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(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
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 35
SUCTION LINE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 35
. . . . . 35SPECIFICATIONS - CHARGE CAPACITY
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 46A/C COMPRESSOR
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION - HIGH PRESSURE RELIEFVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION - HIGH PRESSURE RELIEFVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - A/C
COMPRESSOR NOISE
. . . . . . . . . . . . . . . . . 36
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 37INSTALLATION
INSTALLATION INSTALLATION - 5.9L DIESEL ENGINE
. . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . 39A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVALREMOVAL - 3.7, 4.7 and 5.7L ENGINES . . . . 39
REMOVAL - 5.9L DIESEL ENGINE . . . . . . . . . 40
REMOVAL - 8.0L Engine . . . . . . . . . . . . . . . . 40INSTALLATION
INSTALLATION - 3.7, 4.7 and 5.7L ENGINES . 41
INSTALLATION - 5.9L DIESEL ENGINE . . . . . 42
. . . . . . . . . . . . . 42
INSTALLATION - 8.0L EngineINSTALLATION
INSTALLATION INSTALLATION A/C EVAPORATOR
. . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . 47DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47A/C ORIFICE TUBE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING - FIXED ORIFICETUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50HEATER CORE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50REFRIGERANT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTING- REFRIGERANTSYSTEM LEAKS
. . . . . . . . . . . . . . . . . . . . . . 51
24 - 32
PLUMBING
DR
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 51
STANDARD PROCEDURE- REFRIGERANT
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 52
STANDARD PROCEDURE- REFRIGERANT
SYSTEM CHARGE. . . . . . . . . . . . . . . . . . . . . 52
REFRIGERANT LINE COUPLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
PLUMBING DESCRIPTION - REFRIGERANT LINE
The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube, which is sandwiched between rubber lay- ers, is used for the R-134a air conditioning system on this vehicle. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecu- lar structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight alumi- num or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumb- ing will reduce the capacity of the entire air condi- tioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3
inches) from an exhaust manifold.OPERATION- REFRIGERANT LINES
High pressures are produced in the refrigerant sys- tem when the air conditioning compressor is operat- ing. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.
The refrigerant lines and hoses are coupled with other components of the HVAC system with either 3
O-ring spring lock couplings or dual axes seals.The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53REFRIGERANT OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
STANDARD PROCEDURE - REFRIGERANTOIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
WARNING
SERVICE WARNINGS
WARNING: THE AIR CONDITIONING SYSTEM CON- TAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. SERI- OUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CON- TACT OCCURS, SEEK MEDICAL ATTENTION IMME- DIATELY. DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DIS- PLACE THE OXYGEN AND CAUSE SUFFOCATION. THE EVAPORATION RATE OF R-134a REFRIGER- ANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGER- ANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. THE R-134a SERVICE EQUIPMENT OR THE VEHI- CLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COM- PRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROP- ERTY DAMAGE.
DR PLUMBING (Continued) CAUTION
SERVICE CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used. Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result. R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible. Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can cause noise and system failure. Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrig- erant. Do not remove the secondary retention clip from any spring-lock coupler connection while the refrig- erant system is under pressure. Recover the refrig- erant before removing the secondary retention clip. Open the fittings with caution, even after the sys- tem has been discharged. Never open or loosen a connection before recovering the refrigerant. The refrigerant system must always be evacuated before charging. Do not open the refrigerant system or uncap a replacement component until you are ready to ser- vice the system. This will prevent contamination in the system. Before disconnecting a component, clean the out- side of the fittings thoroughly to prevent contami- nation from entering the refrigerant system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal with clean refrigerant oil before connect- ing. Do not remove the sealing caps from a replacement component until it is to be installed. line, avoid sharp When installing a refrigerant bends that may restrict refrigerant flow. Position the refrigerant lines away from exhaust system compo- nents or any sharp edges, which may damage the line. Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refriger- ant system will not tolerate overtightening. fitting, use a When disconnecting a refrigerant wrench on both halves of the fitting. This will pre-
PLUMBING
24 - 33
vent twisting of the refrigerant lines or tubes. Refrigerant oil will absorb moisture from the atmo- sphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. Keep service tools and the work area clean. Con- tamination of the refrigerant system through care- less work habits must be avoided.
CAUTION - REFRIGERANT HOSES/LINES/ TUBES PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is oper- ating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight.
A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good con- dition and properly routed.
There are two types of refrigerant fittings: † All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak.† Unified plumbing connections with gaskets can- not be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing.
Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connec- tion with a second wrench.
The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrig- erant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210.
PLUMBING
24 - 34
PLUMBING (Continued)DR
The refrigerant system will remain chemically sta- ble as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if is present in the refrigerant system.
foreign material
When it is necessary to open the refrigerant sys- tem, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed.
All tools, including the refrigerant recycling equip- ment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant.
