2006 VA Service Manual - aie-services

2006 VA Service Manual - aie-services
HEATING & AIR CONDITIONING
VA
24 - 1
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page
HEATING & AIR CONDITIONING
DESCRIPTION . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
A/C PERFORMANCE . . . . . . . .
HEATER PERFORMANCE TEST
ATC FUNCTION TEST . . . . . . .
SPECIFICATIONS
HEATING-A/C SYSTEM . . . . . .
............1
............2
............3
...........5
............6
page
CONTROLS-FRONT . . . . . . . . . . . . . . . . . . . . . . . . 8
CONTROLS - REAR . . . . . . . . . . . . . . . . . . . . . . 24
DISTRIBUTION - FRONT . . . . . . . . . . . . . . . . . . . 45
DISTRIBUTION - REAR . . . . . . . . . . . . . . . . . . . . 52
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 104
............6
HEATING & AIR CONDITIONING
DESCRIPTION
An automatic temperature control (ATC) single
zone type heating-A/C system is standard equipment
on this model.
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser
will reduce the performance of the A/C and engine
cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to 7 - Cooling for more information
before opening or attempting any service to the
engine cooling system.
All vehicles are equipped with a common ventilation housing (Fig. 1) located in the engine compartment which includes:
• Blower motor
• Blower motor resistor block
• Recirculation door and actuator
Fig. 1 Ventilation Housing
1
2
3
4
-
NUT (5)
WASHER (5)
VENTILATION HOUSING
HOUSING COVER
All vehicles are also equipped with a common
heater housing (Fig. 2) mounted under the instrument panel which includes:
• Heater core
• Evaporator core
• Evaporator temperature sensor
• Expansion valve
• Air outlet temperature sensor
• Mode doors
24 - 2
HEATING & AIR CONDITIONING
VA
A heater booster is used to aid in warming the
engine coolant. The heater booster system can be
switched on while the vehicle is being driven to help
the engine reach its normal operating temperature
quickly and will help aid in heating up the air within
the passenger compartment quickly when requested
by the operator (Fig. 4).
Fig. 2 Heater Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
Some vehicles are equipped with an additional
Denso 10S17 A/C compressor mounted to the engine
which is used for the optional rear A/C system and
various add-on A/C systems (Fig. 3).
Fig. 3 Denso 10S17 A/C Compressor
Fig. 4 Heater Booster
OPERATION
Outside air enters the vehicle through the hood
opening at the base of the windshield, and passes
through the ventilation housing located in the engine
compartment into the heater housing located behind
the instrument panel. Air flow velocity is adjusted
with the blower motor speed selector thumbwheel on
the A/C-heater control. The air intake openings must
be kept free of snow, ice, leaves, and other obstructions for the HVAC system to receive a sufficient volume of outside air.
The automatic temperature control (ATC) system
controls interior temperature by taking actual values
from the temperature sensors and the CAN bus and
comparing them to the nominal value of the temperature control switch. The electric pulsed heater valve
is then energized depending on the requested quantity of heat and an electrically-operated water pump
gives a nearly constant water flow for exact temperature regulation. If the solenoid is not energized, the
coolant circuit to the heat exchanger is fully open. To
control the temperature the solenoid valve is pulsed
by the ATC in periods of four seconds.
The mode control knob on the A/C-heater control is
used to direct the conditioned air flow to the selected
air outlets. The mode control knob operates the mode
doors by cables connected to the mode doors.
VA
When the outside air contains smoke, odors, high
humidity, or if rapid cooling is desired, interior air
can by recirculated by selecting the Recirculation
Mode with the mode control knob. The mode control
knob operates the recirculation door through use of a
vacuum actuator. When the Recirculation Mode is
selected, the recirculation door is closed to prevent
outside air from entering the passenger compartment.
To maintain minimum evaporator temperature and
prevent evaporator freezing, an evaporator temperature sensor is used.
The A/C system is designed for the use of non-CFC,
R-134a refrigerant only and uses an expansion valve
to meter refrigerant flow to the evaporator.
DIAGNOSIS AND TESTING
A / C PERFORMANCE
The A/C system is designed to provide the passenger compartment with low temperature and low
humidity air. The A/C evaporator, located in the
HVAC housing is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins of the A/C evaporator, the air transfers its heat
to the refrigerant in the evaporator coils and the
moisture in the air condenses on the evaporator fins.
During periods of high heat and humidity, an A/C
system will be more effective in the Recirculation
mode (max-A/C). With the system in the Recirculation mode, only air from the passenger compartment
passes through the A/C evaporator. As the passenger
compartment air dehumidifies, the A/C system performance levels rise.
Humidity has an important bearing on the temperature of the air delivered to the interior of the vehicle. It is important to understand the effect that
humidity has on the performance of the A/C system.
When humidity is high, the A/C evaporator has to
perform a double duty. It must lower the air temperature, and it must lower the temperature of the
moisture in the air that condenses on the evaporator
fins. Condensing the moisture in the air transfers
heat energy into the evaporator fins and coils. This
reduces the amount of heat the A/C evaporator can
absorb from the air. High humidity greatly reduces
the ability of the A/C evaporator to lower the temperature of the air.
However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Wringing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from their
A/C system on humid days. A performance test is the
best way to determine whether the system is performing up to design standards. This test also provides valuable clues as to the possible cause of
HEATING & AIR CONDITIONING
24 - 3
trouble with the A/C system. The ambient air temperature in the location where the vehicle will be
tested must be a minimum of 21° C (70° F) for this
test.
A / C PERFORMANCE TEST
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
NOTE: Very specific instructions and conditions
pertain to this procedure which are significantly different than procedures used in other vehicle applications. Follow each step in the order they are
presented. Do not skip steps or change conditions
from those stated or results will be adversely
affected and invalid.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Check for diagnostic trouble codes using a
DRBIIIt scan tool. If no DTCs are found in the
engine control module (ECM), go to Step 2. If any
DTCs are found, repair as required, then proceed to
Step 2.
(2) Place the vehicle in the shade and operate the
heating-A/C system under the following conditions.
• Engine at idle at operating temperature
• All doors or windows open
• Transaxle in Neutral
• All A/C duct louvers open
• A/C-heater controls set to fresh air (NOT Recirculate), full cool, panel mode, high blower and with
A/C compressor engaged.
NOTE: The A/C compressor clutch is de-energized
under any of the following conditions:
• Restricted compressor (thermal fuse in the pulley)
• Low pressure in the system
• Low evaporator temperature
• Hard acceleration (WOT)
• High coolant temperatures
(3) Insert a thermometer in the driver side center
panel air outlet and operate the A/C system until the
thermometer temperature stabilizes.
24 - 4
HEATING & AIR CONDITIONING
(4) With the A/C compressor clutch engaged, duct
temperature should not be less than 2° C (35° F) or
more than 12° C (54° F). The compressor clutch may
cycle, depending upon the ambient temperature and
humidity. If the clutch cycles, use the readings
obtained before the clutch disengaged.
(5) If the A/C compressor clutch has not cycled off
and the duct temperature is less than 2° C (35° F),
check the evaporator temperature sensor and circuit
VA
by performing the ATC Function Test (Refer to 24 HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - ATC FUNCTION TEST).
(6) If the air outlet temperature fails to meet the
specifications, refer to the A/C System Diagnosis
chart.
A/C SYSTEM DIAGNOSIS
Condition
Possible Causes
Correction
Rapid A/C compressor clutch
cycling (ten or more cycles
per minute).
Very low refrigerant system
charge.
See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the refrigerant system.
1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Faulty fuse.
2. Check the fuses in the Power distribution
block and junction block. Repair the shorted
circuit or component and replace the fuses, if
required. Refer to Group 8.
3. Faulty A/C compressor
clutch coil.
3. See A/C Compressor Clutch Coil in this
group. Test the compressor clutch coil and
replace, if required.
4. Improperly installed or faulty
evaporator temperature sensor.
4. See Evaporator Temperature Sensor in this
group. Test the sensor and replace, if required.
5. Faulty A/C pressure transducer.
5. See A/C Pressure Transducer in this
group. Test the sensor and replace, if required.
6. Faulty engine Control Module (ECM).
6. Refer to Group 9 - Engine Electrical Diagnostics for testing of the ECM. Test the ECM
and replace, if required.
1. Excessive refrigerant oil in
system.
1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level,
if required.
2. Blend door cable improperly
installed or faulty.
2. See Mode Door Cables in this group. Inspect the cable for proper operation and replace, if required.
3. Blend-air door(s) inoperative
or sealing improperly.
3. See HVAC Housing in this group. Inspect
the blend-air door(s) for proper operation and
sealing. Repair if required.
Normal pressures, but A/C
Performance Test air temperatures at center panel outlet
are too high.
HEATING & AIR CONDITIONING
VA
Condition
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
The low side pressure is too
high, and the high side pressure is too low.
The low side pressure is too
low, and the high side pressure is too high.
Possible Causes
24 - 5
Correction
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
2. Refrigerant flow through the
A/C evaporator is restricted.
2. See A/C Evaporator in this group. Replace
the restricted A/C evaporator, if required.
3. Faulty A/C compressor.
3. See A/C Compressor in this group. Replace the A/C compressor, if required.
1. A/C condenser air flow restricted.
1. Check the A/C condenser for damaged
fins, foreign objects obstructing air flow
through the condenser fins, and missing or
improperly installed air seals. Clean, repair, or
replace components as required.
2. Refrigerant flow through the
receiver/drier is restricted.
2. See Receiver/Drier in this group. Replace
the restricted receiver/drier, if required.
3. Inoperative radiator cooling
fan.
3. Test the radiator cooling fan and replace, if
required. Refer to Group 7 - Cooling.
4. Refrigerant system overcharged.
4. See Refrigerant System Charge in this
group. Recover the refrigerant from the refrigerant system. Charge the refrigerant system
to the proper level, if required.
5. Air in the refrigerant system.
5. See Refrigerant System Leaks in this
group. Test the refrigerant system for leaks.
Repair, evacuate and charge the refrigerant
system, if required.
6. Engine overheating.
6. Test the engine cooling system and repair,
if required. Refer to Group 7 - Cooling.
1. Accessory drive belt slipping.
1. Inspect the accessory drive belt condition
and tension. Repair as required. Refer to
Group 7 - Cooling.
2. Faulty A/C expansion valve.
2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Faulty A/C compressor.
3. See A/C Compressor in this group. Replace the A/C compressor, if required.
1. Restricted refrigerant flow
through the refrigerant lines.
1. See Liquid Line, Suction Line and Discharge Line in this group. Inspect the refrigerant lines for kinks, tight bends or improper
routing. Correct the routing or replace the refrigerant line, if required.
2. Restricted refrigerant flow
through the A/C expansion
valve.
2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Restricted refrigerant flow
through the A/C condenser.
3. See A/C Condenser in this group. Replace
the restricted A/C condenser, if required.
HEATER PERFORMANCE TEST
MAXIMUM HEATER OUTPUT
Before performing the following tests, perform the
ATC Function Test using the DRBIIIt and refer to
Cooling for the procedures to check the radiator coolant level, serpentine drive belt tension, radiator air
flow and the radiator fan operation.
Engine coolant is provided to the heater core
through a heater valve and heater hose. With the
engine idling at normal operating temperature, set
the heater-A/C controls as follows:
• Temperature control in the full hot position
24 - 6
HEATING & AIR CONDITIONING
• Mode control in the floor heat position
• Blower motor control in the highest speed position
Using a test thermometer, check the temperature
of the air being discharged at the floor outlets. Com-
VA
pare the test thermometer reading to the Temperature Reference chart.
TEMPERATURE REFERENCE CHART
Ambient Temperature
Celsius
Minimum Floor Outlet Temperature
Fahreheit
Celsius
Fahreheit
15.5°
60°
62.2°
144°
21.1°
70°
63.8°
147°
26.6°
80°
65.5°
150°
32.2°
90°
67.2°
153°
If the floor outlet air temperature is insufficient,
check for a faulty heater valve (perform ATC Function Test) and verify that the cooling system is operating to specifications (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS AND TESTING).
Both of the heater hoses should be HOT to the touch
(the coolant return heater hose should be slightly
cooler than the supply hose. If the coolant return
hose is much cooler than the supply hose, locate and
repair the engine coolant flow obstruction in the
heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
• Pinched or kinked heater hoses.
• Improper heater hose routing.
• Plugged heater hoses or supply and return ports
at the cooling system connections.
• Inoperative or stuck heater water valve.
• Plugged heater core.
If proper coolant flow is verified, and heater floor
outlet air temperature is insufficient, a mechanical
problem may exist.
POSSIBLE LOCATIONS OR CAUSE OF INSUFFICIENT HEAT
• An obstructed cowl air intake.
• Obstructed heater system outlets.
• Heater water valve not functioning properly.
TEMPERATURE CONTROL
If outlet air temperature cannot be adjusted with
the A/C-heater temperature control, one of the following could require service:
• Faulty A/C-heater control switch.
• Faulty temperature sensor.
• Faulty A/C-heater control cable or actuator.
• Faulty A/C-heater control module.
ATC FUNCTION TEST
The automatic temperature control (ATC) system
can perform an self-test, which can be activated by
the DRBIIIt scan tool to confirm that the A/C system
is performing satisfactorily. This test provides a
quick confirmation of heating and A/C system performance to the service technician. Refer to Body Diagnostic Procedures for the appropriate diagnostic
information.
SPECIFICATIONS
HEATING - A / C SYSTEM
FRONT A/C SYSTEM
Description
Notes
A/C Compressor
Item
Denso 7SBU16C
ND-8 PAG oil
Freeze-up Control
Evaporator temperature sensor
HVAC housing mounted input to A/Cheater control
- operating
range of -10°
C (14° F) to
40° C (104°
F)
HEATING & AIR CONDITIONING
VA
Item
Description
Notes
Low psi Control
A/C Pressure
Transducer
Liquid line
mounted input to PCM
- operating
range of 200
kPa (29 psi)
to 2799 kPa
(406 psi)
High psi Control
High Pressure
Relief Valve
Receiver/drier
mounted opens at a
discharge
pressure over
3999 kPa
(580 psi)
Refrigerant
Charge Capacity
Refer to the A/C
Underhood Specification Label
located in the
engine compartment
A/C Clutch Coil
Draw
2.0-3.7 amps @
12V ± 0.5V @
21° C (70° F)
A/C Clutch Air
Gap
0.5 - 0.88 mm
(0.020 - 0.035
in.)
R-134a refrigerant
REAR A/C SYSTEM
Item
Description
Notes
A/C Compressor
Denso 10S17
ND-8 PAG oil
Freeze-up Control
Evaporator Temperature Sensor
Input to rear
A/C control
module evaporator fin
mounted cycles clutch
off below 1.6°
C (35° F),
cycles clutch
back on
above 3.9° C
(39° F)
Low psi Control
A/C Low Pressure Switch
Input to rear
A/C control
module - suction line
mounted cycles clutch
off below 30
kPa (4.4 psi)
Item
Description
24 - 7
Notes
High psi Control
A/C High Pressure Switch
Input to rear
A/C control
module - condenser inlet
tube mounted
- cycles clutch
off above
2551 kPa
(370 psi)
Refrigerant
Charge Capacity
Refer to the Rear
A/C Specification
Label
R-134a refrigerant
A/C Clutch Coil
Draw
3.3 amps @ 12V
± 0.5V @ 21° C
(70° F)
A/C Clutch Air
Gap
0.35 - 0.60 mm
(0.014 - 0.024
in.)
24 - 8
CONTROLS-FRONT
VA
CONTROLS - FRONT
TABLE OF CONTENTS
page
A/C COMPRESSOR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE
A/C COMPRESSOR CLUTCH AIR GAP . . . . . . 9
A/C COMPRESSOR CLUTCH BREAK-IN . . . . . 9
REMOVAL
.............................9
INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
A/C COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH COIL . . . . . . . . 12
A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
A/C PRESSURE TRANSDUCER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
AIR OUTLET TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
AMBIENT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A / C COMPRESSOR CLUTCH
DESCRIPTION
The A/C compressor clutch assembly consists of a
stationary electromagnetic field coil, a hub bearing
and pulley assembly, and a clutch plate (Fig. 1). The
field coil and the hub bearing and pulley assembly
are each retained on the nose of the compressor front
housing with snap rings. The clutch plate is splined
to the compressor shaft and secured with a bolt.
The compressor clutch plate and pulley and the
clutch field coil are available for service replacement.
page
REMOVAL . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . .
BLOWER MOTOR RESISTOR
DESCRIPTION . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . .
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH . . . . . . .
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . .
IN-CAR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
IN-CAR TEMPERATURE SENSOR . .
MODE DOOR CABLES
REMOVAL . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . .
RECIRCULATION DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . .
. . . . . . . 17
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CONTROLS-FRONT
VA
24 - 9
STANDARD PROCEDURE
A / C COMPRESSOR CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following procedure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley friction surfaces.
(2) If the air gap is not between specifications
(Refer to 24 - HEATING & AIR CONDITIONING SPECIFICATIONS), add or subtract shims until the
desired air gap is obtained.
Fig. 1 A/C Compressor Clutch
1
2
3
4
5
6
7
-
BOLT
CLUTCH PLATE
PULLEY AND BEARING
FIELD COIL
SNAP RING
SNAP RING
SHIM (2)
OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is
part of the pulley.
The compressor clutch engagement is controlled by
several components:
• A/C switch on the A/C-heater control panel
• Evaporator temperature sensor
• A/C pressure transducer
• Air temperature sensor
• CAN bus messages
The compressor clutch is de-energized under any of
the following conditions:
• Blocked compressor (thermal fuse in the pulley)
• Low pressure in the system
• Low evaporator temperature
• Hard acceleration (WOT)
• High coolant temperatures
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
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 heater-A/C control in the
Recirculation Mode, the A/C button in the on position, 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, pulley, 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) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil
wire harness connector on the top of the compressor.
(4) Remove the retainer securing the compressor
clutch coil lead on the top of the compressor.
(5) Remove the bolt that secures the compressor
clutch to the compressor shaft (Fig. 2). If necessary, a
band-type oil filter wrench or strap wrench can be
placed around the clutch plate to aid in bolt
removal.
24 - 10
CONTROLS-FRONT
VA
Fig. 2 Compressor Shaft Bolt and Clutch Plate
1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
(6) Tap the clutch plate lightly with a plastic mallet to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3). Be certain not to lose
the shim or shims.
CAUTION: Do not pry between the clutch plate and
the pulley to remove it from the compressor shaft.
Prying may damage the clutch plate.
Fig. 3 Clutch Plate And Shim(s)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
(7) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch pulley to the front of
the compressor, then slide the pulley off of the compressor (Fig. 4).
Fig. 4 Pulley Snap Ring
1 - SNAP RING
(8) Remove the screw that secures the clutch coil
wire harness connector bracket and ground clip to
the top of the compressor housing.
(9) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the compressor clutch coil to the front of the
compressor, then slide the clutch coil off of the compressor (Fig. 5).
CONTROLS-FRONT
VA
24 - 11
pinched between the compressor front cover and the
clutch coil.
NOTE: A new snap ring must be used to secure the
clutch coil to the compressor. The bevel side of the
snap ring must face outward.
(2) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring that
secures the clutch coil to the front cover of the compressor. The bevel side of the snap ring must be facing outward and both snap ring eyelets must be
oriented to the right or left of the clutch coil dowel
pin on the compressor. Be certain that the snap ring
is fully and 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 failure and severe damage to the compressor front
cover.
Fig. 5 Clutch Coil Snap Ring
1
2
3
4
-
SNAP RING PLIERS
CLUTCH COIL
SNAP RING
COMPRESSOR
INSPECTION
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the factory using a burnishing operation. No attempt should
be made to separately replace the compressor clutch
pulley or clutch plate. The clutch coil may be serviced
separately.
(1) Examine the friction surfaces of the clutch pulley and the clutch plate for wear. The clutch pulley
and clutch plate should be replaced if there is excessive wear or scoring.
(2) Examine the friction surfaces of the clutch pulley and the clutch plate for oil contamination. If the
friction surfaces are oily, the clutch pulley and clutch
plate should be replaced. Also inspect the shaft and
nose area of the compressor for oil. Remove the felt
packing from around the compressor shaft in the
compressor front cover. If the felt is saturated with
oil, the compressor front shaft seal is leaking and the
compressor will also have to be replaced.
(3) Check the clutch pulley bearing for roughness
or excessive leakage of grease. Replace the clutch
pulley and clutch plate if the bearing is faulty.
INSTALLATION
(1) Align the dowel pin on the back of the clutch
field coil with the hole in the compressor front cover,
and position the clutch coil onto the compressor. Be
certain that the cluch coil wire harness leads are
properly oriented and routed so that they are not
(3) Install and tighten the screw that secures the
clutch coil wire harness connector bracket and
ground clip to the top of the compressor housing.
(4) Install the pulley onto the front of the compressor. If necessary, place a block of wood on the friction
surface and tap gently with a hammer (Fig. 6).
CAUTION: Do not mar the friction surfaces of the
pulley.
Fig. 6 Pulley Assembly Install
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
24 - 12
CONTROLS-FRONT
front cover of the compressor. Be certain that the
snap ring is properly fully and properly seated in the
groove.
(6) If the original clutch plate and clutch pulley
are to be reused, reinstall the original shim(s) on the
compressor shaft against the shoulder. If a new
clutch plate and/or clutch pulley are being used,
install a trial stack of shims 1.0 mm (0.040 in.) thick
on the compressor shaft against the shoulder.
(7) Install the clutch plate onto the compressor
shaft.
(8) Install and tighten the compressor shaft bolt. If
necessary, a band-type oil filter wrench or a strap
wrench can be placed around the clutch plate to aid
in bolt tightening. Tighten the bolt to 17.5 N·m (155
in. lbs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is still correct. Spin the
pulley before performing a final check of the air
gap.
(9) If a new clutch plate and/or clutch pulley are
being installed, the air gap between the clutch plate
and clutch pulley must be checked (Refer to 24 HEATING & AIR CONDITIONING/CONTROLS/A/C
COMPRESSOR CLUTCH - STANDARD PROCEDURE).
(10) Install the retainer that secures the compressor clutch coil lead to the top of the compressor.
(11) Reconnect the engine wire harness connector
to the clutch coil lead on the top of the compressor.
(12) Reinstall the serpentine accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION).
(13) Reconnect the battery negative cable.
(14) If a new clutch plate and/or clutch pulley are
being installed, the new clutch components must be
burnished (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH
- STANDARD PROCEDURE).
A / C COMPRESSOR CLUTCH
COIL
DIAGNOSIS AND TESTING
A / C COMPRESSOR CLUTCH COIL
The air conditioning compressor clutch coil electrical circuit is controlled by the ATC control module
which is integral to the heater-A/C control. Begin
testing of a suspected compressor clutch coil problem
by performing the ATC Function Test using the
DRBIIIt scan tool.
VA
PRELIMINARY CHECKS
(1) If no diagnostic trouble codes (DTCs) are found
in the A/C-heater control or the powertrain control
module (PCM), go to Step 2. If any DTCs are found,
repair as required.
(2) If the A/C compressor clutch still will not
engage, verify the refrigerant charge level (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS). If the refrigerant charge level is
OK, go to TESTS. If the refrigerant charge level is
not OK, adjust the refrigerant charge as required.
TESTS
(1) Verify the battery state of charge (Refer to 8 ELECTRICAL/BATTERY
SYSTEM/BATTERY
DIAGNOSIS AND TESTING).
(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the A/C-heater control in the A/C mode
and the blower motor at low speed, start the engine
and allow it to run at a normal idle speed.
(4) The A/C compressor clutch should engage
immediately, and the clutch coil supply voltage
should be within two volts of the battery voltage. If
the coil supply voltage is OK, go to Step 5. If the coil
supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary.
