blower motor resistor
harness connector.
(5) Close the glove box door. (6) Connect the battery negative cable.
BLOWER MOTOR SWITCH DESCRIPTION
The A/C Heater blower motor is controlled by a four position rotary-type blower motor switch, mounted in the A/C Heater control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position on the blower motor switch.
OPERATION
The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR SWITCH
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
DR BLOWER MOTOR SWITCH (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
(2) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the A/C Heater control from the instrument panel. Check for continuity between the ground cir- cuit cavity of the A/C Heater control wire harness connector and a good ground. There should be conti- nuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required.
(3) With the A/C Heater control wire harness con- nector unplugged, place the A/C Heater mode control switch knob in any position except the Off position. Check for continuity between the ground circuit ter- minal and each of the blower motor driver circuit ter- minals of the A/C Heater control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the A/C Heater control con- nector and the blower motor resistor as required. If not OK, replace the faulty A/C Heater control unit.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
CONTROLS
24 - 19
The blower motor switch cannot be repaired and, if faulty or damaged, the entire A/C Heater control unit must be replaced. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CON- TROL - REMOVAL)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) The blower motor switch cannot be repaired and, if faulty or damaged the entire A/C heater con- trol unit must be replaced(Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL - INSTALLATION).
DEFROST DOOR ACTUATOR REMOVAL - FLOOR - DEFROST DOOR ACTUATOR
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly from to 23 - BODY/INSTRUMENT
the vehicle(Refer PANEL - REMOVAL).
(3) Remove the electrical connector from the actua-
tor (Fig. 15).
CONTROLS
24 - 20
DEFROST DOOR ACTUATOR (Continued)DR
MODE DOOR ACTUATOR DESCRIPTION
Fig.15HVACHousing-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
(4) Remove the mounting screws from the actua-
tor.
(5) Remove the actuator from the HVAC housing.
INSTALLATION - FLOOR - DEFROST DOOR ACTUATOR
(1) Install the floor-defrost door actuator to the
HVAC assembly.
N·m (20 in. lbs.).
(2) Install the mounting screws and tighten to 2.2
(3) Install the actuator electrical connector. (4) Install the instrument panel assembly into the vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL ASSEMBLY - INSTALLA- TION).
(5) Connect the battery negative cable.
Fig.16HVACHousing-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
The mode door actuator is a reversible, 12-volt Direct Current (DC), servo motor (Fig. 16). The sin- gle mode door actuator is located on the driver side end of the heater-A/C housing unit, close to the top of the distribution housing. The mode door actuator is mechanically connected to the mode door. The mode door actuator is interchangeable with the actuators for the blend air door(s) and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the heater-A/C unit housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the mode door. The mode door actuator does not require mechanical indexing
DR MODE DOOR ACTUATOR (Continued)
to the mode door linkage, as it is electronically cali- brated by the heater-A/C control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced.
OPERATION
The mode door actuator is connected to the heater- A/C control module through the vehicle electrical sys- tem by a dedicated two-wire take out and connector of the HVAC wire harness. The mode door actuator can move the mode door in two directions. When the heater-A/C control module pulls the voltage on one side of the motor connection high and the other con- nection low, the mode door will move in one direction. When the module reverses the polarity of the voltage to the motor, the mode door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and rela- tive position of the mode door actuator and the mode door. The heater-A/C control module learns the mode door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
CONTROLS
24 - 21
zone systems only lower actuator in present. For dual zone systems remove second actuator which is mounted on top of HVAC housing (Fig. 17).
Fig.17HVACHousing-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
(5) Remove the mode door actuators from the dis-
tribution housing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel assembly(Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the electricial connector from the
actuator (single or dual zone as required).
(4) Remove the two screws that secure the mode door actuators to the distribution housing. For single
CONTROLS
24 - 22
MODE DOOR ACTUATOR (Continued) INSTALLATIONWARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Position the mode door actuators onto the heat- er/AC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
(2) Install and tighten the two screws that secure the mode door actuators to the distribution housing. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector for the mode door actuators to the actuator connector receptacle.
(4) Install the instrument panel assembly(Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).
(5) Reconnect the battery negative cable. (6) Perform the heater-A/C control calibration pro- cedure. (Refer to 24 - HEATING & AIR CONDITION- ING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CON- TROL CALIBRATION).