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
When servicing the air conditioning system, a R-134a refrigerant recovery/recycling/charging sta- tion that meets SAE Standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.
recovery/recycling/charging
A manifold gauge set may be needed with some recovery/recycling/charging equipment (Fig. 1). The service hoses on the gauge set being used should have manual (turn wheel), or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not com- patible and system damage will result.
LOW PRESSURE GAUGE HOSE The low pressure hose (Blue with Black stripe) attaches to the suction
Fig.1MANIFOLDGAUGESET-TYPICAL
1 - HIGH PRESSURE GAUGE 2 - VALVE 3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK STRIPE) 4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE) 5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE) 6 - VALVE 7 - LOW PRESSURE GAUGE
service port. This port is located on the suction line between the accumulator outlet and the compressor. HIGH PRESSURE GAUGE HOSE The high pres- sure hose (Red with Black stripe) attaches to the dis- charge service port. This port is located on the liquid line between the condenser outlet and the evaporator. RECOVERY/RECYCLING/EVACUATION/CHARG- ING HOSE The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacu- ate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.
STANDARD PROCEDURE - REFRIGERANT RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrig-
DR PLUMBING (Continued)
PLUMBING
24 - 35
erant system. Refer to the operating instructions sup- plied by the equipment manufacturer for the proper care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the com- pressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant sys- tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy- cling/charging station that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle.
(2) Recover the refrigerant(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(3) Open the low and high side valves and start the charging station vacuum pump. When the suc- tion gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn off the vac- uum pump.
(a) If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. (Refer to 24 - HEATING & AIR CON- DITIONING/PLUMBING - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec- ified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes. (4) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(5) The refrigerant system is now ready to be charged with R-134a refrigerant. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - SPECIFICA- TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions sup- plied by the equipment manufacturer for proper care and use of this equipment.
The R-134a refrigerant charge capacity for this
vehicle is 0.7371 Kg (26 oz.).
NOTE: Always refer to the HVAC underhood sticker for current refrigerant charge level and refrigerant oil specifications.
SPECIFICATIONS - CHARGE CAPACITY
The R-134a refrigerant system charge capacity for
this vehicle is: 0.7371 Kg. (26 oz.).
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION
The air conditioning system uses a Sanden SD-7
reciprocating swash plate-type compressor on all models. This compressor has a fixed displacement of 165 cubic centimeter and has both the suction and discharge ports located on the cylinder head. A label identifying the use of R-134a refrigerant is located on the compressor.DESCRIPTION - HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the com- pressor cylinder head, which is on the rear of the compressor. This mechanical valve is designed to vent refrigerant from the system to protect against damage to the compressor and other system compo-
PLUMBING
24 - 36
A/C COMPRESSOR (Continued)nents, caused by condenser air flow restriction or an overcharge of refrigerant.
OPERATION
OPERATION
The compressor is driven by the engine through an electric clutch, drive rotor and belt arrangement. The compressor is lubricated by refrigerant oil that is cir- culated throughout the refrigerant system with the refrigerant.
The compressor draws in low-pressure refrigerant vapor from the evaporator through its suction port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is then pumped to the condenser through the compressor dis- charge port.
The compressor cannot be repaired. If faulty or damaged, the entire compressor assembly must be replaced. The compressor clutch, pulley and clutch coil are available for service.
OPERATION - HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents the system when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes when a minimum discharge pressure of 2756 kPa (400 psi) is reached.The high pressure relief valve vents only enough refrigerant to reduce the system pressure, and then re-seats itself. The majority of the refrigerant is con- served in the system. If the valve vents refrigerant, it does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali- brated unit. The valve cannot be adjusted or repaired, and must not be removed or otherwise dis- turbed. The valve is only serviced as a part of the compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR NOISE
When investigating an air conditioning related noise, you must first know the conditions under which the noise occurs. These conditions include: weather, vehicle speed, transmission in gear or neu- tral, engine speed, engine temperature, and any other special conditions. Noises that develop during air conditioning operation can often be misleading. For example: What sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and depending upon belt tension, belts can develop noises that are mistaken for a compressor
DR
noise. Improper belt tension can cause a misleading noise when the compressor clutch is engaged, which may not occur when the compressor clutch is disen- gaged. Check the serpentine drive belt condition and tension as described in Cooling before beginning this procedure.
(1) Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Switch the compressor on and off several times to clearly iden- tify the compressor noise. Listen to the compressor while the clutch is engaged and disengaged. Probe the compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to bet- ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard- ware and retighten. Tighten the compressor clutch mounting nut. Be certain that the clutch coil is mounted securely to the compressor, and that the clutch plate and rotor are properly aligned and have the correct air gap. (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - INSTALLATION)
(3) To duplicate a high-ambient temperature condi- tion (high head pressure), restrict the air flow through the condenser. Install a manifold gauge set to be certain that the discharge pressure does not exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual noises. Also check the refrigerant lines for kinks or sharp bends that will restrict refrigerant flow, which can cause noises. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - CAU- TION)
(5) If the noise is from opening and closing of the high pressure relief valve, evacuate and recharge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO- CEDURE - REFRIGERANT SYSTEM EVACUATE) (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE - REFRIG- ERANT SYSTEM CHARGE) If the high pressure relief valve still does not seat properly, replace the compressor.