(5) For the acceptable A/C clutch coil current draw
specifications refer to 24 - HEATING & AIR CONDITIONING - SPECIFICATIONS. Specifications apply
for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by
turning on electrical accessories until voltage reads
below 12.5 volts.
(a) If the A/C clutch coil current reading is zero,
the coil is open and must be replaced.
(b) If the A/C clutch coil current reading is above
specifications, the coil is shorted and must be
replaced.
A / C HEATER CONTROL
DESCRIPTION
This ATC system uses a combination of electrical
and mechanical controls. These controls provide the
vehicle operator with a number of setting options to
help control the climate and comfort within the vehicle.
The A/C-heater control is located on the instrument
panel inboard of the steering column and below the
CONTROLS-FRONT
VA
radio (Fig. 7). The A/C-heater control contains a rotary-type temperature control, a rotary-type mode control, a thumbwheel-type blower motor speed control
and an A/C mode push button switch and indicator
lamp. The A/C-heater control also features a push
button switch and indicator lamp for the residual
engine heat utilization (REST) function, cabin heater
or the heater booster (as equipped).
24 - 13
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT
PANEL
CENTER
BEZEL
REMOVAL).
(3) Remove the two screws that secure the A/Cheater control to the instrument panel (Fig. 8).
(4) Pull the A/C-heater control away from the
instrument panel far enough to access the connections on the back of the control.
(5) Mark and disconnect the two control cables
from the A/C-heater control.
(6) Disconnect the two wiring harness connectors
from the A/C-heater control.
(7) If A/C-heater control is to be replaced, remove
the two mounting brackets from the A/C-heater control.
Fig. 7 A/C-Heater Control
OPERATION
To control the interior temperature, the A/C-heater
control uses the actual values from the temperature
sensors and the CAN bus and compares them with
the nominal value of the temperature control switch.
The A/C-heater control is diagnosed using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The A/C-heater control is diagnosed using a
DRBIIIt scan tool. Refer to Body Diagnostic Procedures.
The A/C-heater control cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
Fig. 8 A/C-Heater Control
1
2
3
4
5
6
7
-
A/C-HEATER CONTROL
CONTROL CABLE
CONTROL CABLE
WIRE HARNESS CONNECTOR
WIRE HARNESS CONNECTOR
MOUNTING BRACKET (2)
SCREW (2)
INSTALLATION
(1) If removed, install the two mounting brackets
to the A/C-heater control.
(2) Connect the two wire harness connectors into
the back of the A/C-heater control.
(3) Connect the two control cables to the A/Cheater control.
NOTE: Install the control cable of bottom adjustment lever to the front adjustment wheel of the A/Cheater control.
(4) Position the A/C-heater control into the instrument panel.
24 - 14
CONTROLS-FRONT
(5) Install the two A/C-heater control retaining
screws. Tighten the screws to 2 N·m (17 in. lbs.).
(6) Install the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTALLATION).
(7) Reconnect the negative battery cable.
A / C PRESSURE TRANSDUCER
DESCRIPTION
The A/C pressure transducer is installed on the liquid line fitting located at the top of the receiver/drier
(Fig. 9). A rubber O-ring seals the connection
between the transducer and the fitting. Three terminals within a molded plastic connector receptacle on
the top of the transducer connect it to the vehicle
electrical system through a wire lead and connector.
The A/C pressure transducer cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
VA
through its connection to a fitting on the liquid line.
The transducer will change its internal resistance in
response to the pressures it monitors. The ATC control module provides a five volt reference signal and
monitors the output voltage of the transducer on the
transducer return circuit to determine refrigerant
pressure. The ATC module is preprogrammed to
respond to this and other sensor inputs by controlling
the operation of the air conditioning compressor
clutch and the auxiliary radiator cooling fan to help
optimize air conditioning system performance and to
protect the system components from damage. The
A/C pressure transducer input to the ATC module
also prevents the A/C compressor clutch from engaging when the ambient temperature is below 0.556° C
(33° F) due to the pressure/temperature relationship
of the refrigerant.
The A/C pressure transducer is diagnosed by performing the ATC Function Test using the DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The A/C pressure transducer cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING
A / C PRESSURE TRANSDUCER
Fig. 9 A/C Pressure Transducer
1 - A/C PRESSURE TRANSDUCER
2 - PIEZORESISTIVE ELEMENT
3 - WIRE CONNECTOR
OPERATION
The A/C pressure transducer monitors the pressures in the high side of the refrigerant system
The A/C pressure transducer is tested using a
DRBIIIt scan tool. Refer to Body Diagnostic Procedures. Before testing the A/C pressure transducer, be
certain that the transducer wire harness connections
are clean of corrosion and properly connected. For
the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.7 and 4.56
volts is required. Voltage outside this range indicate
a low or high refrigerant system pressure condition
to the ATC control module. The control module is
programmed to respond to a low or high refrigerant
system pressure by suppressing operation of the compressor. Refer to the A/C Pressure Transducer Voltage chart for the possible condition indicated by the
transducer voltage readings.
CONTROLS-FRONT
VA
24 - 15
A/C PRESSURE TRANSDUCER VOLTAGE
Voltage
0.0
Possible Cause
1. No transducer supply voltage from ATC control module.
2. Shorted transducer circuit.
3. Faulty transducer.
0.150 to 0.450
1. Ambient temperature below 10° C (50° F).
2. Low refrigerant system pressure.
0.451 to 4.519
1. Normal refrigerant system pressure.
4.520 to 4.850
1. High refrigerant system pressure.
5.0
1. Open transducer circuit.
2. Faulty transducer.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 10).
(4) Using an open end wrench, remove the A/C
pressure transducer from the fitting on the liquid
line.
(5) Remove the O-ring seal from the A/C pressure
transducer and discard.
Fig. 10 A/C Pressure Transducer
1
2
3
4
-
WIRE HARNESS CONNECTOR
A/C PRESSURE TRANSDUCER
O-RING SEAL
LIQUID LINE FITTING
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer.
(2) Using an open end wrench, install and tighten
the A/C pressure transducer into the fitting on the
liquid line. Tighten the transducer to 12 N·m (106 in.
lbs.).
(3) Reconnect the wire harness connector to the
transducer.
(4) Reconnect the battery negative cable.
(5) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE).
24 - 16
CONTROLS-FRONT
(6) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE).
AIR OUTLET TEMPERATURE
SENSOR
DESCRIPTION
The air outlet temperature sensor is a two-wire
temperature sensing element that detects the temperature of the air coming out of the heater housing
unit (Fig. 11). The sensor is attached to heater housing unit directly behind the ATC heater-A/C control
panel. The thermistor will change resistance as the
temperature changes.
VA
The air outlet temperature sensor is diagnosed by
performing the ATC Function Test using the DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The air outlet temperature sensor cannot be
adjusted or repaired, and if faulty or damaged, it
must be replaced.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the heater-A/C control from the instrument panel (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL REMOVAL).
(3) Disconnect the wire harness connector from the
air outlet temperature sensor (Fig. 12).
(4) Remove the air outlet temperature sensor from
the heater housing.
Fig. 11 Air Outlet Temperature Sensor
1 - AIR OUTLET TEMPERATURE SENSOR
2 - NTC THERMISTOR
3 - WIRE CONNECTOR
OPERATION
The air outlet temperature sensor monitors the
temperature of the air coming out of the heater housing unit. The sensor will change its internal resistance in response to the temperatures it monitors.
The ATC control module is connected to the sensor
through a sensor ground circuit and a sensor signal
circuit. As the air temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The operating range
of the air outlet temperature sensor is 0° C (32° F)
and 95° C (203° F). The module uses this monitored
voltage reading to an indication of the outlet air temperature. The ATC control module makes adjustments
to
maintain
the
requested
interior
temperature by cycling both the A/C compressor and
solenoid heater valve on and off.
Fig. 12 Air Outlet Temperature Sensor
1 - HEATER HOUSING
2 - AIR OUTLET TEMPERATURE SENSOR
INSTALLATION
(1) Install the air outlet temperature sensor onto
the heater housing.
(2) Connect the wire harness connector to the air
outlet temperature sensor.
(3) Install the heater-A/C control into the instrument panel (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL INSTALLATION).
(4) Reconnect the battery negative cable.
CONTROLS-FRONT
VA
AMBIENT TEMPERATURE SENSOR
DESCRIPTION
The ambient air temperature sensor is a variable
resistor that monitors the air temperature outside of
the vehicle. The ambient air temperature sensor is
connected to the instrument cluster through a twowire harness lead and connector of the vehicle electrical system (Fig. 13). The instrument cluster sends
out a message on the CAN bus to the ATC control
module which uses the sensor data to maintain optimum cabin temperature levels.
The ambient air temperature sensor is mounted to
the front licence plate bracket by three integral
retaining tabs.
24 - 17
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front license plate bracket (Refer
to 23 - BODY/EXTERIOR/LICENSE PLATE
BRACKET - REMOVAL).
(3) Disconnect the wire harness connector from the
ambient temperature sensor (Fig. 14).
(4) Disengage the sensor retaining tabs and
remove the ambient temperature sensor from the
front license plate bracket.
Fig. 14 Ambient Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - FRONT LICENSE PLATE BRACKET
INSTALLATION
Fig. 13 Ambient Air Temperature Sensor
1 - AMBIENT TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
3 - RETAINING TABS (3)
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the instrument cluster. The resistance in
the sensor changes as temperature changes. Based
upon the resistance in the sensor, the instrument
cluster sends the ATC control module a specific voltage on the temperature sensor signal circuit, which
is programmed to correspond to a specific temperature.
The ambient temperature sensor is diagnosed
using the DRBIIIt scan tool. Refer to Body Diagnostic Procedures.
The ambient temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
(1) Install the ambient temperature sensor onto
the front license plate bracket. Make sure the retaining tabs are fully engaged.
(2) Connect the wire harness connector to the
ambient temperature sensor.
(3) Install the front license plate bracket (Refer to
23 - BODY/EXTERIOR/LICENSE PLATE BRACKET
- INSTALLATION).
(4) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
DESCRIPTION
This temperature control system uses a blower
motor resistor (Fig. 15). The blower motor resistor is
mounted to the top of ventilation housing located in
the engine compartment. The blower motor resistor
consists of a molded plastic mounting plate with an
integral retaining tab and wire connector receptacle.
Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink.
24 - 18
CONTROLS-FRONT
The blower motor resistor is accessed for service
without removing any other components.
VA
(1) Disconnect and isolate the negative battery
cable.
(2) Disconnect 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 as required. If
not OK, replace the faulty blower motor resistor.
REMOVAL
Fig. 15 Front Blower Motor Resistor
1 - MOUNTING PLATE
2 - WIRE CONNECTOR RECEPTACLE
3 - CERAMIC HEAT SINK
(1) Disconnect and isolate the negative battery
cable.
(2) Depress the locking tab and remove the blower
motor resistor from the ventilation housing by sliding
the resistor inboard (Fig. 16).
(3) Depress the two locking tabs and disconnect
the wire harness connector from the blower motor
resistor.
(4) Remove the blower motor resistor from the
engine compartment.
OPERATION
The blower motor resistor block has multiple resistor wires. Each resistor wire changes the resistance
in the blower motor current path to change the
blower motor speed. The blower motor switch directs
the current through the correct resistor wire to
obtain the selected speed.
With the blower motor switch in the lowest speed
position, voltage for the motor is applied through all
of the resistor wires. Each higher speed selected with
the blower motor switch applies the blower motor
current path through fewer of the resistor wires,
increasing the blower motor speed. When the blower
motor switch is in the highest speed position, the
blower motor resistor is bypassed and the blower
motor circuit receives a direct path to battery voltage.
The blower motor resistor block cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING
BLOWER MOTOR RESISTOR
NOTE: For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pinout and location views for the various wire harness
connectors, splices and grounds.
Fig. 16 Blower Motor Resistor Block
1 - BLOWER MOTOR RESISTOR
2 - ELECTRICAL CONNECTOR
3 - VENTILATION HOUSING
INSTALLATION
(1) Connect the wire harness connector to the
blower motor resistor and engage the two locking
tabs.
(2) Install the blower motor resistor into the ventilation housing and engage the locking tab. The
housing is indexed to allow mounting in only one
position.
(3) Reconnect the negative battery cable.
CONTROLS-FRONT
VA
BLOWER MOTOR SWITCH
DESCRIPTION
The blower motor is controlled by a thumbwheeltype blower motor control, mounted in the A/C-heater
control (Fig. 17). The switch allows the selection of
four blower motor speeds with the ignition switch in
the On position.
NOTE: The blower motor will operate only at the
lowest speed when the Residual Engine Heat Utilization (REST) function is selected, regardless of the
blower speed setting on the A/C-heater control.
24 - 19
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
The evaporator temperature sensor measures the
temperature of the conditioned air downstream of the
A/C evaporator (Fig. 18). The evaporator temperature
sensor is an electrical thermistor within a molded
plastic case that is inserted into the HVAC housing
near the coldest point of the A/C evaporator. Two terminals within the connector receptacle connect the
sensor to the vehicle electrical system through a wire
lead and connector of the HVAC wire harness.
The external location of the evaporator temperature sensor allows the sensor to be removed or
installed without disturbing the refrigerant in the
A/C system.
Fig. 17 A/C-Heater Control
OPERATION
When the ignition is turned to On, the integral
blower motor switch within the ATC A/C-heater control supplies power to the blower motor switch. The
switch directs power to the individual blower driver
circuits through the blower motor resistor block to
the blower motor and then to ground.
The blower motor switch cannot be adjusted or
repaired, and if faulty or damaged, the A/C-heater
control must be replaced (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/A/C HEATER
CONTROL - REMOVAL).
DIAGNOSIS AND TESTING
BLOWER MOTOR SWITCH
The blower motor switch can be diagnosed by using
the DRBIIIt scan tool. Refer to Body Diagnostic Procedures. For circuit descriptions and diagrams, refer
to the appropriate wiring information.
Fig. 18 Sensor-Evaporator Temperature
1
2
3
4
-
EVAPORATOR TEMPERATUE SENSOR
A/C EVAPORATOR
HVAC HOUSING
WIRE CONNECTOR
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the temperatures it monitors. The A/C-heater control is connected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor
decreases and the voltage monitored by the A/Cheater control decreases. The A/C-heater control uses
this monitored voltage reading to an indication of the
evaporator temperature. The A/C-heater control is
programmed to respond to this input by cycling the
A/C compressor clutch off if the evaporator temperature sensor reads between 1° C (33° F) and 3.5° C
(38° F) to protect the A/C evaporator from freezing.
24 - 20
CONTROLS-FRONT
VA
The external location of the sensor allows the sensor
to be removed or installed without disturbing the
refrigerant in the A/C system.
The evaporator temperature sensor is diagnosed by
performing the ATC Function Test using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
(3) Remove glove compartment.
(4) Remove cover from instrument cluster (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL).
(5) Remove the instrument cluster (Refer to 8 ELECTRICAL/INSTRUMENT
CLUSTER
REMOVAL).
(6) Remove passenger side airbag.
(7) Remove cover above air nozzle on passenger
side.
(8) Remove speaker.
(9) Remove center section of instrument panel.
(10) Remove A/C-heater control from the instrument panel (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C HEATER CONTROL REMOVAL).
(11) Remove instrument panel top section.
(12) Remove electrical connections.
(13) Remove air bezels from instrument panel.
(14) Disconnect the wire harness connector from
evaporator temperature sensor (Fig. 19).
(15) Remove evaporator temperature sensor from
HVAC housing.
Fig. 19 Evaporator Temperature Sensor
1 - WIRE HARNESS CONNECTOR
2 - EVAPORATOR TEMPERATURE SENSOR
INSTALLATION
(1) Install the probe of the evaporator temperature
sensor between the fins of the A/C evaporator.
NOTE: The probe must not go into the same hole
(in the A/C evaporator ) that the probe was removed
from.
(2) Install the wire harness connector to the evaporator temperature sensor.
(3) Install the air bezels to the instrument panel.
(4) Install the electrical connections.
(5) Install the instrument panel top section (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION).
(6) Install the A/C-heater control (Refer to 24 HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - INSTALLATION).
(7) Install the center section of the instrument
panel.
(8) Install the speaker (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION).
(9) Install the cover above the air nozzle on the
passenger side.
(10) Install the passenger side airbag.
(11) Install the instrument cluster (Refer to 8 ELECTRICAL/INSTRUMENT CLUSTER - INSTALLATION).
(12) Install the cover to the instrument cluster.
(13) Install glove compartment.
(14) Install the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION).
(15) Reconnect the negative battery cable.
CONTROLS-FRONT
VA
24 - 21
IN - CAR TEMPERATURE SENSOR
MODE DOOR CABLES
DESCRIPTION
The air distribution control cables (mode door
cables) can be removed and installed without having
to remove the instrument panel from the vehicle.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT
PANEL
CENTER
BEZEL
REMOVAL).
(3) Remove the A/C-heater control (Refer to 24 HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL).
(4) Mark and disconnect the control cables from
the A/C-heater control.
(5) Mark and disconnect the control cables from
the HVAC housing retainers (Fig. 21).
(6) Disconnect the control cables from the mode
door levers and remove the cables from the vehicle.
The in-car temperature sensor measures the actual
air temperature within the passenger compartment.
The in-car temperature sensor is located inside of the
A/C-heater control behind a vented panel (Fig. 20)
and is not a separate serviceable component. The
A/C-heater control must be replaced if there is a fault
relating to the in-car temperature sensor.
REMOVAL
Fig. 20 In-Car Temperature Sensor
1 - A/C-HEATER CONTROL
2 - IN-CAR TEMPERATURE SENSOR
OPERATION
Air from the passenger compartment flows over the
thermistor of the in-car temperature sensor. The
thermistor changes resistance with air temperature.
The ATC A/C-heater control measures this resistance
and calculates the temperature of the air. The A/Cheater control then makes adjustments to maintain
the selected passenger compartment temperature.
The in-car temperature sensor cannot be adjusted
or repaired, and if faulty or damaged, the A/C-heater
control must be replaced (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/A/C HEATER
CONTROL - REMOVAL).
DIAGNOSIS AND TESTING
IN - CAR TEMPERATURE SENSOR
The in-car temperature sensor is diagnosed by performing the ATC Function Test using the DRBIIIt
scan tool. Refer to Body Diagnostic Procedures. For
circuit descriptions and diagrams, refer to the appropriate wiring information.
Fig. 21 Air Distribution Control Cables
1 - AIR DISTRIBUTION CONTROL CABLES
2 - ADJUSTMENT LEVERS
3 - HVAC HOUSING
INSTALLATION
(1) Connect the two control cables to the mode
door levers (Fig. 22).
(2) Connect the two control cables to the A/Cheater control.
NOTE: Install the control cable of bottom adjustment lever to the front adjustment wheel of the A/Cheater control.
(3) Hold the A/C-heater control in its installation
position.
24 - 22
CONTROLS-FRONT
NOTE: While holding the A/C-heater control in the
installation position, verify that the control cables
are not twisted.
VA
mounted on the outboard side of the ventilation
housing above the blower motor in the engine compartment.
(4) Turn the mode control knob on the A/C-heater
control to the nine-o-clock position.
(5) Turn the upper mode door lever counter-clockwise until it reaches its stop and install the cable
into the retainer in this position (arrow).
(6) Turn the lower mode door lever clockwise until
it reaches its stop and install the cable into the
retainer in this position (arrow).
(7) Operate the mode control and verify that the
mode door cables are properly adjusted.
(8) Install the A/C-heater control and the two
retaining screws. Tighten the screws to 2 N·m (17 in.
lbs.).
(9) Install the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTALLATION).
(10) Reconnect the negative battery cable.
Fig. 23 Recirculation Door Actuator
1 - RECIRCULATION DOOR ACTUATOR
2 - VACUUM CONNECTOR
3 - ELECTRONIC CONTROL SOLENOID
OPERATION
Fig. 22 Adjusting Air Distribution Control Cables
1
2
3
4
5
6
-
MODE CONTROL KNOB
UPPER MODE DOOR CABLE
UPPER MODE DOOR LEVER
LOWER MODE DOOR LEVER
LOWER MODE DOOR CABLE
HEATER-A/C CONTROL
RECIRCULATION DOOR ACTUATOR
DESCRIPTION
This vehicle uses a two-position vacuum operated
recirculation door actuator to move the recirculation
door (Fig. 23). Vacuum supply to the recirculation
door actuator is controlled by an integral electronic
control solenoid. The recirculation door actuator is
The recirculation door actuator uses engine vacuum, which is controlled by an integral electrical
solenoid. The electrical solenoid is connected to the
A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector. The
output shaft of the recirculation door actuator is
keyed to a pivot shaft, which is keyed to the recirculation door shaft. The recirculation door actuator can
move the recirculation door in two directions.
The recirculation door actuator is controlled by an
electrical switch that is integral to the A/C-heater
control. When the rotary-type mode control is moved
to the recirculation position, a signal is sent to the
electrical solenoid within the recirculation door
actuator. This signal causes the solenoid to open a
port to engine vacuum which pulls the output shaft
into the actuator, which moves the recirculation-air
door. The actuator is spring loaded so the door moves
to the fresh-air position when no vacuum is supplied
through the electrical solenoid.
The recirculation door actuator can be diagnosed
by performing the ATC Function Test using a
DRBIIIt scan tool. Refer to Body Diagnostic Procedures.
The recirculation door actuator cannot be repaired
and, if faulty or damaged, it must be replaced.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
CONTROLS-FRONT
VA
(2) Disconnect the wire harness connector from the
recirculation door actuator (Fig. 24).
(3) Disconnect the vacuum line from the recirculation door actuator.
(4) Remove the two screws that secure the recirculation door actuator to the ventilation housing.
(5) Disconnect the actuator shaft from the recirculation door pivot lever and remove the actuator from
the vehicle.
Fig. 24 Recirculation Door Actuator
1
2
3
4
5
6
-
WIRE HARNESS CONNECTOR
RECIRCULATION DOOR ACTUATOR
SCREW (2)
PIVOT LEVER
ACTUATOR SHAFT
VACUUM LINE
INSTALLATION
(1) Connect the actuator shaft to the recirculation
door pivot lever.
(2) Install the two screws that secure the recirculation door actuator to the ventilation housing.
Tighten the screws to 2 N·m (17 in. lbs.).
(3) Connect the vacuum line to the recirculation
door actuator.
(4) Connect the wire harness connector to the
recirculation door actuator.
(5) Reconnect the battery negative cable.
24 - 23
24 - 24
CONTROLS - REAR
VA
CONTROLS - REAR
TABLE OF CONTENTS
page
A/C CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
A/C CONDENSER FAN RELAY
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
A/C CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
A/C HIGH PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
A/C LOW PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
BLOWER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
REAR BLOWER MOTOR SWITCH
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page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
REAR A/C TEMPERATURE CONTROL .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
REAR TEMPERATURE SENSOR . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR FILTER - REAR BLOWER
MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
SUPPRESSOR FILTER - REAR CONDENSER
FAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . .
. . . . 36
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. . . . . . . . . 36
A / C CLUTCH RELAY
DESCRIPTION
The rear A/C clutch relay for the rear A/C system
is an International Standards Organization (ISO)type relay (Fig. 1). Relays conforming to the ISO
specifications have common physical dimensions, current capacities, terminal functions and patterns. The
rear A/C clutch relay is an electromechanical device
that uses a low current input controlled by the rear
A/C control module to control the high current output
to the A/C clutch field coil for the rear A/C system.
The rear A/C clutch relay is located in the relay
block in the rear A/C evaporator housing.
CONTROLS - REAR
VA
24 - 25
DITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear A/C clutch relay from the relay
block (Fig. 2).
Fig. 1 Rear A/C Clutch Relay
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
OPERATION
The ISO-standard rear A/C clutch relay is an electromechanical switch that uses a low current input
from the rear A/C control module to control the high
current output to the rear A/C clutch. The movable,
common feed relay contact is held against the fixed,
normally closed relay contact by spring pressure.