RECIRCULATION DOOR ACTUATOR DESCRIPTION
The recirculation door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The single recirculation door actuator is located on the passen- ger side end of the heater-A/C housing unit. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation door actuator is interchangeable with the actuators for the blend air door(s) and the mode doors. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with two screws to the intake air housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the
DR
recirculation air door. The recirculation door actuator does not require mechanical indexing to the recircu- lation air door, as it is electronically calibrated by the heater-A/C control module. The recirculation door actuator cannot be adjusted or repaired and, if dam- aged or faulty, it must be replaced.
OPERATION
The recirculation door actuator is connected to the heater-A/C control module through the vehicle elec- trical system by a dedicated two-wire take out and connector of the HVAC wire harness. The recircula- tion door actuator can move the recirculation door in two directions. When the heater-A/C control module 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 module reverses the polarity of the voltage to the motor, the recirculation air door moves in the opposite direction. When the module makes the voltage to both connec- tions high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the heater-A/C control module. This feedback signal allows the module to monitor the operation and rela- tive position of the recirculation door actuator and the recirculation air door. The heater-A/C control module learns the recirculation air door stop posi- tions during the 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 can be diagnosed using a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator.
DR RECIRCULATION DOOR ACTUATOR (Continued)
CONTROLS
24 - 23
(3) Disconnect the HVAC wire harness connector for the recirculation door actuator from the actuator connector receptacle (Fig. 18).
(5) Remove the recirculation door actuator from
the intake air housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Position the recirculation door actuator onto the intake air housing. If necessary, rotate the actua- tor slightly to align the splines on the actuator out- put shaft with those in the recirculation air door.
(2) Install and tighten the two screws that secure the recirculation door actuator to the lower intake air housing. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle.
(4) Install
the Instrument Panel(Refer to 23 - PANEL/INSTRUMENT
BODY/INSTRUMENT PANEL ASSEMBLY - INSTALLATION).
(5) Reconnect the battery negative cable. (6) Perform the heater-A/C control calibration pro- cedure. (Refer to 24 - HEATING & AIR CONDITION- ING/CONTROLS - FRONT/A/C-HEATER CONTROL - STANDARD PROCEDURE - HEATER-A/C CON- TROL CALIBRATION).
Fig.18HVACHousing-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
(4) Remove the two screws that secure the recircu-
lation door actuator to the intake air housing.
24 - 24
DISTRIBUTION
DISTRIBUTION
TABLE OF CONTENTS
page
DR
page
AIR OUTLETS
. . . . . . . . . . . . . 24
REMOVAL - PANEL OUTLETS INSTALLATION - PANEL OUTLETS . . . . . . . . . . 24BLEND DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25BLOWER MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - BLOWERMOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26DEFROST DOOR
REMOVAL - DEFROST DOOR . . . . . . . . . . . . . 27
INSTALLATION - DEFROST DOOR . . . . . . . . . . 27FLOOR DISTRIBUTION DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR OUTLETS REMOVAL - PANEL OUTLETS
(1) Use a trim stick or another suitable wide flat- bladed tool to gently pry the panel outlet grill out of the panel outlet housing (Fig. 1). The panel outlet grill is retained by a light snap fit.
INSTALLATION - PANEL OUTLETS
To install, position the grill housing in the panel outlet housing and press firmly until it snaps into place.
BLEND DOOR REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
HVAC HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29INSTRUMENT PANEL DUCTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29MODE DOOR
REMOVAL - FLOOR - DEFROST DOOR . . . . . . 30
INSTALLATION - FLOOR - DEFROST DOOR . . 30RECIRC DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30Fig.1DashPanel
1 - Headlight Switch 2 - Air Outlets 3 - Instrument Cluster 4 - Climate Control 5 - Radio 6 - Airbag 7 - Glove Box 8 - Heated Seat Switch (if equipped) 9 - Transfer Case Control Switch (if equipped) 10 - Cigar Lighter 11 - Cup Holders 12 - Ash Tray (if equipped) 13 - Power Outlet
CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
DR BLEND DOOR (Continued)
(1) Recover refrigerant(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(2) Remove and disassemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL) (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - DISASSEMBLY)
Fig.2DualZoneHVACHousing-(typicalsingle
zone)
1 - Passenger Side Blend Door Lever (if equipped) 2 - Passenger Side Blend Door (if equipped) 3 - Fin Sensor Wire 4 - Lower Blower Motor Mounting Housing 5 - HVAC Evaporator 6 - Fin Sensor 7 - Driver Side Blend Door 8 - Driver Side Blend Door Lever
(3) Remove the levers from the driver and passen-
ger side blend air doors (Fig. 2).
(4) Gently slide the drivers or passenger side blend air door toward the out side of the case and tilt and lift the doors out of the case.