(6) If the noise is from liquid slugging on the suc- tion line. Check the refrigerant oil level and the refrigerant system charge. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGER- ANT OIL - STANDARD PROCEDURE) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - SPECIFICATIONS - CHARGE CAPACITY) If either is out of specification range reclaim, evacuate and recharge the refrigerent system(Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/REFRIG- ERANT - STANDARD PROCEDURE), (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/RE-
DR A/C COMPRESSOR (Continued)
PLUMBING
24 - 37
FRIGERANT - STANDARD PROCEDURE) and (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT - STANDARD PROCE- DURE). If the liquid slugging condition continues replace the accumulator(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR - REMOVAL). If after replaceing the accumulator the slugging condition still exists then replace the com- pressor.(Refer to 24 - HEATING & AIR CONDITION- ING/PLUMBING/A/C COMPRESSOR - REMOVAL)
(7) If the noise continues, replace the compressor
and repeat Step 1.
REMOVAL
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the suction and discharge refrigerant line manifold from the compressor. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - REMOVAL) (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - REMOVAL) Install plugs in, or tape over all of the opened refrigerant fittings.
(6) Remove the bolts that secure the compressor to
the mounting bracket (Fig. 2).
(7) Remove the compressor from the mounting
bracket.
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE
Fig.2A/CCOMPRESSOR-3.7LENGINE-(typical
4.7,5.7&8.0L)
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR 5 - A/C COMPRESSOR CLUTCH AND PULLEY 6 - COMPRESSOR MOUNTPERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator. (1) Recover the refrigerant from the refrigerant system. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the bolt that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings.
(6) Remove the four bolts that secure the compres-
sor to the mounting bracket (Fig. 3).
(7) Remove the a/c compressor from the mounting
bracket.
PLUMBING
24 - 38
A/C COMPRESSOR (Continued)DR
AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket. (2) On the 3.7L, 4.7L, 5.7L and 8.0L gasoline engines install and tighten the bolts in the following sequence (Fig. 4): † The number one bolt (rear) is hand tightened † The number three bolt is then hand tightened † The number two bolt is also hand tightened and
first then tightened to 55 N·m (41 ft. lbs.)
and torqued to 40 N·m ( 30 ft. lbs.)
torqued to 55 N·m ( 41 ft. lbs.)
Fig.3COMPRESSORREMOVE/INSTALL-DIESEL
ENGINE
1 - ENGINE 2 - BRACKET 3 - A/C COMPRESSOR 4 - BOLTS
INSTALLATION
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
The compressor may be removed and repositioned without disconnecting the refrigerant lines or dis- charging the refrigerant system. Discharging is not necessary if servicing the compressor clutch or clutch coil, the engine, the cylinder head, or the generator.
If a replacement compressor
NOTE: is being installed, be certain to check the refrigerant oil level. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - STANDARD PRO- CEDURE - REFRIGERANT OIL LEVEL) Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING &
Fig.4A/CCOMPRESSOR-3.7LENGINE-(typical
4.7,5.7&8.0L)
1 - COMPRESSOR BOLT #1
2 - COMPRESSOR BOLT #2
3 - COMPRESSOR BOLT #3
4 - A/C COMPRESSOR 5 - A/C COMPRESSOR CLUTCH AND PULLEY 6 - COMPRESSOR MOUNT(3) Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. Tighten the fastener to 28 N·m (250 in. lbs.).(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ SUCTION LINE - INSTALLATION) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C DISCHARGE LINE - INSTALLATION)
(4) Install the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Plug in the compressor clutch coil wire harness
connector.
(6) Connect the battery negative cable.
DR A/C COMPRESSOR (Continued)
(7) Evacuate the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS- TEM CHARGE)
INSTALLATION - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - WARNING) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION)(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES PRECAUTIONS)
If a replacement compressor
NOTE: is being installed, be certain to check the refrigerant oil level. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - STANDARD PRO- CEDURE) Use only refrigerant oil of the type recommended for the compressor in the vehicle. (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket. Tighten the four mounting bolts to 24 N·m (210 in. lbs.).
(2) Remove the tape or plugs from all of the opened refrigerant line fittings. Install the suction and discharge line manifold to the compressor. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C SUCTION AND DISCHARGE LINE - INSTALLATION)
(3) Install the serpentine drive belt(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(4) Plug in the compressor clutch coil wire harness
connector.
(5) Connect the battery negative cable. (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)
PLUMBING
24 - 39
A/C CONDENSER DESCRIPTION