When the electromagnetic relay coil is energized, it
draws the movable common feed relay contact away
from the fixed, normally closed relay contact and,
holds it against the fixed, normally open relay contact. This action allows high current to flow to the
A/C clutch field coil.
When the relay coil is de-energized, spring pressure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses.
The rear A/C clutch relay terminals are connected
to the vehicle electrical system through a receptacle
in the relay block located in the rear A/C evaporator
housing.
The rear A/C clutch relay cannot be repaired and,
if faulty or damaged, it must be replaced. Refer to
the appropriate wiring information for diagnosis and
testing of the ISO-standard relay and for complete
HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CON-
24 - 26
CONTROLS - REAR
VA
Fig. 2 Rear A/C Clutch Relay
1 - REAR A/C EVAPORATOR HOUSING
2 - BLOWER MOTOR RELAY K204
3 - BLOWER MOTOR RELAY K203
4 - BLOWER MOTOR RELAY K201
5 - REAR CONDENSER FAN RELAY K205
6 - REAR COMPRESSOR RELAY K206
INSTALLATION
(1) Position the rear A/C clutch relay into the
proper receptacle of the relay block located in the
rear A/C evaporator housing.
(2) Align the A/C clutch relay terminals with the
terminal cavities in the relay block receptacle and
push down firmly on the relay until the terminals
are fully seated.
(3) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(4) Reconnect the negative battery cable.
A / C CONDENSER FAN RELAY
DESCRIPTION
The rear A/C condenser fan relay for the rear A/C
system is an International Standards Organization
(ISO)-type relay (Fig. 3). Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal functions and patterns.
The rear A/C condenser fan relay is an electromechanical device that uses a low current input to control the high current output to the A/C condenser fan
for the rear heating-A/C system.
The rear A/C condenser fan relay is located in the
relay block in the rear A/C evaporator housing.
Fig. 3 Rear A/C Condenser Fan Relay
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
OPERATION
The ISO-standard rear A/C condenser fan relay is
an electromechanical switch that uses a low current
input from the rear A/C control module to control the
high current output to the rear A/C condenser cooling
fan. The movable, common feed relay contact is held
against the fixed, normally closed relay contact by
spring pressure. When the electromagnetic relay coil
VA
is energized, it draws the movable common feed relay
contact away from the fixed, normally closed relay
contact and, holds it against the fixed, normally open
relay contact. This action allows high current to flow
to the electric cooling fan motor.
When the relay coil is de-energized, spring pressure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses.
The rear A/C condenser fan relay terminals are
connected to the vehicle electrical system through a
receptacle in the relay block located in the rear A/C
evaporator housing.
The rear A/C condenser fan relay cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for diagnosis and testing of the ISO-standard relay
and for complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear A/C condenser fan relay from
the relay block (Fig. 4).
CONTROLS - REAR
24 - 27
24 - 28
CONTROLS - REAR
VA
Fig. 4 Rear A/C Condenser Fan Relay
1 - REAR A/C EVAPORATOR HOUSING
2 - BLOWER MOTOR RELAY K204
3 - BLOWER MOTOR RELAY K203
4 - BLOWER MOTOR RELAY K201
5 - REAR CONDENSER FAN RELAY K205
6 - REAR COMPRESSOR RELAY K206
INSTALLATION
(1) Position the rear A/C condenser fan relay into
the proper receptacle of the relay block located in the
rear A/C evaporator housing.
(2) Align the A/C condenser fan relay terminals
with the terminal cavities in the relay block receptacle and push down firmly on the relay until the terminals are fully seated.
(3) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(4) Reconnect the negative battery cable.
A / C CONTROL MODULE
DESCRIPTION
The rear A/C control module (Fig. 5) is connected
to the rear A/C blower motor switch, rear evaporative
temperature sensor, rear A/C temperature control
and the temperature sensor.
The rear A/C control module is located in the upper
left side of the rear A/C evaporator housing.
Fig. 5 Rear A/C Control Module
1 - REAR A/C CONTROL MODULE
2 - MOUNTING TABS
3 - WIRE HARNESS CONNECTOR
OPERATION
The rear A/C control module is supplied fused battery power through the rear blower switch. The control module receives input signals from the rear A/C
blower motor switch, rear A/C temperature control,
rear temperature sensor and the rear evaporator
temperature sensor when the front A/C switch is
turned on. The rear A/C control module uses the
VA
input signals to control rear blower motor speed and
output air temperature, and to prevent freezing of
the rear evaporator core.
The rear A/C control module cannot be repaired
and, if faulty or damaged, it must be replaced. Refer
to the appropriate wiring information for complete
HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and disconnect the wire harness connector from the
rear A/C control module (Fig. 6).
(4) Remove the two screws that secure the rear
A/C control module to the rear A/C evaporator housing and remove the control module.
CONTROLS - REAR
24 - 29
24 - 30
CONTROLS - REAR
VA
Fig. 6 Rear A/C Control Module
1 - REAR A/C EVAPORATOR HOUSING
2 - REAR A/C CONTROL MODULE
INSTALLATION
(1) Position the rear A/C control module to the
rear A/C evaporator housing.
(2) Install the two screws that secure the rear A/C
control module to the rear A/C evaporator housing.
Tighten the screws to 2 N·m (17 in. lbs.).
(3) Connect the wire harness connector to the rear
A/C control module.
(4) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(5) Reconnect the negative battery cable.
3 - WIRE HARNESS CONNECTOR
4 - SCREW (2)
The rear refrigerant system must be discharged
prior to removing the rear A/C high pressure
switch.
A / C HIGH PRESSURE
SWITCH
DESCRIPTION
The rear A/C high pressure switch provides a signal to the rear A/C control module to control rear A/C
compressor clutch engagement/disengagement and,
control rear A/C condenser cooling fan operation (Fig.
7). The rear A/C control module will disengage the
rear A/C clutch if the rear refrigerant system pressure exceeds approximately 2551 kPa (370 psi).
The rear A/C high pressure switch is mounted on a
fitting located on the inlet tube of the rear A/C condenser.
Fig. 7 Rear A/C High Pressure Switch
1 - REAR PRESSURE SWITCH
2 - WIRE CONNECTOR
OPERATION
The contacts in the rear A/C high pressure switch
open and close causing the rear A/C control module
to turn the rear A/C clutch on and off. This prevents
CONTROLS - REAR
VA
rear A/C compressor operation when the rear discharge line pressure approaches high levels, and also
reduces electrical surging from rear A/C clutch
engagement.
The rear A/C high pressure switch controls rear
A/C condenser cooling fan operation by monitoring
the rear discharge line pressure. When the rear discharge pressure rises above approximately 1900 to
2200 kPa (280 to 320 psi) the rear A/C condenser
cooling fan will turn on. The rear condenser cooling
fan will turn off when the rear discharge pressure
drops to approximately 1600 kPa (235 psi).
The rear A/C high pressure switch contacts open
when the rear discharge line pressure rises above
approximately 3100 to 3375 kPa (450 to 490 psi). The
rear A/C high pressure switch contacts close when
the rear discharge line pressure drops to approximately 1860 to 2275 kPa (270 to 330 psi).
The rear A/C high pressure switch is factory-calibrated and cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced. Refer to the
appropriate wiring information for complete HVAC
wiring diagrams.
24 - 31
Fig. 8 Rear A/C High Pressure Switch
1
2
3
4
-
REAR A/C CONDENSER
WIRE HARNESS CONNECTOR
REAR A/C HIGH PRESSURE SWITCH
REAR DISCHARGE LINE FITTING
REMOVAL
INSTALLATION
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
NOTE: Replacement of the PTFE thread sealing
tape is required anytime the rear A/C high pressure
switch is removed from the rear discharge line. Failure to replace the sealing tape could result in a rear
refrigerant system leak.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the wire harness connector from the
rear A/C high pressure switch (Fig. 8).
(6) Remove the rear A/C high pressure switch and
install a plug into, or tape over the opened rear discharge line fitting.
(1) Remove the tape or plug from the rear discharge line fitting.
(2) Install PTFE thread sealing tape onto the rear
A/C high pressure switch and install the switch onto
the rear discharge line. Tightened the A/C high pressure switch to 10 N·m (88 in. lbs.).
(3) Connect the wiring harness connector to the
rear A/C high pressure switch.
(4) Reconnect the negative battery cable.
(5) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(6) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(7) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(8) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
24 - 32
CONTROLS - REAR
A / C LOW PRESSURE SWITCH
DESCRIPTION
The rear A/C low pressure switch provides a signal
to the rear A/C control module to regulate the rear
refrigerant system pressure and control rear A/C
evaporator temperature (Fig. 9). The rear A/C control
module will disengage the rear A/C clutch if the rear
refrigerant system suction line pressure falls below
30 kPa (4.4 psi).
The rear A/C low pressure switch is mounted on a
fitting located on the rear suction line near the left
side of the rear A/C evaporator housing.
The rear refrigerant system must be discharge
prior to removing the rear A/C low pressure switch.
Fig. 9 Rear A/C Low Pressure Switch
1 - REAR PRESSURE SWITCH
2 - WIRE CONNECTOR
OPERATION
The rear A/C low pressure switch is electrically
connected in series with the rear A/C high pressure
switch, between ground and the rear A/C control
module.
The rear A/C low pressure switch contact opens or
closes the path the ground, signaling the rear A/C
control module to turn the rear A/C clutch on and off.
This regulates the rear refrigerant system pressure
and controls rear A/C evaporator temperature. Controlling the rear evaporator temperature prevents
condensate water on the evaporator fins from freezing and obstructing rear A/C system air flow.
The rear A/C low pressure switch contacts are open
when the rear suction line pressure is approximately
152 kPa (22 psi) or lower. The rear A/C low pressure
switch contacts will close when the rear suction line
pressure rises to approximately 234 to 262 kPa (34 to
38 psi) or above. Lower ambient temperatures, below
VA
approximately -1° C (30° F), will also cause the rear
A/C low pressure switch contacts to open due to the
pressure/temperature relationship of the refrigerant
in the system.
The rear A/C low pressure switch is factory-calibrated and cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced. Refer to the
appropriate wiring information for complete HVAC
wiring diagrams.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the insulating tape from around the
area of the rear A/C low pressure switch (Fig. 10).
(5) Disconnect the wire harness connector from the
rear A/C low pressure switch.
(6) Remove the rear A/C low pressure switch and
install a plug into, or tape over the opened rear suction line fitting.
CONTROLS - REAR
VA
24 - 33
BLOWER MOTOR RELAY
DESCRIPTION
The three rear blower motor relays used for the
rear A/C system are International Standards Organization (ISO)-type relays (Fig. 11). Relays conforming
to the ISO specifications have common physical
dimensions, current capacities, terminal functions
and patterns. The rear blower motor relays are electromechanical devices that switches fused battery
current directly to the rear blower motors. The rear
blower motor relays are energized when the relay
coils are provided battery current by the rear blower
motor switch (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/BLOWER
MOTOR
SWITCH - DESCRIPTION).
The rear blower motor relays are located in the
relay block in the rear A/C evaporator housing.
Fig. 10 Rear A/C Low Pressure Switch
1
2
3
4
5
-
INSULATING TAPE
REAR A/C EVAPORATOR HOUSING
WIRE HARNESS CONNECTOR
REAR A/C LOW PRESSURE SWITCH
REAR SUCTION LINE FITTING
INSTALLATION
NOTE: Replacement of the PTFE thread sealing
tape is required anytime the rear A/C low pressure
switch is removed from the rear suction line line.
Failure to replace the sealing tape could result in a
rear refrigerant system leak.
(1) Remove the tape or plug from the rear suction
line fitting.
(2) Install PTFE thread sealing tape onto the rear
A/C low pressure switch and install the switch onto
the rear suction line. Tightened the A/C low pressure
switch to 10 N·m (88 in. lbs.).
(3) Connect the wiring harness connector to the
rear A/C low pressure switch.
(4) Install new insulating tape around the rear A/C
low pressure switch area.
(5) Reconnect the negative battery cable.
(6) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(7) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(8) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
Fig. 11 Rear Blower Motor Relays
1 - STANDARD ISO RELAY
2 - TERMINAL PATTERN
OPERATION
The three ISO-standard rear blower motor relays
are electromechanical switches that uses a low current input from the rear blower motor switch to control the high current output to the rear blower
motors. The movable, common feed relay contact is
held against the fixed, normally closed relay contact
by spring pressure. When the electromagnetic relay
coil is energized, it draws the movable common feed
relay contact away from the fixed, normally closed
relay contact and, holds it against the fixed, normally
open relay contact. This action allows high current to
flow to the rear blower motors.
When the relay coil is de-energized, spring pressure returns the movable relay contact back against
the fixed, normally closed contact point. The resistor
24 - 34
CONTROLS - REAR
or diode is connected in parallel with the relay coil,
and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses.
The rear blower motor relay terminals are connected to the vehicle electrical system through receptacles in the relay block located in the rear A/C
evaporator housing.
The rear blower motor relays cannot be repaired
and, if faulty or damaged, they must be replaced.
Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for
complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and remove the rear blower motor relays as necessary from the relay block (Fig. 12).
VA
CONTROLS - REAR
VA
24 - 35
Fig. 12 Rear Blower Motor Relays
1 - REAR A/C EVAPORATOR HOUSING
2 - BLOWER MOTOR RELAY K204
3 - BLOWER MOTOR RELAY K203
4 - BLOWER MOTOR RELAY K201
5 - REAR CONDENSER FAN RELAY K205
6 - REAR COMPRESSOR RELAY K206
INSTALLATION
(1) Position the rear blower motor relays into the
proper receptacle of the relay block located in the
rear A/C evaporator housing as necessary.
(2) Align the blower motor relay terminals with
the terminal cavities in the relay block receptacle
and push down firmly on the relay until the terminals are fully seated.
(3) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(4) Reconnect the negative battery cable.
BLOWER MOTOR SWITCH
DESCRIPTION
The blower motor for the optional rear A/C system
is controlled by a three position rocker switch
mounted in the switch panel located on the instrument panel (Fig. 13). The rear A/C blower motor
switch allows the selection of one of two blower
motor speeds and an Off position.
Fig. 13 Rear Air Conditioning Switch
OPERATION
With the front A/C switch activated, the rear
blower motor speed can be selected by pressing the
rocker switch upwards (high speed) or downwards
(low speed). To turn the rear blower motor off, switch
the blower motor switch to the center position.
Depending on the blower motor switch position, a
blower motor speed command signal is sent to one of
the two blower motor relays. When activated, relay 1
sends power through an integral resistor within the
rear A/C control module and then to the blower
24 - 36
CONTROLS - REAR
VA
motor, while relay 2 when activated, sends power
directly to the blower motor.
The rear blower motor switch cannot be repaired
and, if faulty or damaged, it must be replaced.
ity in only the other blower motor switch speed
position.
(6) If OK, test and repair the rear blower motor
switch wire harness circuits. If not OK, replace the
faulty rear blower motor switch.
DIAGNOSIS AND TESTING
REMOVAL
REAR BLOWER MOTOR SWITCH
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
Before testing the rear blower motor switch, verify
that the front A/C system is functional by performing
the ATC Fuction Test using the DRBIIIt scan tool.
Use a volt/ohmmeter to test the rear blower motor
switch. For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire
harness connectors, splices and grounds.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the
rear blower motor switch.
(3) Check for continuity between terminal 10 and
terminals 1, 7 and 4 of the blower motor switch. In
all instances, there should be continuity.
NOTE: To check the switch’s internal circuits, connect the negative lead of the ohmmeter to terminal
10 and the positive ohmmeter lead to terminals 1, 7
and 4. To check the switch’s integral light emitting
diodes, reverse the ohmmeter leads.
(4) Check for continuity between the rear blower
motor switch terminals 3 and 7 as you move the
blower motor switch to each of the two speed positions, and the Off position. There should be continuity in only one blower motor switch speed position.
(5) Check for continuity between the rear blower
motor switch terminals 4 and 8 as you move the
blower motor switch to each of the two speed positions, and the Off position. There should be continu-
NOTE: The rear A/C blower motor switch is used on
vehicles with the optional rear A/C system.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory switch panel from the
instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ACCESSORY SWITCH BEZEL REMOVAL).
(3) Disconnect the wire harness connector from the
rear A/C blower motor switch (Fig. 14).
(4) Disengage the retaining tabs and remove the
rear A/C blower motor switch from the accessory
switch panel.
CONTROLS - REAR
VA
Fig. 14 Rear A/C Blower Motor Switch
1 - WIRE HARNESS CONNECTOR
2 - REAR A/C BLOWER MOTOR SWITCH
3 - ACCESSORY SWITCH PANEL
INSTALLATION
(1) Install the rear A/C blower motor switch into
the accessory switch panel. Make sure the retaining
tabs are fully engaged.
(2) Connect the wire harness connector to the rear
A/C blower motor switch.
(3) Install the accessory switch panel (Refer to 23 BODY/INSTRUMENT
PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION).
(4) Reconnect the negative battery cable.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
The rear evaporator temperature sensor (Fig. 15) is
used to signal the rear A/C control module to cycle
the rear A/C clutch in order to control rear evaporator temperature. Controlling the evaporator temperature prevents condensation on the evaporator fins
from freezing and obstructing rear A/C system air
flow.
The rear evaporator temperature sensor consists of
a probe and a switch unit. The probe, which is a Negative Temperature Coefficient (NTC) thermistor in a
capillary tube, is inserted between the rear evaporator coil fins to monitor evaporator temperature. The
switch unit contains internal control logic that monitors the input from the probe in order to switch an
internal transistor that controls the output signal to
the rear A/C control module.
The rear evaporator temperature sensor is located
in the rear A/C evaporator housing.
24 - 37
Fig. 15 Rear Evaporator Temperature Sensor
1
2
3
4
-
SWITCH UNIT
MOUNTING TAB (2)
CAPILLARY TUBE
WIRE CONNECTORS
OPERATION
The rear evaporator temperature sensor signals
the rear A/C control module to cycle the rear A/C
clutch off if the rear evaporator temperature goes
below approximately 1.6° C (35° F). When the temperature reaches above approximately 3.9° C (39° F),
the rear evaporator temperature sensor signals the
rear A/C control module to cycle the rear A/C clutch
back on.
The rear evaporator temperature sensor cannot be
adjusted or repaired. If faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and disconnect the two wire harness connectors from
the rear evaporator temperature sensor (Fig. 16).
(4) Carefully remove the sensor probe from the
rear A/C evaporator.
(5) Remove the two screws that secure the rear
evaporator sensor to the rear A/C evaporator housing
and remove the sensor.
24 - 38
CONTROLS - REAR
VA
Fig. 16 Rear Evaporator Temperature Sensor
1 - REAR A/C EVAPORATOR HOUSING
2 - SCREWS (2)
3 - REAR EVAPORATOR SENSOR SWITCH UNIT
4 - WIRE HARNESS CONNECTORS
5 - REAR EVAPORATOR SENSOR PROBE
INSTALLATION
(1) Position the rear evaporator temperature sensor to the rear A/C evaporator housing.
(2) Install the two screws that secure the rear
evaporator temperature sensor to the rear A/C evaporator housing. Tighten the screws to 2 N·m (17 in.
lbs.).
(3) Install the sensor probe into the rear A/C evaporator.
(4) Connect the two wire harness connectors to the
rear evaporator temperature sensor.
(5) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(6) Reconnect the negative battery cable.
TEMPERATURE CONTROL
DESCRIPTION
The temperature control for the optional rear A/C
system is a thumbwheel-type control mounted in the
switch panel on the instrument panel (Fig. 17). The
rear A/C temperature control allows the selection of
four temperature settings when the rear A/C blower
motor is activated.
Fig. 17 Rear A/C Temperature Control
OPERATION
With the front A/C switch and rear blower motor
activated, the rear A/C output temperature can be
selected by rotating the thumbwheel control upwards
(increase cooling) or downwards (decrease cooling).
Depending on the rear A/C temperature control position, a temperature command signal is sent to the
CONTROLS - REAR
VA
rear A/C control module. The temperature of the circulated internal air of the rear compartment is measured by a temperature sensor located in the rear
evaporator unit. The value of the temperature sensor
is compared in the rear A/C control module with an
adjusted value at the rear A/C temperature control.
The rear A/C temperature control cannot be
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING
REAR A / C TEMPERATURE CONTROL
Before testing the rear A/C temperature control,
verify that the front A/C system is operating correctly
by performing the ATC Function Test using the
DRBIIIt scan tool. Use a volt/ohmmeter to test the
control. For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire
harness connectors, splices and grounds.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
24 - 39
(5) If OK, test and repair the rear A/C temperature control wire harness circuits. If not OK, replace
the faulty rear A/C temperature control.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
NOTE: The rear A/C temperature control is used
only on models with the optional rear A/C unit.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory switch panel from the
instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ACCESSORY SWITCH BEZEL REMOVAL).
(3) Disconnect the wire harness connector from the
rear A/C temperature control (Fig. 18).
(4) Disengage the retaining tabs and remove the
rear A/C temperature control from the accessory
switch panel.
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the
rear A/C temperature control.
(3) Check for continuity between terminal 9 and
terminals 3 and 5 of the A/C temperature control. In
all instances, there should be continuity.
NOTE: To check the switch’s internal circuits, connect the positive lead of the ohmmeter to terminal 9
and the negative lead to terminals 3 and 5. To
check the switches integral light emitting diode,
reverse the ohmmeter leads.
(4) Check for resistance between terminal 3 and 5
of the A/C temperature control as you move the control to each temperature position. Resistance should
be present and should change for each position.
Fig. 18 Rear A/C Temperature Control
1 - WIRE HARNESS CONNECTOR
2 - REAR A/C TEMPERATURE CONTROL
3 - ACCESSORY SWITCH PANEL
24 - 40
CONTROLS - REAR
INSTALLATION
(1) Install the rear A/C temperature control into
the accessory switch panel. Make sure the retaining
tabs are fully engaged.
(2) Connect the wire harness connector to the rear
A/C temperature control.
(3) Install the accessory switch panel (Refer to 23 BODY/INSTRUMENT
PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION).
(4) Reconnect the negative battery cable.
TEMPERATURE SENSOR
DESCRIPTION
The rear temperature sensor (Fig. 19) provides an
air outlet temperature signal to the rear A/C control
module through a two-wire harness lead and connector.
The rear temperature sensor is located in the rear
A/C evaporator housing.
VA
DIAGNOSIS AND TESTING
REAR TEMPERATURE SENSOR
(1) Disconnect and isolate the negative battery
cable.
(2) Disconnect the wire harness connector from the
rear temperature sensor.
(3) Measure the resistance of the rear temperature
sensor. At –40° C (–40° F), the sensor resistance
should be approximatley 336 kilohms. At 55° C (131°
F), the sensor resistance is should be approximaytly
25 kilohms. The rear sensor resistance should read
between these two values.
(4) If OK, test and repair the rear temperature
sensor wire harness circuits. Refer to the appropriate
wiring information for rear temperature sensor circuit descriptions and for complete HVAC wiring diagrams. If not OK, replace the faulty temperature
sensor (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS - REAR/TEMPERATURE SENSOR
- REMOVAL).
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Reach up into the rear A/C evaporator housing
and disconnect the wire harness connector from the
rear temperature sensor (Fig. 20).
(4) Carefully remove the rear temperature sensor
from the bracket.
Fig. 19 Rear Temperature Sensor
1 - REAR TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
OPERATION
The rear A/C temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the rear A/C control module. The resistance in the sensor changes as air temperature
changes. Based upon the resistance in the sensor, a
specific voltage on the temperature sensor signal circuit is returned to the rear A/C control module,
which is programmed to correspond to a specific temperature.
The rear A/C temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
CONTROLS - REAR
VA
24 - 41
Fig. 20 Rear Temperature Sensor
1 - REAR A/C EVAPORATOR HOUSING
2 - TEMPERATURE SENSOR
INSTALLATION
3 - BRACKET
4 - WIRE HARNESS CONNECTOR
evaporator housing.