(5) Inspect doors, seals and case for damage or
binding and repair or replace as required.
INSTALLATION
NOTE: Vehicles equiped with single zone HVAC systems will only have one blend air door, dual zone systems have two blend air doors.
DISTRIBUTION
24 - 25
(1) Place the blend door pivot shafts in to the pivot holes in the bottom of the lower half of the HVAC housing.
(2) Blend doors are installed by carefully tipping the doors in and then sliding each door into position. (3) Install blend door levers to each door, position levers so that the doors are able to move smoothly without any binding. Adjust as required to insure proper operation.
(4) Check all sealing surfaces and reposition or
replace any seals as required.
(5) Assemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - ASSEMBLY)
(6) Install the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRI- BUTION/HVAC HOUSING - INSTALLATION)
(7) Run calibration test.
BLOWER MOTOR DESCRIPTION
The blower motor and blower wheel are located in the passenger side end of the HVAC housing, below the glove box. The blower motor controls the velocity of air flowing through the HVAC housing by spinning a squirrel cage-type blower wheel within the housing at the selected speed. The blower motor and wheel can be removed from the housing inside the vehicle without removing the dash or HVAC housing assem- bly.
OPERATION
The blower motor will only operate when the igni- tion switch is in the On position, and the A/C Heater mode control switch knob is in any position, except Off. The blower motor receives a fused battery feed through the blower motor relay whenever the igni- tion switch is in the On position. The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center (PDC). Blower motor speed is controlled by regulating the ground path through the A/C Heater control blower motor switch and the blower motor resistor.
The blower motor and blower motor wheel cannot be repaired and, if faulty or damaged, they must be replaced. The blower motor and blower wheel are ser- viced only as a unit.
DISTRIBUTION
24 - 26
BLOWER MOTOR (Continued) DIAGNOSIS AND TESTING - BLOWER MOTORWARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
ness connectors
For circuit descriptions and diagrams, (Refer to Appropriate Wiring Information). Possible causes of an inoperative blower motor include:
† Faulty fuse † Faulty blower motor circuit wiring or wire har- † Faulty blower motor resistor † Faulty blower motor relay † Faulty blower motor switch † Faulty A/C Heater mode control switch † Faulty blower motor. Possible causes of the blower motor not operating † Faulty blower motor switch † Faulty blower motor resistor † Faulty blower motor circuit wiring or wire har-
in all speeds include:
ness connectors.
VIBRATION
Possible causes of blower motor vibration include: † Improper blower motor mounting † Improper blower wheel mounting † Blower wheel out of balance or bent † Blower motor faulty.
NOISE
To verify that the blower is the source of the noise, unplug the blower motor wire harness connector and operate the HVAC system. If the noise goes away, possible causes include:
† Foreign material in the HVAC housing † Improper blower motor mounting † Improper blower wheel mounting † Blower motor faulty.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING
DR
COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
The blower motor is located on the passenger side
of the vehicle under the dash
(1) Disconnect and isolate the battery negative
cable.
Fig.3BlowerMotorAssembly-(CaseRemoved
fromvehicleforgraphic)
1 - Blower Motor Resistor Mounting Screws (2) 2 - Blower Motor Resistor 3 - Blower Motor Resistor Connector 4 - Blower Motor Mounting Screw 5 - Blower Motor Assmebly 6 - Blower Motor Wire 7 - Blower Motor Mounting Screw 8 - HVAC Housing 9 - Blower Motor Wire Hold Down 10 - Blower Motor Mounting Screw
(2) Unplug the blower motor wire harness connec-
tor (Fig. 3).
(3) Remove the three screws that secure the blower motor and wheel assembly to the HVAC hous- ing.
(4) Rotate and tilt the blower motor unit as needed for clearance to remove the blower motor and wheel from the HVAC housing.
INSTALLATION
(1) Align and install the blower motor and wheel
assembly into the HVAC housing.
(2) Install the three mounting screws and tighten
to 2.2 N·m (20 in. lbs.).
DR BLOWER MOTOR (Continued)
(3) Plug in the blower motor wire harness connec-
tor.
(4) Connect the battery negative cable.
DEFROST DOOR REMOVAL - DEFROST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - WARNING) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAU- TION).
(1) Recover refrigerant(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(2) Remove and disassemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL) (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - DISASSEMBLY)
(3) Remove the defrost door actuator. (4) Remove the defrost door from the HVAC hous- ing, by first removing the actuator if not already removed. Then carefully move the door so that one pivot point cleans then tilt and lift the door out of the HVAC housing.