(1) Carefully install the rear temperature sensor
onto the bracket located in the rear A/C evaporator
housing.
(2) Connect the temperature sensor wire harness
connector.
(3) Connect the wire harness connector to the rear
temperature sensor.
(4) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(5) Reconnect the negative battery cable.
SUPPRESSOR FILTER - REAR
BLOWER MOTOR
DESCRIPTION
The two interference suppression filters (Fig. 21)
for the two rear blower motors protects the rear A/C
control circuits and the vehicles electrical system
from voltage spikes which may be generated by the
two blower motors or the three rear blower motor
relays. The suppression filters also impede the propagation of RF interference into the vehicles electrical
system by the rear blower motors to ensure interference-free radio reception.
The rear blower motor suppression filters are
located near the rear blower motors in the rear A/C
Fig. 21 Rear Blower Motor Suppression Filter
1
2
3
4
-
REAR BLOWER MOTOR SUPPRESSION FILTER (2)
WIRE CONNECTOR (TO BLOWER MOTOR)
WIRE CONNECTOR (TO REAR A/C HARNESS)
MOUNTING BRACKET
OPERATION
The rear blower motor suppression filters provide
protection against transient interference signals or
similar interference to the electronic rear blower
motor circuits which can effect the performance of
24 - 42
CONTROLS - REAR
the rear A/C control module circuits and radio reception quality. The suppression filters for the rear
blower motors consist of capacitors and inductance
coils.
The rear blower motor suppression filters cannot
be repaired and, if faulty or damaged, they must be
replaced. Refer to the appropriate wiring information
for complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Disconnect the two wire harness connectors
from the rear blower motor suppression filter being
serviced (Fig. 22).
(4) Remove the screw that secures the each rear
blower motor suppression filter to the rear A/C evaporator housing and remove the suppression filters as
required.
VA
CONTROLS - REAR
VA
24 - 43
Fig. 22 Rear Blower Motor Suppression Filter – LH shown, RH similar
1 - REAR A/C EVAPORATOR HOUSING
2 - SUPPRESSION FILTER WIRE CONNECTOR
3 - BLOWER MOTOR WIRE CONNECTOR
INSTALLATION
(1) Position the rear blower motor suppression filter being serviced to the rear A/C evaporator housing.
(2) Install the screw that secures each rear blower
motor suppression filter to the rear A/C evaporator
housing. Tighten the screw(s) to 2 N·m (17 in. lbs.).
(3) Connect the two suppression filter wire harness connectors.
(4) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
(5) Reconnect the negative battery cable.
SUPPRESSOR FILTER - REAR
CONDENSER FAN
DESCRIPTION
The interference suppression filter (Fig. 23) for the
rear A/C condenser fan protects the rear A/C control
circuits and the vehicles electrical system from voltage spikes which may be generated by the rear condenser fan motor or the rear condenser fan relay. The
suppression filter also impedes the propagation of RF
interference into the vehicles electrical system by the
4 - SCREW
5 - REAR BLOWER MOTOR SUPPRESSION FILTER (2)
rear condenser fan to ensure interference-free radio
reception.
The rear condenser fan suppression filter is located
in the rear A/C condenser housing near the rear condenser fan.
24 - 44
CONTROLS - REAR
VA
Fig. 23 Rear Condenser Fan Suppression Filter
1
2
3
4
-
REAR CONDENSER FAN SUPPRESSION FILTER
WIRE CONNECTOR (TO CONDENSER FAN)
MOUNTING BRACKET
WIRE CONNECTOR (TO REAR A/C HARNESS)
OPERATION
The rear condenser fan suppression filter provides
protection against transient interference signals or
similar interference to the electronic rear condenser
fan circuits which can effect the performance of the
rear A/C control module circuits and radio reception
quality. The suppression filter for the rear condenser
fan consist of capacitors and inductance coils.
The rear condenser fan suppression filter cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER-REAR - REMOVAL).
(3) Disconnect the two wire harness connectors
from the rear condenser fan suppression filter (Fig.
24).
(4) Remove the rear condenser fan (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C CONDENSER FAN - REMOVAL).
(5) Remove the two bolts, washers and nuts that
secure the rear condenser fan suppression filter to
the rear A/C condenser housing and remove the suppression filter.
Fig. 24 Rear Condenser Fan Suppression Filter
1
2
3
4
5
-
REAR A/C CONDENSER HOUSING
CONDENSER FAN WIRE CONNECTOR
BOLT, WASHER AND NUT (2)
SUPPRESSION FILTER WIRE CONNECTOR
REAR CONDENSER FAN SUPPRESSION FILTER
INSTALLATION
(1) Position the rear condenser fan suppression filter to the rear A/C condenser housing.
(2) Install the two bolts, washers and nuts that
secure the rear condenser fan suppression filter to
the rear A/C condenser housing. Tighten the bolts to
5 N·m (44 in. lbs.).
(3) Install the rear condenser fan (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C CONDENSER FAN - INSTALLATION).
(4) Connect the wiring harness connectors to the
rear condenser fan suppression filter and the rear
condenser fan.
(5) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
(6) Reconnect the negative battery cable.
DISTRIBUTION - FRONT
VA
24 - 45
DISTRIBUTION - FRONT
TABLE OF CONTENTS
page
AIR FILTER
REMOVAL . . . . . .
INSTALLATION . .
AIR OUTLETS
REMOVAL . . . . . .
INSTALLATION . .
BLOWER MOTOR
REMOVAL . . . . . .
INSTALLATION . .
DEFROSTER DUCTS
REMOVAL . . . . . .
INSTALLATION . .
. . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . 47
AIR FILTER
REMOVAL
(1) Remove the insulation blanket from the ventilation housing in the engine compartment (Fig. 1).
(2) Open the locking clips at the front and rear of
the ventilation housing.
(3) Slide the ventilation housing cover in the direction of the arrow shown.
(4) Remove the air filter.
page
FLOOR DISTRIBUTION DUCTS
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
HVAC HOUSING
REMOVAL . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . .
ASSEMBLY . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
INSTRUMENT PANEL DUCTS
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
. . . . . . . . . . . . . . . 47
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(2) Install the ventilation housing cover
(3) Close the locking clips at the front and rear of
the ventilation housing.
NOTE: The locking tabs should retain the ventilation housing cover securely.
(4) Install the insulation blanket onto the ventilation housing.
AIR OUTLETS
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
Fig. 1 Air Filter Element
1 - VENTILATION HOUSING INSULATION BLANKET
2 - LOCKING CLIP (2)
3 - AIR FILTER
INSTALLATION
(1) Install the air filter into the ventilation housing.
(1) Disconnect and isolate the battery negative
cable.
(2) If servicing the driver side air outlets, remove
the instrument cluster bezel (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER
BEZEL
REMOVAL).
(3) If servicing the passenger side air outlets,
remove the passenger side airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG
REMOVAL).
24 - 46
DISTRIBUTION - FRONT
VA
(4) If servicing the passenger side air outlets,
remove the passenger side air nozzle reinforcing
plate screws and the reinforcing plate (Fig. 2).
(5) If servicing the passenger side air outlets,
remove the passenger side air nozzle assembly using
a trim stick or other suitable wide flat blade tool,
until the snap features on the nozzle assembly are
released.
Fig. 3 Instrument Panel Air Outlets
Fig. 2 Passenger Side Air Nozzle Cover
1
2
3
4
5
-
FRONT SCREWS (2)
BRACKET
BRACKET SCREWS
NOZZLE COVER
INSTRUMENT PANEL
(6) If servicing the passenger side air outlets,
remove the air outlet retaining bracket from the
right side of the instrument panel (Fig. 3).
(7) Remove the instrument panel end cover screws
and the left and/or right side cover.
(8) Remove the air outlet retaining screws and the
air outlets as required.
1
2
3
4
5
6
-
SCREW (15)
LH END COVER
RH END COVER
BRACKET
PASSENGER SIDE AIR OUTLET (2)
DRIVER SIDE AIR OUTLET (2)
INSTALLATION
(1) Install the air outlets and retaining screws as
required. Tighten the screws to 2 N·m (17 in. lbs.).
(2) Install the left and/or right side instrument
panel end cover and retaining screws as required.
Tighten the screws to 2 N·m (17 in. lbs.).
(3) If servicing the passenger side air outlets,
install the air outlet retaining bracket to the right
side of the instrument panel. Tighten the screw to 2
N·m (17 in. lbs.).
(4) If servicing the passenger side air outlets,
install the passenger side air nozzle assembly by
pressing the nozzle assembly firmly and evenly into
the instrument panel, until the snap features are
fully engaged.
(5) If servicing the passenger side air outlets,
install the passenger side air nozzle reinforcing plate
and retaining screws. Tighten the screws to 2 N·m
(17 in. lbs.).
(6) If servicing the passenger side air outlets,
install the passenger side airbag (Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG
INSTALLATION).
(7) If servicing the driver side air outlets, install
the instrument cluster bezel (Refer to 23 - BODY/INSTRUMENT PANEL/CLUSTER BEZEL - INSTALLATION).
(8) Reconnect the battery negative cable.
DISTRIBUTION - FRONT
VA
24 - 47
BLOWER MOTOR
DEFROSTER DUCTS
REMOVAL
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the engine air cleaner housing cover
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER ELEMENT - REMOVAL).
(3) Position the ventilation housing insulation
blanket out of the way of the blower motor assembly.
(4) Disconnect the wire harness connector from the
blower motor (Fig. 4).
(5) Remove the three blower motor retaining
screws.
(6) Remove the blower motor assembly from the
ventilation housing.
(1) Remove the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL - REMOVAL).
(2) Remove the screw that secures the left and/or
right side defroster duct to the heater housing,
depending on the duct being removed (Fig. 5).
(3) Remove the defroster duct(s) from the housing.
Fig. 5 Defroster Duct - RH Shown, LH Typical
1 - HEATER HOUSING
2 - SCREW
3 - DEFROSTER DUCT
INSTALLATION
Fig. 4 Blower Motor Assembly
1
2
3
4
5
-
VENTILATION HOUSING
SCREWS (3)
WIRE HARNESS CONNECTOR
BLOWER MOTOR
INSULATION BLANKET
INSTALLATION
(1) Install the blower motor assembly into the ventilation housing.
(2) Install the three blower motor retaining
screws. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Connect the wire harness connector to the
blower motor.
(4) Install the ventilation housing insulation blanket.
(5) Install the engine air cleaner cover (Refer to 9 ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
(6) Reconnect the negative battery cable.
(1) Install the left and/or right side defroster duct
on to the heater housing.
(2) Install the screw that secures the defroster
duct to the housing. Tighten the screw(s) to 2 N·m
(17 in. lbs.).
(3) Install the instrument panel (Refer to 23 BODY/INSTRUMENT PANEL - INSTALLATION).
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Remove the instrument panel (Refer to 23 BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(2) Remove the defroster ducts (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL).
(3) Remove the screws that secure the left and
right floor distribution ducts to the instrument panel
support (Fig. 6).
(4) Remove floor distribution ducts from the center
floor distribution duct.
24 - 48
DISTRIBUTION - FRONT
(5) Remove the shift mechanism (Refer to 21 TRANSMISSION/TRANSAXLE/AUTOMATIC
NAG1/SHIFT MECHANISM - REMOVAL).
(6) Remove center floor distribution duct from the
heater housing.
VA
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
NOTE: The HVAC housing must be removed from
the vehicle and the two halves of the housing separated for service access of the heater core, A/C
evaporator and each of the various mode doors.
Fig. 6 Floor Distribution Duct, RH Shown, LH
Typical
1
2
3
4
-
HEATER HOUSING
SCREW (1)
RH FLOOR DUCT
CENTER FLOOR DUCT
INSTALLATION
(1) Install the center floor distribution duct onto
the heater housing.
(2) Install the shift mechanism (Refer to 21 TRANSMISSION/TRANSAXLE/AUTOMATIC
NAG1/SHIFT MECHANISM - INSTALLATION).
(3) Install the left and right floor distribution
ducts onto the center floor distribution duct.
(4) Install the left and right floor distribution duct
retaining screws to the instrument panel support.
Tighten the screws to 2 N·m (17 in. lbs.).
(5) Install the defroster ducts (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DEFROSTER DUCTS - INSTALLATION).
(6) Install the instrument panel (Refer to 23 BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
HVAC HOUSING
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY)
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - DRAINING COOLING SYSTEM).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the air cleaner housing (Refer to 9 ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(5) Remove the windshield washer reservoir (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).
(6) Remove the air filter from the ventilation housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/AIR FILTER - REMOVAL).
(7) Disconnect the wire harness and vacuum connectors from the recirculation door actuator (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - REMOVAL).
(8) Disconnect the wire harness connector from the
blower motor resistor block (Refer to 24 - HEATING
&
AIR
CONDITIONING/CONTROLS/BLOWER
MOTOR RESISTOR BLOCK - REMOVAL).
(9) Disconnect the wire harness connector from the
blower motor (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/BLOWER MOTOR REMOVAL).
(10) Remove the nuts and washers that secure the
ventilation housing to the body and remove the ventilation housing from the vehicle (Fig. 7).
DISTRIBUTION - FRONT
VA
24 - 49
(20) Disconnect the wire harness connector from
the evaporator temperature sensor and air outlet
temperature sensor (Fig. 8).
(21) Remove the wire harness from the bracket
located on the right side of the heater housing and
position the wire harness out of the way.
(22) Disconnect the A/C-heater control cables from
the mode door levers (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR CABLE
- REMOVAL).
(23) Disconnect the evaporator drain tube from the
HVAC housing.
(24) Remove the five bolts securing the HVAC
housing to the body.
NOTE: Make sure that the interior is protected in
case of loss of residual fluids from the heater core
and the A/C evaporator.
(25) Remove the HVAC housing from the vehicle.
Fig. 7 Ventilation Housing
1
2
3
4
-
NUT (5)
WASHER (5)
VENTILATION HOUSING
HOUSING COVER
(11) Disconnect the heater hoses from the heater
core.
(12) Disconnect the heater hoses from the heater
core tubes. Install plugs in, or tape over the opened
heater core tubes.
(13) Remove the two bolts securing the refrigerant
lines to the evaporator tubes and disconnect the lines
from the tubes. Install plugs in, or tape over all of
the opened refrigerant line fittings.
(14) Remove the seals from the refrigerant line fittings and discard.
(15) Install plugs in, or tape over the opened
refrigerant line fittings and evaporator tubes.
(16) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL REMOVAL).
(17) Remove the defroster, floor distribution and
instrument panel ducts (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/DEFROSTER
DUCTS - REMOVAL), (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/FLOOR DISTRIBUTION DUCTS - REMOVAL) and (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
INSTRUMENT PANEL DUCTS - REMOVAL).
(18) Disconnect the two bulkhead ground connections near instrument cluster area.
(19) Remove the passenger airbag bracket (Refer
to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG - REMOVAL).
Fig. 8 Heater Housing
1
2
3
4
5
6
7
-
HEATER HOUSING
AIR TEMP SENSOR WIRE CONNECTOR
WIRE HARNESS
WIRE HARNESS CONNECTOR
BOLT (4)
EVAP TEMP SENSOR WIRE CONNECTOR
EVAPORATOR DRAIN TUBE
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Place the HVAC housing in the upright position
on a work bench, making allowance for leakage of
fluids.
24 - 50
DISTRIBUTION - FRONT
(3) Remove the gasket located at the A/C evaporator and heater core tubes and the gasket that seals
the ventilation housing to the HVAC housing (Fig. 9).
(4) Remove the 12 screws that secure the two
housing halves together.
(5) Seperate the two housing halves.
(6) Remove the heater core from the lower housing.
(7) Remove the wire harness.
(8) Remove the three heater core tube retaining
bolts and the heater core tube assembly from the
heater core.
(9) Remove the heater core tube seals and discard.
(10) Install plug in, or tape over the opened heater
core fittings.
(11) Remove the A/C evaporator from the lower
housing.
VA
(3) Lubricate two new rubber O-ring seals with
clean engine coolant and install them onto the heater
core fitting.
(4) Connect the heater core tube assembly to the
heater core and install the three retaining bolts.
Tighten the bolts to 5 N·m (45 in. lbs.).
(5) Install the wire harness.
(6) Install the heater core into the lower housing.
(7) Install the two housing halves together.
(8) Install the 12 screws that secure the two housing halves together. Tighten the screws to 2 N·m (17
in. lbs.).
(9) Install the gasket for the A/C evaporator and
heater core tube outlets and the gasket that seals the
ventilation housing to the HVAC housing.
(10) Install the HVAC housing (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
INSTALLATION
NOTE: High pressures are produced in the refrigerant system when the A/C compressor is operating.
Extreme care must be exercised to make sure that
each of the refrigerant system connections is pressure-tight and leak free.
Fig. 9 HVAC Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
ASSEMBLY
(1) Install the A/C evaporator into the lower housing.
(2) Remove the tape or plugs from the heater core
fittings.
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
is positioned correctly.
(2) Install the screws that secure the HVAC housing to the dash panel. Tighten the screws to 4.5 N·m
(40 in. lbs.).
(3) Connect the HVAC housing wire harness connectors and install the wiring harness to the bracket.
(4) Connect the A/C-heater control cables to the
mode door levers (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR CABLE
- INSTALLATION).
(5) Reinstall the passenger airbag bracket (Refer
to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
AIRBAG - INSTALLATION).
(6) Reconnect the two bulkhead ground connection
near the instrument cluster area.
(7) Reinstall the defroster, floor distribution and
instrument panel ducts.
(8) Reinstall the instrument panel (Refer to 23 BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(9) Unplug or remove the tape from the opened
refrigerant line fittings.
(10) Lubricate two new rubber O-ring seals with
clean refrigerant oil and install them onto the evaporator core fittings.
(11) Connect the refrigerant line terminal block to
the evaporator tubes.
DISTRIBUTION - FRONT
VA
(12) Install the two bolts that secure the refrigerant line terminal block to the A/C evaporator.
Tighten the bolts to 5 N·m (45 in. lbs.).
(13) Unplug or remove the tape from the heater
core hoses and tubes.
(14) Connect the heater hoses to the heater core
tubes and install the heater hose clamps.
(15) Install the ventilation housing to the dash
panel.
(16) Install the nuts and washers that secure the
ventilation housing to the dash panel. Tighten the
nuts to 5 N·m (45 in. lbs.).
(17) Connect the wire harness connectors to the
blower motor, blower motor resistor block and the
recirculation door actuator.
(18) Connect the vacuum harness connector to the
recirculation door actuator.
(19) Install the air filter into the ventilation housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/AIR
FILTER
INSTALLATION).
(20) Install the windshield washer reservoir (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - INSTALLATION).
(21) Install the air cleaner housing (Refer to 9 ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
(22) Reconnect the negative battery cable.
(23) If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).
(24) Refill the engine cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - COOLANT SYSTEM FILL).
(25) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(26) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
INSTRUMENT PANEL DUCTS
REMOVAL
(1) Remove the instrument panel (Refer to 23 BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(2) Remove the defroster ducts (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL).
(3) Remove the floor distribution ducts (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBUTION/FLOOR
DISTRIBUTION
DUCTS
REMOVAL).
24 - 51
(4) If removing the right instrument panel duct,
remove the passenger air bag module and bracket
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG - REMOVAL).
(5) Remove the screws that secure the left and/or
right instrument panel duct and remove the duct(s)
as required (Fig. 10).
Fig. 10 Instrument Panel Duct - RH Shown, LH
Typical
1
2
3
4
5
-
RH DEFROSTER DUCT
SCREW (2)
RH INSTRUMENT PANEL DUCT
RH FLOOR DISTRIBUTION DUCT
CENTER FLOOR DISTRIBUTION DUCT
INSTALLATION
(1) Connect the instrument panel duct(s) to the
heater housing as required.
(2) Install the instrument panel duct retaining
screws. Tighten the screws to 2 N·m (17 in. lbs.).
(3) If servicing the right instrument panel duct,
install the passenger air bag module and bracket
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSENGER AIRBAG - INSTALLATION).
(4) Install the floor distribution ducts (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBUTION/FLOOR DISTRIBUTION DUCTS - INSTALLATION).
(5) Install the defroster ducts (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/DEFROSTER DUCTS - INSTALLATION).
(6) Install the instrument panel (Refer to 23 BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
24 - 52
DISTRIBUTION - REAR
VA
DISTRIBUTION - REAR
TABLE OF CONTENTS
page
A/C CONDENSER COVER
REMOVAL . . . . . . . . . . . .
INSTALLATION . . . . . . . .
A/C CONDENSER HOUSING
REMOVAL . . . . . . . . . . . .
INSTALLATION . . . . . . . .
A/C EVAPORATOR COVER
REMOVAL . . . . . . . . . . . .
INSTALLATION . . . . . . . .
. . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . 55
page
A/C EVAPORATOR HOUSING
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
AIR FILTER
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
BLOWER MOTOR
REMOVAL . . . . . . . . . . . . .
INSTALLATION . . . . . . . . .
. . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . 59
A / C CONDENSER COVER
A / C CONDENSER HOUSING
REMOVAL
REMOVAL
(1) Unlock the six quick-release fasteners by turning them 90 degrees in either direction (Fig. 1).
(2) Remove the rear A/C condenser cover from the
rear A/C condenser housing.
Fig. 1 Rear A/C Condenser Cover
1
2
3
4
-
QUICK-RELEASE FASTENER AND WASHER (6)
RUBBER DAMPING WASHER (6)
REAR CONDENSER COVER
REAR A/C CONDENSER HOUSING
INSTALLATION
(1) Inspect the six rubber damping washers for
correct sealing. Replace the washers as required.
(2) Position the rear A/C condenser cover over the
rear A/C condenser housing.
(3) Lock the six quick-release fasteners by turning
them 90 degrees in either direction.
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear A/C wire harness from the
rear blower motor suppression filter and the rear A/C
high pressure switch (Fig. 2).
(6) Remove the retaining straps that secure the
rear A/C wire harness to the rear liquid line and
position the wire harness out of the way.
(7) Remove the screw and bracket that secures the
rear discharge line to the right side of the rear condenser housing.
(8) Disconnect the rear discharge line from the
rear A/C condenser and remove and discard the
O-ring seal.
VA
(9) Disconnect the rear liquid line from the rear
refrigerant reservoir outlet and remove and discard
the O-ring seal.
(10) Install plugs into, or tape over the rear refrigerant line fittings and condenser and reservoir ports.
(11) Remove the eight nuts and washers that
secure the rear A/C condenser housing to the roof
panel.
(12) Carefully separate the body sealer between
the rear A/C condenser housing and the roof panel
and with help from an assistant, remove the condenser housing.
(13) Remove any shims and trim the body sealer
on top of the roof panel down to a thickness of 2 mm
(0.078 in.).
DISTRIBUTION - REAR
24 - 53
24 - 54
DISTRIBUTION - REAR
VA
Fig. 2 Rear A/C Condenser Housing
1
2
3
4
5
-
REAR A/C CONDENSER HOUSING
LIQUID LINE
REAR REFRIGERANT RESERVOIR
REAR A/C HIGH PRESSURE SWITCH
REAR CONDENSER OUTLET TUBE
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C condenser is being replaced. The refrigerant oil
must be drained from the old condenser and measured to determine the amount of refrigerant oil to
add to the new condenser. Use only refrigerant oil
of the type recommended for the rear A/C compressor in the vehicle.
(1) If the rear A/C condenser is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C condenser. Drain the old condenser and measure the refrigerant oil. Fill the new
condenser with the same amount of new refrigerant
oil that was drained out of the old condenser.
(2) Install new body sealant and any removed
shims onto the top of the roof panel.
(3) With help from an assistant, position the rear
A/C condenser housing onto the top of the roof panel.
(4) Install the eight nuts and washers that secure
the rear A/C condenser housing to the roof panel.
Tighten the nuts to 25 N·m (18 ft. lbs.).
(5) Remove the tape or plugs from the rear liquid
line fitting and rear refrigerant reservoir port.
(6) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made
6
7
8
9
-
SUCTION LINE
NUT AND WASHER (8)
REAR A/C WIRE HARNESS
REAR BLOWER MOTOR SUPPRESSION FILTER
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(7) Connect the rear liquid line to the rear refrigerant reservoir outlet. Tighten the liquid line nut to
35 N·m (26 ft. lbs.).
(8) Remove the tape or plugs from the rear discharge line fitting and rear condenser port.
(9) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear discharge line
fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(10) Connect the rear discharge line to the rear
A/C condenser. Tighten the discharge line nut to 35
N·m (26 ft. lbs.).
(11) Install the bracket and screw that secures the
rear discharge line to the right side of the rear condenser housing. Tighten the screw securely.
(12) Connect the rear A/C wire harness to the rear
blower motor suppression filter and to the rear A/C
high pressure switch.
(13) Install new retaining straps to secure the rear
A/C wire harness to the rear liquid line.
(14) Install a new rear receiver/drier (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
DISTRIBUTION - REAR
VA
24 - 55
(15) Reconnect the negative battery cable.
(16) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(18) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(19) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
A / C EVAPORATOR COVER
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the rear dome lamps from the center
and rear roof duct panels (Fig. 3).
(3) Remove the push-pin fasteners that secure the
center and rear roof duct panels to the roof duct and
remove the panels.
(4) Disconnect the dome light wire harness connector and remove the dome light wire harness from the
roof duct.
(5) Remove the six screws that secure the rear A/C
evaporator cover to the front of the rear A/C evaporator housing.
(6) Remove the three push-pin fasteners that
secure the rear A/C evaporator cover to the rear of
the evaporator housing and remove the cover.
Fig. 3 Rear A/C Evaporator Cover
1
2
3
4
5
6
7
-
REAR A/C EVAPORATOR COVER
DOME LAMP WIRE HARNESS
SCREW (6)
REAR DOME LAMPS
PUSH-PIN FASTENER (22)
CENTER ROOF DUCT PANEL
REAR ROOF DUCT PANEL
INSTALLATION
(1) Position the rear A/C evaporator cover to the
rear A/C evaporator housing.
(2) Install the three push-pin fasteners that secure
the rear A/C evaporator cover to the rear of the evaporator housing.
(3) Install the six screws that secure the rear A/C
evaporator cover to the front of the evaporator housing. Tighten the screws to 2.2 N·m (21 in. lbs.).
(4) Install the dome light wire harness to the roof
duct and reconnect the harness.
(5) Position the center and rear roof duct panels to
the roof duct and install the push-pin fasteners.
(6) Install the rear dome lamps into the center and
rear roof duct panels.
(7) Reconnect the negative battery cable.
A / C EVAPORATOR HOUSING
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
24 - 56
DISTRIBUTION - REAR
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear A/C wire harness from the
rear condenser fan suppression filter and the rear
A/C high pressure switch and remove the retaining
straps that secure the wire harness to the rear liquid
line (Fig. 4).
Fig. 4 Rear A/C Wire Harness - Condenser Side
1
2
3
4
5
-
REAR CONDERSER FAN SUPPRESSION FILTER
REAR A/C HIGH PRESSURE SWITCH
REAR A/C WIRE HARNESS
GROMMET
RETAINING STRAPS
(6) Disengage the rear A/C wire harness grommet
from the roof panel and pull the wire harness down
into the vehicle (Fig. 5).
(7) Disconnect the rear body wire harness connector from the rear A/C wire harness.
(8) Remove the retaining straps that secure the
rear dome lamp harness to the rear A/C evaporator
housing and position the rear dome lamp harness out
of the way.
(9) Remove the nut that secures the positive wire
lead to the rear A/C system terminal block and position the wire lead out of the way.
(10) Remove the insulating tape from around the
rear evaporator connections.
VA
(11) Disconnect the rear liquid line from the rear
A/C expansion valve and remove and discard the
O-ring seal.
(12) Disconnect the rear suction line from the rear
evaporator outlet tube and remove and discard the
O-ring seal.
(13) Install plugs into, or tape over the opened
refrigerant line fittings and rear expansion valve and
evaporator tube ports.
(14) Disconnect and install plugs into the two rear
evaporator drain hoses.
(15) Support the rear A/C evaporator housing and
remove the nine screws, four bolts and washers and
four damping washers that secure the rear A/C evaporator housing to the roof panel.
(16) With help from an assistant, remove the rear
A/C evaporator housing from the vehicle.
(17) If required, remove the rear A/C evaporator
from the rear A/C evaporator housing (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/
REAR A/C EVAPORATOR - REMOVAL).
DISTRIBUTION - REAR
VA
24 - 57
Fig. 5 Rear A/C Evaporator Housing
1
2
3
4
5
6
7
8
9
-
REAR A/C EVAPORATOR HOUSING
REAR A/C WIRE HARNESS
REAR BODY WIRE HARNESS
NUT
POSITIVE WIRE LEAD
GROUND LEAD
GROMMET
SEALING WASHER (4)
BOLT AND WASHER (4)
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C evaporator is being replaced. The refrigerant oil
must be drained from the old evaporator and measured to determine the amount of refrigerant oil to
add to the new evaporator. Use only refrigerant oil
of the type recommended for the rear A/C compressor in the vehicle.
(1) If the rear A/C evaporator is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C evaporator. Drain the old evaporator and measure the refrigerant oil. Fill the new
evaporator with the same amount of new refrigerant
oil that was drained out of the old evaporator.
(2) With help from an assistant, position and support the rear A/C evaporator housing into the vehicle.
(3) Inspect the four rubber damping washers for
correct sealing. Replace the washers as required.
CAUTION: Be sure to install the rear A/C system
ground lead with one of the rear evaporator housing retaining bolts. Failure to correctly install the
10
11
12
13
14
15
16
17
-
REAR EVAPORATOR DRAIN HOSES
SCREW (9)
REAR DOME LAMP HARNESS
REAR A/C EVAPANSION VALVE
REAR LIQUID LINE FITTING
REAR A/C EVAPORATOR OUTLET TUBE
REAR SUCTION LINE FITTING
INSULATING TAPE
ground lead could result in improper operation or
possible damage to the rear A/C system.
(4) Position the ground lead to the rear A/C evaporator housing and install the four bolts and washers
and four damping washers that secure the evaporator housing to the roof panel. Tighten the bolts to 25
N·m (18 ft. lbs.).
(5) Install the nine screws that secure the rear A/C
evaporator housing to the roof panel. Tighten the
screws to 5 N·m (45 in. lbs.).
(6) Unplug and connect the two rear evaporator
drain hoses.
(7) Remove the tape or plugs from the refrigerant
line fittings and the rear expansion valve and evaporator tube ports.
(8) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(9) Connect the rear liquid line to the rear A/C
expansion valve. Tighten the liquid line nut to 35
N·m (26 ft. lbs.).
24 - 58
DISTRIBUTION - REAR
(10) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear suction line fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(11) Connect the rear suction line to the rear evaporator outlet tube. Tighten the suction line nut to 35
N·m (26 ft. lbs.).
(12) Install new insulating tape around the rear
evaporator connections.
(13) Install the positive wire lead onto the rear
A/C system terminal block and install the retaining
nut. Tighten the nut securely.
(14) Reposition the rear dome lamp harness and
install the retaining straps that secure the harness
to the rear A/C evaporator housing.
(15) Connect the rear A/C wire harness connector
to the rear body wire harness.
(16) Route the rear A/C wire harness up through
the roof panel and install the grommet.
(17) Connect the rear A/C wire harness to the rear
condenser fan suppression filter and the rear A/C
high pressure switch and install the retaining straps
that secure the wire harness to the rear liquid line.
(18) Reconnect the negative battery cable.
(19) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(20) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(21) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
(22) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
AIR FILTER
REMOVAL
(1) Unlock the eight quick-release fasteners by
turning them 90 degrees counter clockwise (Fig. 6).
(2) Remove the rear air inlet grate from the rear
A/C evaporator cover.
(3) Remove the rear particulate air filter by disengaging the velcro-type retainers.
(4) Carefully clean the rear particulate air filter
using compressed air.
VA
Fig. 6 Rear Particulate Air Filter
1
2
3
4
-
QUICK-RELEASE FASTENER (8)
REAR A/C EVAPORATOR COVER
REAR PARTICULATE AIR FILTER
REAR AIR INLET GRATE
INSTALLATION
NOTE: Replace the rear particulate air filter if it is
heavily soiled or damaged.
(1) Position the rear particulate air filter and
engage the velcro-type retainers.
(2) Install the rear air inlet grate onto the rear
A/C evaporator cover.
(3) Lock the eight quick-release fasteners by turning them 90 degrees clockwise.
BLOWER MOTOR
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Disconnect the wire harness connectors from
the rear blower motor suppression filter and from the
rear blower motor being serviced and remove the
suppression filter (Fig. 7).
(4) Remove the body sealer from around the rear
blower motor area being serviced.
(5) Remove the screws that secure each rear
blower motor to the rear evaporator housing and
remove blower motor.
VA
Fig. 7 Rear Blower Motors - LH shown, RH similar
1
2
3
4
5
6
7
-
REAR BLOWER MOTOR (2)
REAR A/C EVAPORATOR HOUSING
SUPPRESSION FILTER WIRE CONNECTOR
BLOWER MOTOR WIRE CONNECTOR
REAR BLOWER MOTOR SUPPRESSION FILTER
SEALER
SCREW (5 PER MOTOR)
INSTALLATION
(1) Position the rear blower motor being serviced
to the rear A/C evaporator housing.
(2) Install the screws that secure each rear blower
motor to the rear A/C evaporator housing. Tighten
the screws to 5 N·m (45 in. lbs.).
(3) Install a new bead of body sealant to the
blower motor area being serviced.
(4) Install the rear blower motor suppression filter
and connect the wiring harness connectors to the
suppression filter and to the rear blower motor being
serviced.
(5) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
(6) Reconnect the negative battery cable.
DISTRIBUTION - REAR
24 - 59
24 - 60
PLUMBING
VA
PLUMBING
TABLE OF CONTENTS
page
PLUMBING
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
WARNINGS
.....................
CAUTIONS . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS . . . .
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE
EQUIPMENT . . . . . . . . . . . . . . . . . . .
REFRIGERANT SYSTEM RECOVERY
REFRIGERANT SYSTEM EVACUATE
REFRIGERANT SYSTEM CHARGE . .
A/C COMPRESSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE . . . . . . . .
REMOVAL
DENSO 7SBU16C A/C COMPRESSOR
DENSO 10S17 A/C COMPRESSOR . .
INSTALLATION
DENSO 7SBU16C A/C COMPRESSOR
DENSO 10S17 A/C COMPRESSOR . .
A/C CONDENSER
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . .
A/C DISCHARGE LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . .
A/C EVAPORATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . .
A/C EXPANSION VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
A/C EXPANSION VALVE . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . .
ELECTRIC COOLANT PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . .
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page
HEATER CORE
DESCRIPTION . . . . . . . . . .
OPERATION . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
LIQUID LINE
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
RECEIVER/DRIER
DESCRIPTION . . . . . . . . . .
OPERATION . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REFRIGERANT
DESCRIPTION . . . . . . . . . .
OPERATION . . . . . . . . . . . .
REFRIGERANT OIL
DESCRIPTION . . . . . . . . . .
OPERATION . . . . . . . . . . . .
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
SUCTION LINE
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
WATER VALVE
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR A/C CONDENSER FAN
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR A/C EVAPORATOR
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR A/C EXPANSION VALVE
DESCRIPTION . . . . . . . . . .
OPERATION . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR DISCHARGE LINE
DESCRIPTION . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR LIQUID LINE
DESCRIPTION . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
REAR RECEIVER/DRIER
REMOVAL . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . .
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PLUMBING
VA
REAR REFRIGERANT RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . .
REAR SUCTION LINE
DESCRIPTION . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . .
REFRIGERANT LINE COUPLER
DESCRIPTION . . . . . . . . . . . . .
. . . . . . . . . . . . 95
. . . . . . . . . . . . 95
. . . . . . . . . . . . 96
. . . . . . . . . . . . 96
. . . . . . . . . . . . 98
24 - 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99
UNDERBODY LINES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102
. . . . . . . . . . . . 98
PLUMBING
DESCRIPTION
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 layers, 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 molecular structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning 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 the exhaust manifold.
OPERATION
High pressures are produced in the refrigerant system when the air conditioning compressor is operating. 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 cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNINGS
WARNING: The A/C system contains refrigerant
under high pressure. Repairs should only be performed by qualified service personnel. Severe personal injury or death may result from improper
service procedures.
WARNING: Avoid breathing the refrigerant and
refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protection
when servicing the A/C refrigerant system. Serious
eye injury can result from direct contact with the
refrigerant. If eye contact occurs, seek medical
attention immediately.
WARNING: Do not expose the refrigerant to open
flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recommended. Severe personal injury or death may result
from improper service procedures.
WARNING: If accidental system discharge occurs,
ventilate the work area before resuming service.
Large amounts of refrigerant released in a closed
work area will displace the oxygen and cause suffocation and death.
WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely
high. As a result, anything that comes in contact
with the refrigerant will freeze. Always protect the
skin or delicate objects from direct contact with the
refrigerant.
WARNING: The R-134a service equipment or the
vehicle refrigerant system should not be pressure
tested or leak tested with compressed air. Some
mixtures of air and R-134a have been shown to be
combustible at elevated pressures. These mixtures
are potentially dangerous, and may result in fire or
explosion causing property damage, personal injury
or death.
WARNING: The engine cooling system is designed
to develop internal pressures of 97 to 123 kilopascals (14 to 18 pounds per square inch). Do not
remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator drain, radiator
hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system for service.
Failure to observe this warning can result in serious burns from the heated engine coolant.
24 - 62
PLUMBING
CAUTIONS
CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Do not use R-12 equipment
or parts on a R-134a A/C system. These refrigerants
are not compatible and damage to the A/C system
will result.
CAUTION: Never use R-12 refrigerant oil in a A/C
system designed to use R-134a refrigerant oil.
These refrigerant oils are not compatible and damage to the A/C system will result.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approved
leak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
CAUTION: Recover the refrigerant before opening
any fitting or connection. Open the fittings with
caution, even after the system has been discharged. Never open or loosen a connection before
recovering the refrigerant.
CAUTION: If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under
pressure. Recover the refrigerant before removing
the secondary retention clip. Open the fittings with
caution, even after the system has been discharged. Never open or loosen a connection before
recovering the refrigerant.
CAUTION: The internal parts of the A/C system will
remain stable as long as moisture-free refrigerant
and refrigerant oil is used. Abnormal amounts of
dirt, moisture or air can upset the chemical stability.
This may cause operational troubles or even serious damage if present in more than very small
quantities. Before disconnecting a component,
clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant
system. Keep service tools and the work area clean.
Do not open the refrigerant system or uncap a
VA
replacement component until you are ready to service the system. Immediately after disconnecting a
component from the refrigerant system, seal the
open fittings with a cap or plug. This will prevent
contamination from entering the A/C system.
CAUTION: Refrigerant oil will absorb moisture from
the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to
use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a
clean, airtight, and moisture-free container.
CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor
head pressure and can cause compressor noise
and A/C system failure.
DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS
WARNING: R-134a service equipment or vehicle A/C
system should not be pressure tested or leak tested
with compressed air. Mixture of air and R-134a can
be combustible at elevated pressures. These mixtures are potentially dangerous and may result in
fire or explosion causing property damage, personal injury or death.
Avoid breathing A/C refrigerant and lubricant vapor
or mist. Exposure may irritate eyes, nose and
throat. Use only approved service equipment meeting SAE requirements to discharge R-134a system.
If accidental system discharge occurs, ventilate
work area before resuming service.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with
R-134a. This is accomplished by performing a Refrigerant System Charge Level test (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM CHARGE LEVEL) or by completely evacuating
and recharging the A/C system. If the A/C liquid line
pressure is found to be less than 345 kPa (50 psi)
while performing the Refrigerant System Charge
Level test, proceed to the System Empty procedure
below. If liquid line pressure is found to be greater
than 345 kPa (50 psi), proceed to the System Low
procedure. If the refrigerant system is empty or low
in refrigerant charge, a leak at any line fitting or
component seal is likely. A review of the fittings,
lines and components for oily residue is an indication
of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures
as indicated by the symptoms.
VA
SYSTEM EMPTY
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approximately 28 in Hg.)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE). Determine if the
system holds a vacuum for 15 minutes. If vacuum is
held, a leak is probably not present. If system will
not maintain vacuum level, proceed to Step 2.
(2) Prepare and dispense 0.284 kilograms (10
ounces) of R-134a refrigerant into the evacuated
refrigerant system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE) and
proceed to Step 1 of the System Low procedure.
SYSTEM LOW
(1) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(2) Operate the heating-A/C system with the
engine at idle under the following conditions for at
least five minutes.
• Doors or windows open
• Transmission in Park
• A/C-heater controls set to outside air, full cool,
panel mode, high blower and with A/C compressor
engaged
PLUMBING
24 - 63
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used.
Contact an automotive service equipment supplier for
refrigerant recovery/recycling/charging equipment.
Refer to the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment.
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.
CAUTION: A leak detector only designed for R-12
refrigerant will not detect leaks in a R-134a refrigerant system.
(3) Shut the vehicle Off and wait 2-7 minutes.
Then use an electronic leak detector that is designed
to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C
evaporator for leaks, insert the leak detector probe
into the drain tube opening or an air outlet. A dye for
R-134a is available to aid in leak detection. Use only
DaimlerChrysler approved refrigerant dye.
Fig. 1 Manifold Gauge Set - Typical
STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn off (rotate
clockwise) all valves on the equipment being used,
before connecting to or disconnecting from the
refrigerant system. Failure to observe these warnings may result in possible personal injury.
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
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
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not compatible and system damage will result.
24 - 64
PLUMBING
FRONT A / C SYSTEM
• LOW PRESSURE GAUGE HOSE—The low
pressure hose (Blue with Black stripe) attaches to
the suction line service port. This port is located on
the suction line near the dash panel.
• HIGH PRESSURE GAUGE HOSE—The high
pressure hose (Red with Black stripe) attaches to the
discharge line service port. This port is located on the
liquid line between the condenser and the reciverdrier.
• RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE—The center manifold hose (Yellow, or White, with Black stripe) is used to recover,
evacuate, 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.
REAR A / C SYSTEM
• LOW PRESSURE GAUGE HOSE—The low
pressure hose (Blue with Black stripe) attaches to
the suction line service port. This port is located
within the rear A/C evaporator housing near the left
side of the evaporator, below the high-pressure service port.
• HIGH PRESSURE GAUGE HOSE—The high
pressure hose (Red with Black stripe) attaches to the
liquid line service port. This port is located within
the rear A/C evaporator housing near the left side of
the evaporator, above the low-pressure service port.
• RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE—The center manifold hose (Yellow, or White, with Black stripe) is used to recover,
evacuate, 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.
REFRIGERANT SYSTEM RECOVERY
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper
care and use of this equipment.
VA
REFRIGERANT SYSTEM EVACUATE
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
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 compressor 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 system, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.
(2) Open the low and high side valves and start
the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vacuum 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 CONDITIONING/PLUMBING - DIAGNOSIS AND
TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charging station vacuum pump.
(4) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE)
REFRIGERANT SYSTEM CHARGE
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
PLUMBING
VA
CAUTION: A small amount of refrigerant oil is
removed from the A/C system each time the refrigerant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any
oil lost during the recovery process. Refer the
equipment manufacturer instructions for more information.
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 - SPECIFICATIONS - 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 supplied by the equipment manufacturer for proper care
and use of this equipment.
PARTIAL CHARGE METHOD
The partial charge method is used to add a partial
charge to a refrigerant system that is low on refrigerant. To perform this procedure the evaporator inlet
and outlet tube temperatures are measured. The
temperature difference is measured with a temperature meter with one or two clamp-on thermocouple
probes. The difference between the evaporator inlet
and outlet tube temperatures will determine the
amount of refrigerant needed.
Before adding a partial refrigerant charge, check
for refrigerant system leaks. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - DIAGNOSIS
AND TESTING - REFRIGERANT SYSTEM LEAKS)
If a leak is found, make the necessary repairs before
attempting a full or partial refrigerant charge.
(1) Attach a manifold gauge set to the refrigerant
system service ports.
(2) Attach the two clamp-on thermocouple probes
to the inlet and outlet tubes of the evaporator coil.
• If a single thermocouple probe is used, attach
the probe to the evaporator inlet tube just before the
collar of the refrigerant line connector fitting. The
probe must make contact with the bottom surface of
the evaporator inlet tube.
• If dual thermocouple probes are used, attach
probe 1 to the evaporator inlet tube, and probe 2 to
the evaporator outlet tube. Attach both probes to the
evaporator tubes just before the collar of the refrig-
24 - 65
erant line connector fittings. The probes must make
contact with the bottom surfaces of the evaporator
inlet and outlet tubes.
(3) Open all of the windows or doors of the passenger compartment.
(4) Set the A/C button on the A/C Heater controls
to the on position, the temperature control knob in
the full cool position, select Recirculation Mode, and
place the blower motor switch in the highest speed
position.
(5) Start the engine and hold the engine idle speed
at 1,000 rpm. Allow the engine to warm up to normal
operating temperature.
(6) The compressor clutch may cycle, depending
upon ambient temperature, humidity, and the refrigerant system charge level.
(7) Hold the engine idle speed at 1,000 rpm.
(8) Allow three to five minutes for the refrigerant
system to stabilize, then record the temperatures of
the evaporator inlet and outlet tubes.
• If a single probe is used, record the temperature
of the evaporator inlet tube. Then remove the probe
from the inlet tube and attach it to the evaporator
outlet tube just before the collar of the refrigerant
line connector fitting. The probe must make contact
with the bottom surface of the evaporator outlet tube.
Allow the thermocouple and meter time to stabilize,
then record the temperature of the evaporator outlet
tube. Subtract the inlet tube temperature reading
from the outlet tube temperature reading.
• If dual probes are used, record the temperatures
of both the evaporator inlet and outlet tubes. Then
subtract the inlet tube temperature reading from the
outlet tube temperature reading.
(9) If the measured temperature differential is
higher than 22° C to 26° C (40° F to 47° F), add 0.4
kilograms (14 ounces) of refrigerant.
(10) Allow three to five minutes for the refrigerant
system to stabilize, then take a second set of thermocouple measurements. Record the temperature difference to determine if an additional charge is required.
(11) Record the compressor discharge pressure. If
the reading is higher than the pressure shown in the
Compressor Discharge Pressure Chart, the system
could be overcharged. If the reading is equal to, or
lower, than the pressure shown in the chart, continue
with this procedure.
Compressor Discharge Pressure Chart
Ambient Temperature
Compressor Discharge Pressure
16°C
(60°F)
21°C
(70°F)
27°C
(80°F)
32°C
(90°F)
38°C
(100°F)
43°C
(110°F)
1378 kPa
(200 psi)
1516 kPa
(220 psi)
1723 kPa
(250psi)
1930 kPa
(280 psi)
2206 kPa
(320 psi)
2413 kPa
(350 psi)
24 - 66
PLUMBING
VA
(12) EXAMPLE: The ambient temperature is 21°
C (70° F). The evaporator inlet tube temperature is
12° C (54° F) and the evaporator outlet tube temperature is 10° C (50° F). Subtract the inlet tube temperature from the outlet tube temperature. The
difference is -2° C (-4° F). With a -2° C (-4° F) temperature differential at 21° C (70° F) ambient temperature, the system is fully charged.
(13) Add enough refrigerant to bring the refrigerant system up to a full charge.