INSTALLATION - DEFROST DOOR
(1) Install the defrost door in the HVAC housing. (2) Install the defrost door actuator. (3) Assemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - ASSEMBLY)
(4) Install the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRI- BUTION/HVAC HOUSING - INSTALLATION)
(5) Run calibration test.
DISTRIBUTION
24 - 27
FLOOR DISTRIBUTION DUCTS REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Remove the screws that secure the floor duct to
the HVAC housing.
(2) Remove the floor duct from the HVAC housing.
INSTALLATION
(1) Install the floor duct on the HVAC housing. (2) Install the screws that secure the floor duct to the HVAC housing. Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
(3) Install the battery negative cable.
HVAC HOUSING REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehi- cle(Refer to 23 - BODY/INSTRUMENT PANEL - REMOVAL).
DISTRIBUTION
24 - 28
HVAC HOUSING (Continued)(3) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
Fig.4HVACHousing-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
(4) Disconnect the liquid line refrigerant line fit- ting from the evaporator inlet tube (Fig. 4). (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - A/C LINE COU- PLERS)
(5) Disconnect the accumulator inlet tube refriger- ant line fitting from the evaporator outlet tube. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE - A/C LINE COUPLERS) Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Drain the engine cooling system(Refer to 7 -
COOLING - STANDARD PROCEDURE).
DR
(7) Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
(8) Unplug all electrical connectors from the actua-
tors and blower motor.
mounting studs.
(9) Remove the nuts from the HVAC housing
(10) Remove the HVAC housing from inside the vehicle taking care not to allow any remaining cool- ant to drain on the vehicles interior.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle and place it on the workbench. (Refer to 24 - HEAT- ING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Unplug the electrical connectors from each
actuator.
(3) Remove the HVAC assembly wiring harness
from the HVAC case.
(4) Remove the blower motor and blower wheel unit from the HVAC housing. (Refer to 24 - HEAT- ING & AIR CONDITIONING/DISTRIBUTION/ BLOWER MOTOR - REMOVAL)
(5) Remove the heater core mounting screws and carefully remove the heater core assembly(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ HEATER CORE - REMOVAL).
(6) Carefully remove the foam seals from the heater core and evaporator coil tube mounting flange of the HVAC housing. If the either seal is deformed or damaged it must be replaced.
(7) Use a screwdriver to pry off the four snap clips that help secure the upper and lower HVAC housing halves together.
(8) Remove the screws that secure the upper and
lower HVAC housing halves together.
(9) Carefully separate the upper HVAC housing
from the lower half.
ASSEMBLY
(1) Assemble the upper HVAC housing half to the lower half. During assembly, be certain of the follow- ing.
(a) That each of the mode door pivot shaft ends and the temperature blend door shafts are properly engaged in there pivot holes.
(b) That the blower motor is properly indexed
and installed.
(c) If the unit is equipped with air conditioning, that the evaporator coil tube rubber seal is prop- erly positioned in the grooves in both the upper and lower HVAC housing halves.
(d) That the evaporator drain opening is clean. (e) That the evaporator drain shield is installed
correctly.
DR HVAC HOUSING (Continued)
DISTRIBUTION
24 - 29
(2) Install the screws and snap clips that secure the upper and lower HVAC housing halves to each other. Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install the blower motor and wheel unit in the HVAC housing. (Refer to 24 - HEATING & AIR CON- DITIONING/DISTRIBUTION/BLOWER MOTOR - INSTALLATION)
(4) Install the foam seals on the flanges around the heater core and evaporator coil tube mounting flange of the HVAC housing. Repair or replace any seals as required.
(5) Install the electrical wiring harness for the acutators. Make sure the wires are routed through all wiring retainers, replace any retainers that are damaged or missing.
(6) Connect the wiring harness to each actuator,
making sure each connector is securely attached.
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR CONDITIONING, REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - CAUTION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT PRECAU- TIONS)
HOSES/LINES/TUBES
(1) Position the HVAC housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
(2) Install and tighten the nuts onto the HVAC housing mounting studs. Tighten the nuts to 6.2 N·m (55 in.lbs.).
(3) Connect the HVAC system electrical connec-
tors.
(4) Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system(Refer to 7 - COOLING/ENGINE - STANDARD PROCE- DURE).
(5) Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING - STANDARD PROCEDURE - A/C LINE COU- PLERS)
(6) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(7) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
(8) Install the instrument panel in the vehicle(Re- fer to 23 - BODY/INSTRUMENT PANEL - INSTAL- LATION).