(14) Remove the jumper wire from the low pressure cycling clutch switch wire harness connector
and plug the connector back into the switch.
A / C COMPRESSOR
DESCRIPTION
The standard front A/C system uses a Denso
7SBU16C seven cylinder, variable displacement
swash plate-type A/C compressor (Fig. 2). This A/C
compressor has a volume control which is regulated
by an internal control valve and has both the suction
and discharge ports located at the rear of the compressor.
Fig. 3 Denso 10S17C A/C Compressor
1 - A/C COMPRESSOR (DENSO 10S17C)
2 - SUCTION AND DISCHARGE PORT
3 - CYLINDER HEAD
A label identifying the use of R-134a refrigerant is
located on both A/C compressors.
OPERATION
The A/C compressor is driven by the engine
through an electric clutch, drive pulley and belt
arrangement. The A/C compressor is lubricated by
refrigerant oil that is circulated throughout the
refrigerant system with the refrigerant.
The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction port. It then compresses the refrigerant into a
high-pressure, high-temperature refrigerant vapor,
which is then pumped to the A/C condenser through
the compressor discharge port.
The A/C compressor cannot be repaired and, if
faulty or damaged, it must be replaced. The compressor clutch, pulley and bearing assembly, and clutch
field coil are available for service. If an internal failure of the A/C compressor has occurred, the receiver/
drier must also be replaced.
Fig. 2 Denso 7SBU16C A/C Compressor
1 - A/C COMPRESSOR (DENSO 7SBU16C)
2 - SUCTION AND DISCHARGE PORT
3 - INTERNAL CONTROL VALVE
The optional independant Konvekta rear A/C system uses theDenso 10S17C ten cylinder, double-acting swash plate-type A/C compressor (Fig. 3). This
A/C compressor has a fixed displacement of 170 cubic
centimeters (10.374 cubic inches), and has both the
suction and discharge ports located on the cylinder
head at the rear of the compressor.
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 neutral, 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,
PLUMBING
VA
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
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disengaged. Check the 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 identify 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 better localize the source of the noise.
(2) Loosen all of the compressor mounting hardware 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 pulley 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 condition (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 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
(5) If the noise is from opening and closing of the
high pressure relief valve, reclaim, evacuate, and
recharge the refrigerant system. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT RECOVERY)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE) (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE) If the high pressure relief valve still
does not seat properly, replace the a/c compressor.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C COMPRESSOR - REMOVAL)
(6) If the noise is from liquid slugging on the suction line, check the refrigerant oil level and the
refrigerant system charge. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
24 - 67
ANT OIL - STANDARD PROCEDURE) (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING SPECIFICATIONS - CHARGE CAPACITY).
(7) If the noise continues, replace the compressor
and repeat Step 1.
REMOVAL
DENSO 7SBU16C A / C COMPRESSOR
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil or the engine.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(3) Remove the serpentine drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/BELTS-DRIVE REMOVAL).
(4) Disconnect the wire harness connector from the
A/C compressor clutch coil.
(5) Remove the bolts that secure the A/C suction
and discharge lines to the A/C compressor.
(6) Disconnect the A/C suction and discharge lines
from the A/C compressor and remove and discard the
O-ring seals (Fig. 4).
(7) Install plugs in, or tape over the opened refrigerant line fittings and the compressor ports.
(8) Raise the vehicle on a hoist.
(9) If equipped with an add-on rear A/C system,
remove the lower A/C compressor and position it out
of the way (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR
REMOVAL - DENSO 10S17).
(10) Support the A/C compressor and remove the
compressor mounting bolts.
(11) Remove the A/C compressor from the engine
compartment.
24 - 68
PLUMBING
VA
(4) Remove the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/BELTS-DRIVE REMOVAL).
(5) Disconnect the wire harness connector from the
clutch field coil of the A/C compressor (Fig. 5).
(6) Remove the bolts that secure the underbody
suction and discharge lines to the A/C compressor.
(7) Disconnect the underbody suction and discharge lines from the A/C compressor and remove
and discard the O-ring seals.
(8) Install plugs in, or tape over the opened refrigerant line fittings and the compressor ports.
(9) Remove the bolts that secure the A/C compressor to the mounting bracket.
(10) Remove the A/C compressor from the engine
compartment.
Fig. 4 Denso 7SBU16C A/C Compressor
1
2
3
4
5
6
7
8
-
A/C COMPRESSOR
O-RING SEAL
A/C SUCTION LINE
BOLT
RETAINING CLIP
BOLT
A/C DISCHARGE LINE
O-RING SEAL
DENSO 10S17 A / C COMPRESSOR
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
Fig. 5 Denso 10S17 A/C Compressor
1
2
3
4
-
REFRIGERANT LINES
WIRE HARNESS CONNECTOR
BOLTS (3)
A/C COMPRESSOR
INSTALLATION
NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil or the engine.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Raise and support the vehicle.
DENSO 7SBU16C A / C COMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refrigerant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine compartment and loosely install the three compressor
retaining bolts. Tighten the bolts using the following
sequence to 20 N·m (15 ft. lbs.).
PLUMBING
VA
• The upper bolt at the front of the compressor.
• The lower bolt at the front of the compressor.
• The bolt at the rear of the compressor.
(2) If equipped with an add-on rear A/C system,
install the lower A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION - DENSO 10S17).
(3) Lower the vehicle.
(4) Remove the tape or plugs from the opened suction line fitting and the discharge line fitting and the
compressor ports.
(5) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(6) Connect the A/C suction and discharge lines to
the A/C compressor.
(7) Install the bolts that secure the A/C suction
and discharge lines to the A/C compressor. Tighten
the bolts to 23 N·m (17 ft. lbs.).
(8) Connect the wire harness connector to the A/C
compressor clutch coil.
(9) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).
(10) Replace the receiver/drier if the A/C compressor is being replaced due to an internal failure (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING/RECEIVER/DRIER - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
DENSO 10S17 A / C COMPRESSOR
NOTE: Be certain to check the refrigerant oil level if
the A/C compressor is being replaced. See Refrigerant Oil Level in this group for the procedures. Use
only refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
NOTE: If an internal failure of the A/C compressor
has occurred, the receiver/drier must be replaced.
(1) Position the A/C compressor in the engine compartment and loosely install the three compressor
24 - 69
retaining bolts. Tighten the bolts using the following
sequence to 20 N·m (14 ft. lbs.).
• The upper bolt at the front of the compressor.
• The lower bolt at the front of the compressor.
• The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened
underbody suction and discharge line fittings and
compressor ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
(4) Connect the underbody suction and discharge
lines to the A/C compressor.
(5) Install the bolts that secure the underbody suction and discharge lines to the A/C compressor.
Tighten the bolts to 21 N·m (15 ft. lbs.).
(6) Connect the wire harness connector to the A/C
compressor clutch coil.
(7) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/BELTS-DRIVE INSTALLATION).
(8) Lower the vehicle.
(9) Replace the receiver/drier if the A/C compressor
is being replaced due to an internal failure (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
RECEIVER/DRIER - REMOVAL) and (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/RECEIVER/DRIER - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(12) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
A / C CONDENSER
DESCRIPTION
The condenser is located in the air flow in front of
the engine cooling radiator. The condenser is a heat
exchanger that allows the high-pressure refrigerant
gas being discharged by the compressor to give up its
heat to the air passing over the condenser fins.
OPERATION
When the refrigerant gas gives up its heat, it condenses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that
24 - 70
PLUMBING
VA
there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radiator or condenser service.
The condenser cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(3) Remove the front fascia.
(4) Remove the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).
(5) Remove the headlamps from their mounts.
(6) Remove the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER REMOVAL).
(7) Disconnect the A/C discharge and liquid lines
from the A/C condenser and remove and discard the
O-ring seals (Fig. 6).
(8) Install plug in, or tape over the opened liquid
line fitting and the condenser ports.
(9) Disconnect the wire harness connector from the
auxiliary fan.
(10) Remove the auxiliary fan and upper bracket
assembly.
(11) Remove the auxiliary fan lower bracket
retainers and bracket.
(12) Remove the four condenser retaining screws.
(13) Carefully remove the condenser from the vehicle.
Fig. 6 A/C Condenser
1 - SCREW (4)
2 - CONDENSER
3 - LIQUID REFRIGERANT LINE
4 - COMPRESSOR DISCHARGE LINE
5 - NUT (2)
6 - LOWER AUXILIARY FAN BRACKET
7 - NUT (2)
8 - WIRE HARNESS CONNECTOR
9 - AUXILIARY COOLING FAN
10 - SCREW (2)
INSTALLATION
NOTE: If the A/C condenser is being replaced, add
30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Carefully position the A/C condenser into the
engine compartment.
(2) Install the four screws that secure the A/C condenser. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Install the lower auxiliary fan bracket and
retaining nuts. Tighten the nuts to 5 N·m (45 in.
lbs.).
(4) Install the auxiliary fan and upper bracket
assembly. Tighten the screws to 5 N·m (45 in. lbs.).
(5) Connect the wire harness connector to the auxiliary fan.
(6) Remove the tape or plug from the condenser
ports and the opened refrigerant line fittings.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the refrigerant line
fittings.
(8) Connect the A/C discharge and liquid lines to
the A/C condenser.
PLUMBING
VA
(9) Install the nuts that secure the A/C discharge
and liquid lines to the A/C condenser. Tighten the
nuts to 33 N·m (24 ft. lbs.).
(10) Install the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER INSTALLATION).
(11) Install the headlamps into their mounts.
(12) Install the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
(13) Install the front fascia.
(14) Reconnect the negative battery cable.
(15) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(16) Recharge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
24 - 71
(11) Install plug in, or tape over the opened discharge line fitting and the compressor discharge port.
(12) Disconnect the discharge line from the retaining clip and remove the discharge line from the vehicle.
A / C DISCHARGE LINE
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(3) Remove the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).
(4) Remove the nut that secures the discharge line
fitting to the condenser on the left side of the condenser.
(5) Disconnect the discharge line fitting from the
condenser inlet port.
(6) Remove the seal from the discharge line fitting
and discard.
(7) Install plug in, or tape over the opened discharge line fitting and the condenser inlet port.
(8) Remove the bolt that secures the discharge line
fitting to the top of the compressor (Fig. 7).
(9) Disconnect the discharge line fitting from the
compressor discharge port.
(10) Remove the seal from the discharge line fitting and discard.
Fig. 7 A/C Compressor - Refrigerant Lines
1
2
3
4
5
6
7
8
-
A/C COMPRESSOR
O-RING SEAL
A/C SUCTION LINE
BOLT
RETAINING CLIP
BOLT
A/C DISCHARGE LINE
O-RING SEAL
INSTALLATION
Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning 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 the exhaust manifold.
(1) Position the discharge line into the engine compartment.
(2) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fitting.
(4) Connect the discharge line fitting to the compressor discharge port on the top of the compressor.
(5) Install the bolt that secures the discharge line
fitting to the compressor. Tighten the bolt to 23 N·m
(17 ft. lbs.).
24 - 72
PLUMBING
(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fitting.
(8) Connect the discharge line fitting to the condenser inlet port.
(9) Install the nut that secures the discharge line
fitting to the condenser. Tighten the nut to 33 N·m
(24 ft. lbs.).
(10) Install the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
(11) Evacuate the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE)
(12) Charge the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE)
(13) Reconnect the negative battery cable.
A / C EVAPORATOR
DESCRIPTION
The A/C evaporator for the heating-A/C system is
located within the HVAC housing, behind the instrument panel (Fig. 8). The A/C evaporator is positioned
within the HVAC housing so that all air entering the
housing must pass over the evaporator fins before it
is distributed through the heating-A/C system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through
the A/C evaporator.
The A/C evaporator tubes are connected and sealed
to the A/C expansion valve by use of rubber O-rings
and a tapping block.
The A/C evaporator is serviced by removing and
disassembling the HVAC housing.
VA
Fig. 8 Front A/C Evaporator
1 - A/C EVAPORATOR
2 - EVAPORATOR TUBES
3 - TAPPING BLOCK
OPERATION
Refrigerant enters the evaporator from the expansion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas
before it leaves the evaporator.
The evaporator cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
PLUMBING
VA
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Remove the HVAC housing (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
A/C evaporator (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING DISASSEMBLY).
(3) Lift the A/C evaporator out of the lower half of
the HVAC housing (Fig. 9).
24 - 73
type recommended for the A/C compressor in the
vehicle.
(1) Install the A/C evaporator into the lower half of
the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
A / C EXPANSION VALVE
DESCRIPTION
The A/C expansion valve controls the amount of
refrigerant entering the A/C evaporator and is of a
thermostatic expansion valve (TXV) design (Fig. 10).
The A/C expansion valve consists of an aluminum
H-valve type body with an integral thermal sensor.
The A/C expansion valve is located at the dash
panel between the A/C refrigerant lines and the A/C
evaporator.
Fig. 9 HVAC Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
INSTALLATION
NOTE: If the A/C evaporator is being replaced, add
60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
Fig. 10 Front A/C Expansion Valve
1 - A/C EXPANSION VALVE
2 - THERMAL SENSOR
OPERATION
High-pressure, high temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, lowtemperature mixture of liquid and gas before it
enters the A/C evaporator. A thermal sensor in the
A/C expansion valve monitors the temperature of the
refrigerant leaving the A/C evaporator and adjusts
the orifice size at the evaporator inlet to allow the
proper amount of refrigerant into the A/C evaporator
24 - 74
PLUMBING
in order to meet vehicle cooling requirements. Controlling the refrigerant flow through the A/C evaporator ensures that none of the refrigerant leaving the
evaporator is still in a liquid state, which could cause
damage to the A/C compressor.
The A/C expansion valve is factory calibrated and
cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING
A / C EXPANSION VALVE
The A/C expansion valve is located on the engine
side of the dash panel near the shock tower.
The A/C expansion valve can fail in three different
positions (open, closed or restricted).
In an Open Position: this will result in a noisy A/C
compressor or no cooling. The cause can be broken
spring, broken ball or excessive moisture in the A/C
system. If the spring or ball are found to be defective,
replace the A/C expansion valve. If excessive moisture is found in the A/C system, recycle the refrigerant.
In a Closed Position: There will be low suction
pressure and no cooling. This may be caused by a
failed power dome or excessive moisture in the A/C
system. If the power dome on the A/C expansion
valve is found to be defective replace the A/C expansion valve. If excessive moisture is found recycle the
refrigerant.
A Restricted Orifice: There will be low suction
pressure and no cooling. This may be caused by
debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the A/C expansion valve and the receiver-drier.
VA
(4) Disconnect the suction and liquid lines from
the expansion valve.
(5) Remove the seals from the suction and liquid
line fitting and discard.
(6) Install plugs in, or tape over the opened liquid
and suction line fittings and both expansion valve
ports.
(7) Remove the two bolts that secure the expansion valve to the evaporator tube tapping plate.
(8) Remove the expansion valve from the evaporator tube tapping plate.
(9) Remove the seals from the evaporator inlet and
outlet tube fittings and discard.
(10) Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports.
REMOVAL
Fig. 11 A/C Expansion Valve
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Recover the refrigerant from the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the nut that secures the suction and
liquid line fittings to the stud on the A/C expansion
valve (Fig. 11).
1
2
3
4
5
6
7
8
-
EVAPORATOR TUBE TAPPING PLATE
O-RING SEAL (2)
A/C EXPANSION VALVE
BOLT (2)
A/C SUCTION LINE
NUT
A/C LIQUID LINE
O-RING SEAL (2)
INSTALLATION
(1) Remove the tape or plugs from the tapping
plate evaporator inlet and outlet tube fittings and
both ports on the back of the A/C expansion valve.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the tapping plate
evaporator inlet and outlet tube fittings.
(3) Position the A/C expansion valve onto the tapping plate evaporator inlet and outlet tube fittings.
PLUMBING
VA
(4) Install the two bolts that secure the A/C expansion valve to the evaporator tube tapping plate.
Tighten the bolts to 5 N·m (45 in. lbs.).
(5) Remove the tape or plugs from the liquid and
suction line fittings and both expansion valve ports.
(6) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid and suction line fittings.
(7) Connect the liquid line fitting to the A/C expansion valve.
(8) Connect the suction line fitting to the A/C
expansion valve.
(9) Install the nut that secures the suction line
and liquid line fittings to the stud on the A/C expansion valve. Tighten the nut to 10 N·m (89 in. lbs.).
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(12) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
ELECTRIC COOLANT PUMP
DESCRIPTION
The electric coolant pump ensures the uniform flow
of coolant through the heater core without bubbles,
even at low speeds (Fig. 12). The electric coolant
pump is located in the left side of the engine compartment near the battery and is controlled by the
A/C-heater control.
The electric coolant pump housing contains two
coolant hose connections and an electric motor which
drives the vane-type pump using a magnetic
clutch.
24 - 75
Fig. 12 Electric Coolant Pump
1 - ELECTRIC COOLANT PUMP
2 - COOLANT HOSE CONNECTIONS
3 - WIRE CONNECTOR
OPERATION
The electric coolant pump is controlled by the ATC
A/C-heater control and is only operational when the
ignition switch is on under the following conditions:
(1) Vehicle speed below 27 Km/h (17 mph).
(2) Coolant temperature above 65° C (150° F) but
less than 110° C (230 ° F).
(3) Any blower motor speed setting.
(4) Temperature heat setting above the halfway
setting (60% heat).
(5) The pump will turn off at speeds above 48
Km/h (30 mph).
(6) The pump will turn off if the coolant temperature rises above 110° C (230 ° F).
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - DRAINING COOLANT SYSTEM).
(3) Disconnect the wire harness connector from the
electric coolant pump (Fig. 13).
(4) Loosen both hose clamps from the electric coolant pump.
(5) Using a twisting motion gently remove both
heater hoses from the electric coolant pump.
(6) Remove the two electric coolant pump bracket
retaining nuts from the body studs.
(7) Remove the electric coolant pump from the
vehicle.
24 - 76
PLUMBING
VA
Fig. 14 Front Heater Core
Fig. 13 Electric Coolant Pump
1
2
3
4
5
6
-
HEATER HOSE
HOSE CLAMP (2)
HEATER HOSE
ELECTRIC COOLANT PUMP
WIRE HARNESS CONNECTOR
NUT (2)
INSTALLATION
(1) Install the electric coolant pump and mounting
bracket onto the body studs.
(2) Install the two bracket retaining nuts. Tighten
the nuts to 5 N·m (45 in. lbs.).
(3) Using a twisting motion gently install both
hoses onto the electric coolant pump.
(4) Tighten both hose clamps securely.
(5) Connect the wire harness connector to the electric coolant pump.
(6) Reconnect the negative battery cable.
(7) Fill the engine cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - COOLING SYSTEM FILL).
1
2
3
4
-
HEATER CORE
BOLT (3)
HEATER CORE TUBES
O-RING SEALS
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core whenever the heater water
valve is cycled open by the ATC A/C-heater control.
As the coolant flows through the heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
heater water valve controls the heater output air
temperature by controlling the amount of heated
engine coolant flowing through the heater core. The
blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
HEATER CORE
DESCRIPTION
The heater core is mounted into the HVAC housing, located behind the instrument panel (Fig. 14).
The heater core is a heat exchanger made of rows of
tubes and fins. The heater core tubes are attached to
the heater core by using O-ring seals and bolts.
The heater core is serviced by removing and disassembling the HVAC housing.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag deployment.
PLUMBING
VA
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Remove the heater housing (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
heater core (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - DISASSEMBLY).
(3) Lift the heater core out of the lower half of the
HVACr housing (Fig. 15).
(4) If necessary, remove the three heater core tube
retaining bolts and the heater core tube assembly
from the heater core.
(5) Remove the heater core tube seals and discard
as required.
24 - 77
INSTALLATION
(1) If the heater core tube assembly was removed
from the heater core, lubricate two new rubber
O-ring seals with clean engine coolant and install
them onto the heater core fitting.
(2) If required, connect the heater core tube
assembly to the heater core and install the three
retaining bolts. Tighten the bolts to 5 N·m (45 in.
lbs.).
(3) Install the heater core into the bottom half of
the HVAC housing.
(4) Assemble the HVAC housing (Refer to 24 HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
NOTE: If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING).
(5) Install the HVAC housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
LIQUID LINE
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
Fig. 15 HVAC Housing
1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
5 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure sensor
on the fitting for the receiver/drier. The rear section
connects between the receiver/drier and the A/C
expansion valve.
FRONT SECTION
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate they negative batter
cable.
(3) Remove the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).
24 - 78
PLUMBING
(4) Remove the nut that secures the A/C liquid line
to the A/C condenser.
(5) Disconnect the A/C liquid line to the A/C condenser and remove and discard the O-ring seal.
(6) Install plug in, or tape over the opened liquid
line fitting and the condenser outlet port.
(7) Remove the routing clip retaining nut and disengage the routing clip retainer on top of the left
frame rail from the front section of the liquid line.
(8) Remove the A/C pressure sensor from the front
liquid line fitting (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C
PRESSURE
TRANSDUCER - REMOVAL).
(9) Remove the bolt that secures the front section
of the liquid line to the top of the receiver/drier (Fig.
16).
(10) Disconnect the front section of the liquid line
from the receiver/drier and remove and discard the
O-ring seal.
(11) Install plug in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
(12) Remove the front section of the A/C liquid line
from the engine compartment.
VA
(4) Remove the nut that secures the A/C suction
and liquid lines to the stud on the A/C expansion
valve (Fig. 17).
(5) Disconnect the A/C suction and liquid lines
from the A/C expansion valve and remove and discard the O-ring seals.
(6) Disengage the routing clip retainer from the
rear section of the A/C liquid line.
Fig. 17 A/C Expansion Valve
1
2
3
4
5
6
7
8
Fig. 16 Receiver-Drier
1
2
3
4
5
-
RECEIVER/DRIER
A/C LIQUID LINE (REAR SECTION)
A/C PRESSURE TRANSDUCER
A/C LIQUID LINE (FRONT SECTION)
CLAMP
REAR SECTION
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT
STANDARD
PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).
-
EVAPORATOR TUBE TAPPING PLATE
O-RING SEAL (2)
A/C EXPANSION VALVE
BOLT (2)
A/C SUCTION LINE
NUT
A/C LIQUID LINE
O-RING SEAL (2)
(7) Remove the bolt that secures the rear section
of the liquid line to the top of the receiver/drier (Fig.
16).
(8) Disconnect the rear section of the liquid line
from the receiver/drier.
(9) Remove the seal from the liquid line fitting
outlet port and discard.
(10) Install plugs in, or tape over the opened liquid
and suction line fittings, both receiver/drier ports and
both expansion valve ports.
(11) Remove the rear section of the liquid line from
the engine compartment.
PLUMBING
VA
INSTALLATION
NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure transducer on the fitting for the receiver/drier. The rear
section connects between the receiver/drier and the
A/C expansion valve.
FRONT SECTION
(1) Position the front section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the liquid line
fitting and the receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Connect the front section of the liquid line to
the receiver/drier.
(5) Install the bolt that secures the liquid line fitting to the receiver/drier. Tighten the bolt to 7 N·m
(62 in. lbs.).
(6) Position the front section of the liquid line into
the routing clip and install the routing clip onto the
body stud on the left frame rail.
(7) Install the routing clip retaining nut. Tighten
the nut to 5 N·m (45 in. lbs.).
(8) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(9) Lubricate a new O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
(10) Connect the liquid line fitting to the condenser outlet port on the right side of the condenser.
(11) Install the nut that secures the liquid line fitting to the condenser. Tighten the nut to 17 N·m (12
ft. lbs.).
(12) Reinstall the A/C pressure transducer (Refer
to 24 - HEATING & AIR CONDITIONING/CONTROLS/A/C PRESSURE TRANSDUCER - INSTALLATION).
(13) Install the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
(14) Reconnect the battery negative cable.
(15) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE).
(16) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the A/C liquid line
into the engine compartment.
24 - 79
(2) Remove the tape or plugs from the liquid and
suction line fittings, the receiver/drier outlet port and
both expansion valve ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
liquid line fittings for the expansion valve.
(4) Connect the liquid line and suction line fittings
to the A/C expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the stud on the A/C expansion valve. Tighten the nut to 10 N·m (89 in. lbs.).
(6) Lubricate new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(7) Connect the liquid line fitting to the receiver/
drier outlet port.
(8) Install the bolt that secures the liquid line fitting to the receiver/drier. Tighten the bolt to 7 N·m
(62 in. lbs.).
(9) Install the routing clip retainer to the rear section of the liquid line.
(10) Install the grille (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE).
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the left front strut tower in the engine compartment. The receiver/drier is connected between the
front and rear sections of the A/C liquid line between
the condenser outlet and the evaporator inlet.
The receiver/drier cannot be repaired. If the receiver/drier is faulty or damaged, or if the refrigerant
system has been contaminated or left open to the
atmosphere for an indeterminable period or if the
compressor has failed, it must be replaced.
OPERATION
The receiver/drier performs a filtering action to
prevent foreign material in the refrigerant from contaminating the A/C expansion valve. Refrigerant
enters the receiver/drier as a high-pressure, low temperature liquid. Desiccant inside the receiver/drier
absorbs any moisture which may have entered and
become trapped within the refrigerant system. In
addition, during periods of high demand operation of
the A/C system, the receiver/drier acts as a reservoir
to store surplus refrigerant.
24 - 80
PLUMBING
The receiver/drier cannot be repaired. If the receiver/drier is faulty or damaged, or if an internal failure
of the A/C compressor has occurred, the receiver/drier
must be replaced.
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(2) Remove the bolts that secure the front and rear
sections of the A/C liquid line to the top of the receiver/drier (Fig. 18).
(3) Disconnect the liquid line fittings from the
receiver/drier and remove and discard the O-ring
seals.
(4) Install a plug in, or tape over the opened liquid
line fittings and the receiver/drier ports.
(5) Loosen the clamp that secures the receiver/
drier to the mounting bracket.
(6) Remove the receiver/drier from the engine compartment.
VA
INSTALLATION
NOTE: If the receiver/drier is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Position the receiver/drier onto the mounting
bracket on the front left strut tower.
(2) Tighten the clamp that secures the receiver/
drier to the mounting bracket.
(3) Remove the tape or plugs from the liquid line
fittings and the receiver/drier ports.
(4) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line fittings.
(5) Connect the front and rear sections of the liquid line to the receiver/drier.
(6) Install the bolts that secures the liquid line fittings to the receiver/drier. Tighten the bolts to 7 N·m
(62 in. lbs.).
(7) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(8) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
Fig. 18 Receiver/Drier
1
2
3
4
5
-
RECEIVER/DRIER
A/C LIQUID LINE (REAR SECTION)
A/C PRESSURE TRANSDUCER
A/C LIQUID LINE (FRONT SECTION)
CLAMP
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
PLUMBING
VA
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehicle and on the compressor identifying to service technicians that the air conditioning system is equipped
with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each
contains a different additive package. The A/C compressors for this vehicle are designed to use an ND-8
PAG refrigerant oil. Use only the refrigerant oil of
this type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.
PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contamination.
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory,
all components except the compressor are refrigerant
oil free. After the refrigerant system has been
charged and operated, the refrigerant oil in the compressor is dispersed throughout the refrigerant system. The receiver-drier, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrication of the A/C compressor. Too little oil will result in
damage to the A/C compressor. Too much oil will
reduce the cooling capacity of the A/C system.
It will not be necessary to check the oil level in the
A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or
24 - 81
leak from a refrigerant line, a connector fitting, a
component, or a component seal. If a leak occurs, add
30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when a receiver/
drier, A/C evaporator, or A/C condenser are replaced.
See the Refrigerant Oil Capacities chart. When an
A/C compressor is replaced, the refrigerant oil must
be drained from the old compressor and measured.
Drain all of the refrigerant oil from the new compressor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the
old compressor.
REFRIGERANT OIL CAPACITIES
Component
ml
fl oz
Total A/C System Fill
410
13.9
Receiver/Drier
30
1.0
A/C Condenser
30
1.0
A/C Evaporator
60
2.0
A/C Compressor
Drain and measure the oil
from the old compressor see text.
SUCTION LINE
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Recover the refrigerant system. (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY)
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the routing clip retaining nut and disengage the metal routing clip from the A/C suction
line.
(4) Disengage the plastic routing clip located near
the A/C expansion valve from the A/C suction line.
(5) Remove the nut that secures the A/C suction
and liquid lines to the stud on the A/C expansion
valve (Fig. 19).
24 - 82
PLUMBING
VA
(6) Disconnect the A/C suction and liquid lines
from the A/C expansion valve and remove and discard the O-ring seals.
(7) Install plugs in, or tape over the opened liquid
and suction line fittings and both expansion valve
ports.
Fig. 20 A/C Compressor - Refrigerant Lines
Fig. 19 A/C Expansion Valve
1
2
3
4
5
6
7
8
-
EVAPORATOR TUBE TAPPING PLATE
O-RING SEAL (2)
A/C EXPANSION VALVE
BOLT (2)
A/C SUCTION LINE
NUT
A/C LIQUID LINE
O-RING SEAL (2)
(8) Remove the bolt that secures the A/C suction
line to the A/C compressor (Fig. 20).
(9) Disconnect the A/C suction line from the A/C
compressor and remove and discard the O-ring seal.
(10) Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
(11) Remove the A/C suction line from the engine
compartment.
1
2
3
4
5
6
7
8
-
A/C COMPRESSOR
O-RING SEAL
A/C SUCTION LINE
BOLT
RETAINING CLIP
BOLT
A/C DISCHARGE LINE
O-RING SEAL
INSTALLATION
(1) Position the A/C suction line into the engine
compartment.
(2) Remove plugs or tape from the suction line fitting and the compressor suction port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it onto the suction line fitting.
(4) Connect the A/C suction line to the A/C compressor.
(5) Install the bolt that secures the A/C suction
line to the A/C compressor. Tighten the bolt to 23
N·m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid and
suction line fittings and both expansion valve ports.
(7) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid and suction line fittings.
(8) Connect the A/C liquid and suction lines to the
A/C expansion valve.
(9) Install the nut that secures the A/C liquid and
suction lines to the A/C expansion valve. Tighten the
nut to 10 N·m (89 in. lbs.).
(10) Position the metal routing clip around the A/C
suction line and install the routing clip onto the body
stud.
(11) Install the routing clip retaining nut. Tighten
the nut to 5 N·m (45 in. lbs.).
PLUMBING
VA
24 - 83
(12) Install the plastic routing clip retainer onto
the A/C suction line.
(13) Reconnect the negative battery cable.
(14) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
WATER VALVE
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Partially drain the engine cooling system
(Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - DRAINING COOLING SYSTEM).
(3) Disconnect the wire harness connector from the
heater water valve (Fig. 21).
(4) Loosen the hose clamps from the heater water
valve.
(5) Using a twisting motion gently remove the
heater hoses from the heater water valve.
(6) Remove the bolts that secure the heater water
valve bracket.
(7) Remove the bracket and pulsed water control
valve from the engine compartment.
(8) Turn the bracket slightly and remove the water
valve from the rubber mounts.
(9) If necessary, remove the rubber mounts from
the bracket or water valve.
Fig. 21 Heater Water Valve
1
2
3
4
5
6
7
-
HEATER WATER VALVE
HOSE CLAMP (3)
HEATER HOSE (3)
RUBBER MOUNT (2)
BOLTS (2)
BRACKET
RUBBER MOUNT
INSTALLATION
(1) If removed, install the rubber mounts to the
heater water valve or bracket.
(2) Turn bracket slightly to the right and install
the heater water valve to the bracket.
(3) Install the water valve and mounting bracket
into the engine compartment.
(4) Install the two bracket retaining bolts. Tighten
the bolts to 5 N·m (45 in. lbs.).
(5) Using a twisting motion gently install the
heater hoses onto the water valve.
(6) Tighten the hose clamps securely.
(7) Connect the wire harness connector to the
heater water valve.
(8) Reconnect the negative battery cable.
(9) Fill the engine cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - COOLING SYSTEM FILL).
REAR A / C CONDENSER FAN
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
24 - 84
PLUMBING
(3) Disconnect the condenser fan wire harness
from the condenser fan suppression filter (Fig. 22).
(4) Loosen the four bolts that secure the rear A/C
condenser fan to the top of the rear A/C condenser
housing.
(5) Rotate the rear A/C condenser fan counterclockwise and remove the fan from the top of the rear
A/C condenser housing.
VA
tions could result in possible personal injury or
death.
(1) Remove the rear A/C evaporator housing and
place it on a workbench (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - REAR/
REAR A/C EVAPORATOR HOUSING - REMOVAL).
(2) Remove the five screws and washers that
secure the condensate drain pan to the bottom of the
rear A/C evaporator and remove the drain pan (Fig.
23).
(3) Remove the insulating tape from around the
area of the rear A/C expansion valve and disconnect
the expansion valve from the rear A/C evaporator
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REAR A/C EXPANSION VALVE REMOVAL).
(4) Remove the left blower motor from the rear
A/C evaporator housing (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - REAR/
BLOWER MOTOR - REMOVAL).
CAUTION: Be careful when drilling out rivets to prevent damage to the rear A/C components.
Fig. 22 Rear A/C Condenser Fan
1
2
3
4
5
-
REAR A/C CONDENSER FAN
BOLT (4)
REAR CONDENSER FAN SUPPRESSION FILTER
FAN WIRE HARNESS CONNECTOR
REAR A/C CONDENSER HOUSING
(5) Remove the rivets that secure the three covers
to the rear A/C evaporator and remove the covers.
(6) Remove the four rivets that secure the rear A/C
evaporator the bottom of the rear A/C evaporator
housing and remove the evaporator.
INSTALLATION
(1) Position the rear A/C condenser fan to the top
of the rear A/C condenser housing.
(2) Rotate the rear A/C condenser fan clockwise to
engage the fan to the four retaining bolts. Tighten
the bolts to 12 N·m (106 in. lbs.).
(3) Connect the condenser fan wire harness to the
rear condenser fan suppression filter.
(4) Reconnect the negative battery cable.
(5) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
REAR A / C EVAPORATOR
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cau-
Fig. 23 Rear A/C Evaporator
1
2
3
4
5
6
-
REAR A/C EVAPORATOR HOUSING
RIVET (12)
COVERS
REAR A/;C EVAPORATOR
SCREW AND WASHER (5)
CONDENSATE DRAIN PAN
PLUMBING
VA
24 - 85
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
A/C evaporator is being replaced. The refrigerant oil
must be drained from the old evaporator and measured to determine the amount of refrigerant oil to
add to the new evaporator. Use only refrigerant oil
of the type recommended for the rear A/C compressor in the vehicle.
(1) If the rear A/C evaporator is being replaced,
install the correct amount and type of refrigerant oil
into the new rear A/C evaporator. Drain the old evaporator and measure the refrigerant oil. Fill the new
evaporator with the same amount of new refrigerant
oil that was drained out of the old evaporator.
(2) Position the rear A/C evaporator to the bottom
of the rear A/C evaporator housing and install four
new rivets.
(3) Position the three covers to the rear A/C evaporator and install eight new rivets.
(4) Install the left blower motor onto the rear A/C
evaporator housing (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION - REAR/BLOWER
MOTOR - INSTALLATION).
(5) Connect the rear A/C expansion valve to the
rear A/C evaporator and install new insulating tape
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REAR A/C EXPANSION VALVE INSTALLATION).
(6) Position the condensate drain pan to the bottom of the rear A/C evaporator and install the five
screws and washers that secure the drain pan to the
evaporator. Tighten the screws to 2.2 N·m (20 in.
lbs.).
(7) Install the rear A/C evaporator housing (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/REAR A/C EVAPORATOR HOUSING INSTALLATION).
REAR A / C EXPANSION VALVE
DESCRIPTION
The rear A/C expansion valve controls the amount
of refrigerant entering the rear A/C evaporator (Fig.
24). The rear A/C expansion valve is of an externallyequalized thermostatic expansion valve (TXV) design
and consists of a cast metal body with a removable
equalizer tube and an integral thermal sensor which
uses a capillary tube and sensing bulb.
The rear A/C expansion valve is located to the left
of the rear blower motors in the rear evaporator
housing.
Fig. 24 Rear A/C Expansion Valve
1
2
3
4
-
REAR A/C EXPANSION VALVE
EQUALIZER TUBE
CAPILLARY TUBE
SENSING BULB
OPERATION
High-pressure, high temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, lowtemperature mixture of liquid and gas before it
enters the A/C evaporator. A thermal sensor in the
rear A/C expansion valve monitors the temperature
of the refrigerant leaving the rear evaporator by use
of a sensing bulb positioned next to the evaporator
outlet tube. The thermal sensor adjusts the orifice
size at the evaporator inlet to allow the proper
amount of refrigerant into the rear A/C evaporator in
order to meet vehicle cooling requirements. Controlling the refrigerant flow through the A/C evaporator
ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could cause
damage to the A/C compressor.
To overcome the effect of the pressure drop within
the rear A/C evaporator, an external equalizer tube is
connected to the evaporator outlet tube and runs to
the underside if the diaphragm within the expansion
valve.
The rear A/C expansion valve is factory calibrated
and cannot be adjusted or repaired and, if faulty or
damaged, it must be replaced.
24 - 86
PLUMBING
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the insulating tape from around the
area of the rear A/C expansion valve (Fig. 25).
(5) Disconnect the equalizer tube from the rear
evaporator outlet tube.
(6) Disconnect the rear liquid line from the rear
A/C expansion valve and remove and discard the
O-ring seal.
(7) Disconnect the rear A/C expansion valve from
the rear evaporator inlet tube and remove and discard the O-ring seal.
(8) Remove the retaining clamp that secures the
sensor bulb to the evaporator outlet tube and remove
the expansion valve, capillary tube and sensor bulb
as an assembly.
(9) Install plugs into, or tape over the opened
refrigerant line and evaporator tube fittings and
expansion valve ports.
VA
PLUMBING
VA
24 - 87
Fig. 25 Rear A/C Expansion Valve
1
2
3
4
-
INSULATING TAPE
REAR LIQUID LINE
REAR A/C EXPANSION VALVE
REAR A/C EVAPORATOR INLET TUBE
INSTALLATION
(1) Remove the tape or plugs from the rear refrigerant line and evaporator tube fittings and the rear
expansion valve ports.
(2) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear evaporator inlet
tube fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) Install the rear A/C expansion valve onto the
rear evaporator inlet tube. Tighten the nut to 35 N·m
(26 ft. lbs.).
(4) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(5) Connect the rear liquid line to the rear A/C
expansion valve. Tighten the nut to 35 N·m (26 ft.
lbs.).
5
6
7
8
-
RETAINING CLAMP
SENSING BULB AND CAPILLARY TUBE
EQUALIZER TUBE
REAR A/C EVAPORATOR OUTLET TUBE
(6) Connect the equalizer tube to the rear evaporator outlet tube. Tighten the nut to 10 N·m (88 in.
lbs.).
(7) Position the rear expansion valve sensing bulb
onto the rear evaporator outlet tube and install the
retaining clamp securely.
(8) Install new insulating tape around the rear A/C
expansion valve area.
(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(12) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
24 - 88
PLUMBING
REAR DISCHARGE LINE
DESCRIPTION
The rear A/C discharge line is the refrigerant line
that carries refrigerant from the underbody discharge
line to the rear A/C condenser (Fig. 26). The rear A/C
discharge line is retained to the right quarter panel
by two plastic retaining clips.
CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrigerant system connections to leak.
The rear A/C discharge line has no serviceable
parts except for the O-ring seals. The O-ring seals
used on the connections are made from a special type
of rubber not affected by R-134a refrigerant and
must be replaced whenever the rear discharge line is
removed and installed.
If the rear A/C discharge line is found to be leaking
or damaged, it must be replaced.
VA
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Remove the screw and bracket that secures the
rear A/C discharge line to the right side of the rear
A/C condenser housing (Fig. 27).
(6) Disconnect the rear A/C discharge line from the
rear A/C condenser and remove and discard the
O-ring seal.
(7) Disengage the discharge line grommet from the
roof panel and push the grommet down into the
cargo compartment.
Fig. 26 Rear A/C Discharge Line
1
2
3
4
5
-
REAR A/C DISCHARGE LINE
RETAINING CLIPS
TO REAR A/C CONDENSER
RIGHT INNER QUARTER PANEL
TO UNDERBODY DISCHARGE LINE
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
Fig. 27 Rear A/C Discharge Line to Rear Condenser
1
2
3
4
5
-
REAR A/C CONDENSER
GROMMET
REAR A/C DISCHARGE LINE
CONDENSER INLET TUBE
SCREW AND BRACKET
(8) Remove the right quarter trim panel (Refer to
23 - BODY/INTERIOR/QUARTER TRIM PANEL REMOVAL).
(9) Remove the retaining strap that secures the
rear A/C wire harness to the rear A/C discharge line
at the ceiling and position the wire harness out of
the way (Fig. 28).
PLUMBING
VA
Fig. 28 Rear A/C Wire Harness
1
2
3
4
-
REAR A/C EVAPORATOR HOUSING
REAR A/C DISCHARGE LINE
RETAINING STRAP
REAR A/C WIRE HARNESS
(10) Remove the three foam insulators from the
right inner quarter panel (Fig. 29).
(11) Disengage the rear A/C discharge line from
the two retaining clips located on the inner quarter
panel and pull the discharge line down from the top
of the vehicle into the cargo compartment.
(12) Disengage the rear A/C discharge line from
the two retaining clips located underneath of the
vehicle.
(13) Disconnect the rear A/C discharge line from
the underbody discharge line and remove and discard
the O-ring seal.
(14) Remove the foam rubber seal from the opening in the floor of the cargo compartment and pull
the rear A/C discharge line out from underneath the
vehicle.
(15) Install plugs into, or tape over the opened
rear discharge and underbody line fittings and condenser tube.
24 - 89
24 - 90
PLUMBING
VA
Fig. 29 Rear A/C Discharge Line to Underbody
1
2
3
4
5
-
REAR A/C DISCHARGE LINE
RETAINING CLIPS
TO REAR CONDENSER
FOAM RUBBER SEAL
BRACKETS
INSTALLATION
(1) Remove the tape or plugs from the rear discharge and underbody line fittings and the rear condenser tube.
(2) Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear discharge line
fittings. Use only the specified O-ring seals as they
are made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) From underneath the vehicle, route the rear
A/C discharge line into the cargo compartment and
install it into the two retaining clips located under
the vehicle.
(4) Connect the rear A/C discharge line to the
underbody discharge line. Tighten the nut to 35 N·m
(26 ft. lbs.).
(5) Install the foam rubber seal into the floor
panel.
(6) From inside the vehicle, install the rear A/C
discharge line into the two retaining clips located on
the inner quarter panel and route the discharge line
through the opening in the roof.
(7) Seat the grommet to the roof panel and install
a new rear A/C wire harness retaining strap.
(8) Install the three foam insulators to the right
inner quarter panel.
6
7
8
9
-
UNDERBODY DISCHARGE LINE
RIGHT INNER QUARTER PANEL
FOAM INSULATORS
TO UNDERBODY
(9) Install the right quarter trim panel (Refer to
23 - BODY/INTERIOR/QUARTER TRIM PANEL INSTALLATION).
(10) Connect the rear discharge line to the rear
A/C condenser. Tighten the nut to 35 N·m (26 ft.
lbs.).
(11) Install the bracket and screw that secures the
rear discharge line to the right side of the rear condenser housing. Tighten the screw securely.
(12) Reconnect the negative battery cable.
(13) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(14) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(15) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
(16) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
PLUMBING
VA
REAR LIQUID LINE
DESCRIPTION
The rear liquid line is the refrigerant line that carries refrigerant from the rear condenser to the rear
A/C expansion valve. The rear A/C liquid line on this
vehicle is serviced in two sections (Fig. 30).
CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrigerant system connections to leak.
The rear A/C liquid lines have no serviceable parts
except for the O-ring seals. The O-ring seals used on
the connections are made from a special type of rubber not affected by R-134a refrigerant and must be
replaced whenever the rear liquid line is removed
and installed.
If either of the rear liquid lines is found to be leaking or damaged, it must be replaced.
Fig. 30 Rear A/C Liquid Lines
1
2
3
4
-
REAR
REAR
REAR
REAR
A/C CONDENSER
LIQUID LINE (FROM CONDENSER)
RECIEVER/DRIER AND RESERVOIR
LIQUID LINE (TO EXPANSION VALVE)
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
24 - 91
CONDENSER TO RECEIVER / DRIER
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear liquid line from the rear
receiver/drier and remove and discard the O-ring seal
(Fig. 31).
(6) Disconnect the rear liquid line from the rear
condenser and remove and discard the O-ring seal.
(7) Remove the retaining straps that secure the
rear A/C wire harness to the rear liquid line and
remove the liquid line.
(8) Install plugs into, or tape over the opened rear
liquid line fittings and receiver/drier and condenser
ports.
24 - 92
PLUMBING
VA
Fig. 31 Rear Liquid Line - Condenser to Receiver/drier
1 - REAR RECEIVER/DRIER
2 - LIQUID LINE (FROM CONDENSER)
RESERVOIR TO EXPANSION VALVE
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear liquid line from the reservoir and remove and discard the O-ring seal (Fig.
32).
(6) Disconnect the rear liquid line from the rear
expansion valve and remove and discard the O-ring
seal.
(7) Disengage the liquid line grommet from the
roof panel and remove the liquid line.
(8) Install plugs into, or tape over the opened rear
liquid line fittings and reservoir and expansion valve
ports.
3 - REAR A/C CONDENSER
4 - RETAINING STRAPS
PLUMBING
VA
24 - 93
Fig. 32 Rear Liquid Line - Reservoir to Expansion Valve
1 - GROMMET
2 - LIQUID LINE (TO EXPANSION VALVE)
INSTALLATION
CONDENSER TO RECEIVER / DRIER
(1) Remove the tape or plugs from the rear liquid
line fittings and receiver/drier and condenser ports.
(2) Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line fittings. Use only the specified O-ring seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) Connect the rear liquid line to the rear receiver/drier. Tighten the nut to 35 N·m (26 ft. lbs.).
(4) Connect the rear liquid line to the rear A/C
condenser. Tighten the nut to 35 N·m (26 ft. lbs.).
(5) Install the retaining straps that secure the rear
A/C wire harness to the rear liquid line.
(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(8) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(9) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
3 - REAR REFRIGERANT RESERVOIR
4 - REAR A/C EXPANSION VALVE
(10) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
RESERVOIR TO EXPANSION VALVE
(1) Remove the tape or plugs from the rear liquid
line fittings and the reservoir and expansion valve
ports.
(2) Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line fittings. Use only the specified O-ring seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) Connect the rear liquid line to the rear A/C
expansion valve. Tighten the nut to 35 N·m (26 ft.
lbs.).
(4) Route the liquid line through the opening in
the roof and engage the grommet to the roof panel.
(5) Connect the rear liquid line to the rear refrigerant reservoir. Tighten the nut to 35 N·m (26 ft.
lbs.).
(6) Reconnect the negative battery cable.
(7) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
24 - 94
PLUMBING
VA
(8) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(9) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
(10) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
REAR RECEIVER / DRIER
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear refrigerant reservoir from
the rear receiver/drier and remove and discard the
O-ring seal (Fig. 33).
(6) Disconnect the liquid line from the rear receiver/drier and remove and discard the O-ring seal.
(7) Remove the bolt and retaining bracket that
secures the rear receiver/drier to the rear A/C condenser housing and remove the receiver/drier.
(8) Install plugs into, or tape over the opened rear
liquid line fitting and reservoir and receiver/drier
ports.