(9) Connect the battery negative cable. (10) Start the engine and check for proper opera-
tion of the heating and air conditioning systems.
(11) Run the calibration procedure.
INSTRUMENT PANEL DUCTS REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the HVAC assembly from the vehi- cle(Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL).
(3) Disasemble the HVAC housing(Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - DISASSEMBLY).
(4) Remove the panel door actuator from the hous-
ing if not already removed.
(5) With the actuator removed you can take the door and shift it so that one pivot point will clear the housing. You can then tilt the door and remove it from the housing.
INSTALLATION
(1) Take the door and tilt it so one pivot point is installed. The carfully install the second pivot point. Check to be sure no binding of the door is occuring, repair as required.
(2) Reassemble the HVAC housing(Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC assembly into the vehicle(Re- fer to 24 - HEATING & AIR CONDITIONING/DIS- TRIBUTION/INSTRUMENT INSTALLATION).
PANEL DUCTS
(4) Connect the battery negative cable.
24 - 30
DISTRIBUTION
DR
MODE DOOR REMOVAL - FLOOR - DEFROST DOOR
RECIRC DOOR REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - WARNING) and (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAU- TION).
(1) Remove and disassemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL) (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - DISASSEMBLY) (2) Remove the floor door actuator from the lower HVAC housing. (Refer to 24 - HEATING & AIR CON- DITIONING/CONTROLS/MODE DOOR ACTUATOR - REMOVAL - FLOOR DOOR ACTUATOR)
(3) Take the defrost door and shift it so that one pivot point clears the door and remove from the HVAC housing.
INSTALLATION - FLOOR - DEFROST DOOR
(1) Install the floor-defrost door in the HVAC hous-
ing by placing the door in the lower housing.
(2) Assemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - ASSEMBLY)
(3) Install the floor door actuator to the lower HVAC housing. (Refer to 24 - HEATING & AIR CON- DITIONING/CONTROLS/MODE DOOR ACTUATOR - INSTALLATION - FLOOR DOOR ACTUATOR)
(4) Install the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRI- BUTION/HVAC HOUSING - INSTALLATION)
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR CONDITIONING, REVIEW THE WARNINGS AND CAUTIONS IN PLUMBING BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - CAUTION)
(1) Remove the HVAC housing and disassemble. (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - REMOVAL) (Refer to 24 - HEATING & AIR CONDITIONING/ DISTRIBUTION/HVAC HOUSING - DISASSEMBLY) (2) Remove the four screws to remove the recircu- lation door assembly. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/RECIRCULATION DOOR ACTUATOR - REMOVAL)
(3) With the actuator remove take the recircula- tion door and move it to one side so that one pivot point clears the housing. The tilt the recirculation door and remove from the assembly.
INSTALLATION
(1) Guide the recirculation door lever through the air intake grille of the HVAC housing while installing the door in the housing.
(2) Assemble the HVAC housing. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING - ASSEMBLY)
(3) Install the HVAC housing in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/DISTRI- BUTION/HVAC HOUSING - INSTALLATION)
(4) Install the recirculation door actuator on the HVAC housing. (Refer to 24 - HEATING & AIR CON- DITIONING/CONTROLS/RECIRCULATION DOOR ACTUATOR - INSTALLATION)
DR
PLUMBING
24 - 31
PLUMBING
TABLE OF CONTENTS
page
page
PLUMBING
A/C CONDENSER FAN
DESCRIPTION - REFRIGERANT LINE OPERATION- REFRIGERANT LINES WARNING
. . . . . . . 32
. . . . . . . . 32REMOVAL - CONDENSER FAN (GAS ENGINE
ONLY - 3.7, 4.7 & 5.7L)
. . . . . . . . . . . . . . . . . 43
INSTALLATION - CONDENSER FAN (GAS
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . 32
ENGINE ONLY - 3.7, 4.7 & 5.7L)
. . . . . . . . . . 43
CAUTION
SERVICE CAUTIONS CAUTION - REFRIGERANT HOSES/LINES/
. . . . . . . . . . . . . . . . . . 33
TUBES PRECAUTIONS . . . . . . . . . . . . . . . . . 33
A/C DISCHARGE LINE
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 43STANDARD PROCEDURE
INSTALLATION
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT . . . . . . . . . . 34
STANDARD PROCEDURE - REFRIGERANT
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STANDARD PROCEDURE - REFRIGERANT
INSTALLATION INSTALLATION - 5.9L DIESEL ENGINE
. . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . 44LIQUID LINE