Fig. 33 Rear Receiver/Drier
1
2
3
4
5
6
-
REAR A/C CONDENSER HOUSING
REFRIGERANT RESEVOIR
REAR RECEIVER/DRIER
BOLT
LIQUID LINE
RETAINING BRACKET
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
receiver/drier is being replaced. The refrigerant oil
must be drained from the old receiver/drier and
measured to determine the amount of refrigerant oil
to add to the new receiver/drier. Use only refrigerant oil of the type recommended for the rear A/C
compressor in the vehicle.
(1) If the rear receiver/drier is being replaced,
install the correct amount and type of refrigerant oil
into the new rear receiver/drier. Drain the old receiver/drier and measure the refrigerant oil. Fill the new
receiver/drier with the same amount of new refrigerant oil that was drained out of the old receiver/drier.
NOTE: The rear receiver/drier is labeled with a
direction-of-flow arrow to indicate refrigerant flow
through the receiver/drier. Make sure to properly
install the rear receiver/drier in the correct direction.
(2) Position the rear receiver/drier to the rear A/C
condenser housing and install the retaining bracket
and bolt. Tighten the bolt to 25 N·m (18 ft. lbs.).
(3) Remove the tape or plugs from the rear liquid
line fitting and reservoir and receiver/drier ports.
(4) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
PLUMBING
VA
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(5) Connect the rear liquid line to the rear receiver/drier. Tighten the nut to 35 N·m (26 ft. lbs.).
(6) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the receiver/drier outlet
fitting. Use only the specified O-ring seal as it is
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(7) Connect the rear refrigerant reservoir to the
rear receiver/drier. Tighten the nut to 35 N·m (26 ft.
lbs.).
(8) Reconnect the negative battery cable.
(9) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(10) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(11) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(12) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
TIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - REMOVAL).
(5) Disconnect the rear liquid line from the rear
refrigerant reservoir and remove and discard the
O-ring seal (Fig. 34).
(6) Disconnect the rear refrigerant reservoir from
the rear receiver/drier and remove and discard the
O-ring seal.
(7) Remove the bolt and retaining bracket that
secures the rear refrigerant reservoir to the rear A/C
condenser housing and remove the reservoir.
(8) Install plugs into, or tape over the opened rear
liquid line fitting and receiver/drier and reservoir
ports.
REAR REFRIGERANT RESERVOIR
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the air filter from the rear A/C evaporator housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/AIR FILTER REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the cover from the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDI-
24 - 95
Fig. 34 Rear Refrigerant Reservoir
1
2
3
4
5
6
-
REAR A/C CONDENSER HOUSING
LIQUID LINE
REAR REFRIGERANT RESERVOIR
BOLT
REAR RECEIVER/DRIER
RETAINING BRACKET
INSTALLATION
NOTE: Be certain to add refrigerant oil if the rear
refrigerant reservoir is being replaced. The refrigerant oil must be drained from the old refrigerant reservoir and measured to determine the amount of
refrigerant oil to add to the new reservoir. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(1) If the rear refrigerant reservoir is being
replaced, install the correct amount and type of
refrigerant oil into the new rear refrigerant reservoir.
Drain the old refrigerant reservoir and measure the
refrigerant oil. Fill the new refrigerant reservoir with
the same amount of new refrigerant oil that was
drained out of the old reservoir.
24 - 96
PLUMBING
(2) Install a new rear receiver/drier (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING/
REAR RECEIVER/DRIER - INSTALLATION).
(3) Position the rear refrigerant reservoir to the
rear A/C condenser housing and install the retaining
bracket and bolt. Tighten the bolt to 25 N·m (18 ft.
lbs.).
(4) Remove the tape or plugs from the rear liquid
line fitting and receiver/drier and reservoir ports.
(5) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear receiver/drier fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(6) Connect the rear receiver/drier to the rear
refrigerant reservoir. Tighten the nut to 35 N·m (26
ft. lbs.).
(7) Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the rear
A/C compressor in the vehicle.
(8) Connect the rear liquid line to the rear refrigerant reservoir. Tighten the nut to 35 N·m (26 ft.
lbs.).
(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(12) Install the rear air filter (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION REAR/AIR FILTER - INSTALLATION).
(13) Install the cover onto the rear A/C condenser
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION
REAR/A/C
CONDENSER COVER - INSTALLATION).
REAR SUCTION LINE
DESCRIPTION
The rear A/Csuction line is the refrigerant line that
carries refrigerant from the rear A/C evaporator to
the A/C underbody suction line (Fig. 35). The rear
A/C suction line is retained to the left quarter panel
by two plastic retaining clips.
CAUTION: Use only seals specified for the vehicle.
Failure to use the correct seals will cause the refrigerant system connections to leak.
VA
The rear A/C suction line has no serviceable parts
except for the O-ring seals. The O-ring seals used on
the connections are made from a special type of rubber not affected by R-134a refrigerant and must be
replaced whenever the rear A/C suction line is
removed and installed.
If the rear A/C suction line is found to be leaking
or damaged, it must be replaced.
Fig. 35 Rear A/C Suction Line
1
2
3
4
5
-
REAR A/C SUCTION LINE
TO UNDERBODY SUCTION LINE
RETAINING CLIPS
LEFT INNER QUARTER PANEL
TO REAR A/C EVAPORATOR
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(3) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(4) Remove the insulating tape from around the
area of the rear A/C suction line and evaporator outlet tube (Fig. 36).
VA
(5) From inside the vehicle, disconnect the rear
A/C suction line from the rear A/C evaporator and
remove and discard the O-ring seal.
(6) From underneath the vehicle, disconnect the
rear A/C suction line from the underbody suction line
and remove and discard the O-ring seal.
(7) Remove the left quarter trim panel (Refer to 23
- BODY/INTERIOR/QUARTER TRIM PANEL REMOVAL).
(8) Remove the three foam insulators from the left
inner quarter panel.
(9) Remove the foam rubber seal from the opening
in the floor of the cargo compartment.
(10) Disengage the rear A/C suction line from the
two retaining clips located on the inner quarter panel
and remove the suction line.
(11) Install plugs into, or tape over the opened
rear suction and underbody line fittings and evaporator tube.
PLUMBING
24 - 97
24 - 98
PLUMBING
VA
Fig. 36 Rear A/C Suction Line
1
2
3
4
-
REAR A/C SUCTION LINE
RETAINING CLIPS
EVAPORATOR OUTLET TUBE
UNDERBODY SUCTION LINE
INSTALLATION
(1) Remove the tape or plugs from the rear suction
and underbody line fittings and the rear evaporator
tube.
(2) Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear suction line fittings. Use only the specified O-ring seals as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the rear A/C compressor in the vehicle.
(3) Position the rear A/C suction line to the left
inner quarter panel and install it into the two retaining clips.
(4) From inside the vehicle, connect the rear A/C
suction line to the rear A/C evaporator. Tighten the
nut to 35 N·m (26 ft. lbs.).
(5) From underneath the vehicle, connect the rear
A/C suction line to the underbody suction line.
Tighten the nut to 35 N·m (26 ft. lbs.).
(6) Install the three foam insulators to the left
inner quarter panel.
(7) Install the foam rubber seal into the floor
panel.
(8) Install the left quarter trim panel (Refer to 23 BODY/INTERIOR/QUARTER
TRIM
PANEL
INSTALLATION).
(9) Reconnect the negative battery cable.
(10) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
5 - FOAM RUBBER SEAL
6 - FOAM INSULATORS
7 - LEFT INNER QUARTER PANEL
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(12) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
REFRIGERANT LINE COUPLER
DESCRIPTION
A spring-lock type refrigerant line coupler is used
to connect the front section of the underbody discharge line to the compressor section of the discharge
line. A secondary retaining clip may be installed over
the connected coupler for added protection.
The spring-lock refrigerant line coupler requires a
special disconnect tool for disengaging the two coupler halves.
OPERATION
The spring-lock coupler is held together by a garter
spring inside a circular cage on the male half of the
fitting (Fig. 37). When the two coupler halves are
connected, the flared end of the female fitting slips
behind the garter spring inside the cage on the male
fitting. The garter spring and cage prevent the flared
end of the female fitting from pulling out of the
cage.
PLUMBING
VA
24 - 99
Fig. 37 Spring-Lock Coupler - Typical
1
2
3
4
5
6
7
8
-
MALE HALF SPRING-LOCK COUPLER
FEMALE HALF SPRING-LOCK COUPLER
SECONDARY CLIP
CONNECTION INDICATOR RING
COUPLER CAGE
GARTER SPRING
COUPLER CAGE
O-RING SEALS
Fig. 38 Refrigerant Line Spring-Lock Coupler
Disconnect
Two O-rings on the male half of the fitting are
used to seal the connection. These O-rings are compatible with R-134a refrigerant and must be replaced
with O-rings made of the same material.
Secondary clips are installed over the two connected coupler halves at the factory for added blowoff
protection. In addition, some models have a plastic
ring that is used at the factory as a visual indicator
to confirm that these couplers are connected. After
the coupler is connected, the plastic indicator ring is
no longer needed; however, it will remain on the
refrigerant line near the coupler cage.
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the disconnect tool.
REMOVAL
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY).
(2) Remove the secondary retaining clip from the
spring-lock coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 38).
(6) Open and remove the A/C line disconnect tool
from the disconnected spring-lock coupler.
(7) Complete the separation of the two halves of
the coupler fitting.
INSTALLATION
(1) Check to ensure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.
(3) Install new O-rings on the male half of the coupler fitting.
24 - 100
PLUMBING
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a system. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Ensure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Reinstall the secondary retaining clip over the
spring-lock coupler cage.
(9) Evacuate the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(10) Charge the refrigerant system (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the following operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING CAUTIONS). Failure to follow the warnings and cautions could result in possible personal injury or
death.
NOTE: The underbody refrigerant lines for the
optional rear A/C system are serviced in five sections. Two sections are connected the A/C compressor. Two sections of the underbody suction line
(low-side) are connected together by a tapping
block with an O-ring seal. The underbody A/C discharge line uses a spring-lock type refrigerant line
coupler with an O-ring seal.
DISCHARGE LINE
(1) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDI-
VA
TIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(2) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(3) Raise and support the vehicle.
(4) Using the proper A/C line disconnect tool, disconnect the underbody discharge line spring-lock coupler from the compressor section of the underbody
discharge line and remove and discard the O-ring
seal (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT LINE COUPLER REMOVAL) (Fig. 39).
(5) Disconnect the underbody discharge line from
the rear A/C discharge line and remove and discard
the O-ring seal.
(6) Install plug in, or tape over all of the opened
discharge line fittings.
(7) Disengage the fuel lines from the retaining clip
located near the transmission and position the fuel
lines out of the way.
(8) Remove the screws and brackets that secure
the discharge line to the underneath of the vehicle.
(9) Support transmission with a suitable lifting
device and remove the rear transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/
REAR
CROSSMEMBER-TRANSMISSION
REMOVAL).
(10) Remove the underbody discharge line from
the vehicle. Push the discharge line forward and over
the transmission, then pull it rearward to remove.
(11) If necessary, remove the bolt that secures the
compressor section of the underbody discharge line to
the A/C compressor and remove and discard the
O-ring seal. Make sure to plug in, or tape over the
opened discharge line fitting and compressor port.
PLUMBING
VA
24 - 101
Fig. 39 Underbody Discharge Line
1
2
3
4
-
UNDERBODY DISCHARGE LINE
FUEL LINES
REAR A/C DISCHARGE
REAR TRANSMISSION CROSSMEMBER
SUCTION LINE - FRONT SECTION
(1) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(2) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(3) Raise and support the vehicle.
(4) Disconnect the connection of the front section
of the underbody suction line from the compressor
section of the underbody suction line and remove and
discard the O-ring seal (Fig. 40).
(5) Remove the bolt that secures the connection of
the front section of the underbody suction line to the
rear section of the underbody suction line.
(6) Disconnect the front section of the underbody
suction line from the rear section and remove and
discard the O-ring seal.
(7) Install plug in, or tape over all of the opened
suction line fittings.
(8) Remove the screws and brackets that secure
the front section of the underbody suction line to the
underneath of the vehicle and remove the front section of the suction line.
5 - SCREW AND BRACKET (2)
6 - DISCHARGE LINE-COMPRESSOR SECTION
7 - RETAINING CLIP
(9) If necessary, remove the bolt that secures the
compressor section of the underbody suction line to
the A/C compressor and remove and discard the
O-ring seal. Make sure to plug in, or tape over the
opened underbody suction line fitting and compressor
port.
24 - 102
PLUMBING
VA
Fig. 40 Underbody Suction Line - Front Section
1
2
3
4
5
-
UNDERBODY SUCTION LINE-FRONT SECTION
BOLT
UNDERBODY SUCTION LINE-REAR SECTION
SUCTION LINE-COMPRESSOR SECTION
SCREW AND BRACKET (2)
SUCTION LINE - REAR SECTION
(1) Remove the cover from the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - REMOVAL).
(2) Recover the refrigerant from the rear refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE REFRIGERANT RECOVERY).
(3) Raise and support the vehicle.
(4) Remove the bolt that secures the connection of
the front section of the underbody suction line to the
rear section of the underbody suction line (Fig. 41).
(5) Disconnect the front section of the underbody
suction line from the rear section and remove and
discard the O-ring seal.
(6) Disconnect the rear section of the underbody
suction line from the rear A/C suction line and
remove and discard the O-ring seal.
(7) Install plug in, or tape over all of the opened
suction line fittings.
(8) Remove the screws and brackets that secure
the rear section of the underbody suction line to the
underneath of the vehicle and remove the rear section of the suction line.
Fig. 41 Underbody Suction Line - Rear Section
1
2
3
4
5
-
REAR A/C DISCHARGE LINE
UNDERBODY SUCTION LINE-REAR SECTION
SCREW AND BRACKET (3)
BOLT
UNDERBODY SUCTION LINE-FRONT SECTION
INSTALLATION
DISCHARGE LINE
(1) If the compressor section of the underbody discharge line was removed from the A/C compressor,
remove plugs or tape from the discharge line fitting,
lubricate a new rubber O-ring seal with clean refrigerant oil, install it onto the discharge line fitting and
install the bolt that secures the discharge line to the
compressor. Tighten the bolt to 21 N·m (15 ft. lbs.).
(2) Position the underbody discharge line to the
vehicle.
(3) Install the brackets and screws that secure the
underbody discharge line to the underneath of the
vehicle. Tighten the screws to 8 N·m (70 in. lbs.).
(4) Engage the fuel lines to the retaining clips
located near the transmission.
(5) Install the rear transmission crossmember
(Refer to 13 - FRAME & BUMPERS/FRAME/REAR
CROSSMEMBER-TRANSMISSION - INSTALLATION).
(6) Remove the plugs or tape from the discharge
line fittings.
(7) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the discharge
line fittings.
(8) Connect the underbody discharge line springlock coupler to the compressor section of the discharge line and install the secondary retaining clip
(if equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT LINE COUPLER - INSTALLATION).
VA
(9) Connect the rear A/C discharge line to the
underbody discharge line. Tighten the nut to 35 N·m
(26 ft. lbs.).
(10) Lower the vehicle.
(11) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(12) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(13) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
SUCTION LINE - FRONT SECTION
(1) If the compressor section of the underbody suction line was removed from the A/C compressor,
remove plugs or tape from the suction line fitting,
lubricate a new rubber O-ring seal with clean refrigerant oil, install it onto the suction line fitting and
install the bolt that secures the suction line to the
compressor. Tighten the bolt to 21 N·m (15 ft. lbs.).
(2) Position the front section of the underbody suction line to the vehicle.
(3) Install the brackets and screws that secure the
front section of the underbody suction line to the
underneath of the vehicle. Tighten the screws to 8
N·m (70 in. lbs.).
(4) Remove the plugs or tape from the suction line
fittings.
(5) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction line
fittings.
(6) Connect the front section of the underbody suction line to the compressor section of the suction line.
Tighten the nut to 35 N·m (26 ft. lbs.).
(7) Connect the front section of the underbody suction line to the rear section of the suction line and
install the retaining bolt. Tighten the bolt to 25 N·m
(18 ft. lbs.).
(8) Lower the vehicle.
(9) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(10) Charge the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(11) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
PLUMBING
24 - 103
SUCTION LINE - REAR SECTION
(1) Position the rear section of the underbody suction line to the vehicle.
(2) Install the brackets and screws that secure the
rear section of the underbody suction line to the
underneath of the vehicle. Tighten the screws to 8
N·m (70 in. lbs.).
(3) Remove the plugs or tape from the suction line
fittings.
(4) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction line
fittings.
(5) Connect the rear section of the underbody suction line to the front section of the suction line and
install the retaining bolt. Tighten the bolt to 25 N·m
(18 ft. lbs.).
(6) Connect the rear section of the underbody suction line to the rear A/C suction line. Tighten the nut
to 35 N·m (26 ft. lbs.).
(7) Lower the vehicle.
(8) Evacuate the rear refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
(9) Charge the rear refrigerant system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
(10) Install the cover onto the rear A/C evaporator
housing (Refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/A/C EVAPORATOR COVER-REAR - INSTALLATION).
24 - 104
CABIN HEATER
VA
CABIN HEATER
TABLE OF CONTENTS
page
CABIN HEATER
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
SUPPLEMENTAL CABIN HEATER
EXHAUST TUBE
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL DOSING PUMP
DESCRIPTION . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . .
FUEL LINE
STANDARD PROCEDURE
CLEANING
................
. . . . . . . . . 104
. . . . . . . . . 104
. . . . . . . . 104
. . . . . . . . . 105
. . . . . . . . . 106
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.
.
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.
.
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.
.
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.
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.
.
.
. 106
. 106
. 106
. 107
page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
HEATER UNIT
REMOVAL
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 110
WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 110
WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . 111
INLET HOSE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112
. . . . . . . . . 107
CABIN HEATER
DESCRIPTION
Vehicles equipped with the diesel engine are also
equipped with a supplemental cabin heater. This
cabin heater is mounted under the vehicle and operates similar to an oil fired furnace. The heater burns
small amounts of fuel to provide additional heat to
the coolant. Coolant is routed from the engine, to the
supplemental cabin heater and then to the front
heater core. This provides additional heat to the passenger compartment. The supplemental cabin heater
system is interfaced to the vehicles on-board computer systems and DRBIIIt diagnostics.
The supplemental cabin heater has an electronic
control module that monitors the heat output of the
heater. The cabin heater operates at full load (5 kW),
half load or idle mode (no additional heat) depending
on engine coolant temperature.
OPERATION
The supplemental cabin heater is activated by
using the temperature control on the A/C-heater control. The supplemental cabin heater is activated
when the temperature control is set to/or above the
upper set point. The supplemental cabin heater can
operate in a full or partial load range as well as an
idle mode, all dependent on the engine coolant temperature. The heater unit will also turn off if the
temperature control is set to less than the lower set
point. The supplemental cabin heater can take up to
three minutes to completely shut down when either
the heater temperature is set below the lower set
point or the vehicle ignition is turned off.
The supplemental cabin heater only operates when
the engine is running, the mileage exceeds 8 kilometer (5 mph) and the fuel tank volume exceeds 1/8 of a
tank. The heater should start if the coolant temperature is below 40° C (104° F).
NOTE: Do not apply a strong vacuum directly on
the supplemental cabin heater exhaust line. Place
the vacuum within 75 mm (3 inches) of the exhaust
port. Too strong of a vacuum can prevent the heater
from starting. The heater control module monitors
the blower speed and combustion during its startup.
DIAGNOSIS AND TESTING
SUPPLEMENTAL CABIN HEATER
Refer to the Symptoms Diagnosis table for basic
checks of the diesel fueled supplemental cabin heater.
CABIN HEATER
VA
24 - 105
SYMPTOMS DIAGNOSIS
Symptom
Possible Causes
Smell of diesel fuel.
Check cabin heater system integration in vehicle’s fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of external fuel. If presence of external fuel is observed on the heater unit or
in the exhaust tube or after draining and testing. Remove the cabin
heater from vehicle and repair or replace components as required.
Heater does not achieve full load operation.
Check cabin heater operation with DRBIIIT scan tool and replace
components as required.
Continuous white smoke from heater
exhaust during combustion operation.
Check cabin heater operation with DRBIIIT scan tool and replace
components as required. White smoke is typical in extreme weather
conditions.
Heater can not be switched off.
Check cabin heater operation with DRBIIIT scan tool and replace
components as required.
Heater does not operate.
Diagnosis cabin heater control module using the DRBIIIT scan tool
and the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.
Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an extremely sweet smell.
Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is
an internal heater leak and cabin heater should be inspected and
components should be replaced as required.
Loss of fuel (dripping).
Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.
EXHAUST TUBE
REMOVAL
WARNING: There is a potential danger of skin burns
as the supplemental cabin heater unit and its components can become very hot. Make sure the heater
unit is allowed to cool down before any service
work on the cabin heater system is attempted. Failure to observe this warning may result in possible
personal injury.
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 1).
24 - 106
CABIN HEATER
VA
Fig. 1 Cabin Heater Exhaust System
1 - MOUNTING SCREW (3)
2 - STEEL HEATER EXHAUST PIPE
3 - EXHAUST CLAMP (2)
(3) Remove the clamp at the flexible pipe connection and the supplemental heater housing (if
required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehicle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
INSTALLATION
(1) Install the flexible exhaust pipe to the heater
unit. Tighten mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
exhaust and install and tighten the mounting clamp
securely.
(3) Install the three exhaust pipe screws, adjust
pipe placement as needed and tighten the screws
securely.
(4) Install the clamp to connect the steel exhaust
pipe to the flexible exhaust pipe and tighten clamp
securely.
(5) Check exhaust pipe exhaust end placement and
make any final adjustments.
(6) Lower the vehicle.
4 - FLEXIBLE HEATER EXHAUST PIPE
5 - HEATER SHIELD
6 - EXHAUST PIPE MOUNTING CLIP (3)
FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the supplemental cabin heater from the vehicle fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the supplemental cabin heater control module. The pump
supplies diesel fuel from the vehicle fuel tank to the
cabin heater.
REMOVAL
NOTE: The dosing pump is serviceable without
removing the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line (Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 2).
(2) Disconnect the fuel line between the dosing
pump and the cabin heater unit.
CABIN HEATER
VA
24 - 107
Fig. 2 Cabin Heater Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP
NOTE: Position and retain the heater fuel line to
prevent fuel leakage while servicing the dosing
pump.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(3) Disconnect the wiring harness connector to the
fuel pump by depressing the integral spring and pulling the connector away from the pump.
(4) Remove the dosing pump from the rubber isolator.
INSTALLATION
(1) Install the dosing pump onto the rubber isolator.
(2) Connect the fuel lines to the dosing pump and
the cabin heater unit.
NOTE: The connectors should point towards the
cabin heater fuel line.
(3) Use aviation style clamps to attach the hose to
the fuel pump nipples (Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/FUEL LINE
- INSTALLATION).
(4) Connect the wire harness connector to the fuel
pump by depressing the integral spring and pushing
3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
the connector towards the dosing pump. Pull the connector towards the cabin heater to verify the installation.
(5) Verify function of the supplemental cabin
heater.
FUEL LINE
STANDARD PROCEDURE
CLEANING
(1) Remove the cabin heater fuel line (Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - REMOVAL).
(2) With the cabin heater fuel line removed from
the vehicle, place a shop cloth on the fuel tank end of
the fuel line to catch any residue, then apply a small
amount of air pressure to the other end of the fuel
line.
(3) Check to see if air pressure is coming from the
tank end of the line. If pressure is flowing unrestricted the line is clean.
(4) If the fuel line shows any signs of being
restricted after air pressure is applied, the fuel line
should be replaced.
24 - 108
CABIN HEATER
(5) Install the cabin heater fuel line (Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - INSTALLATION).
(6) Verify function of the cabin heater.
REMOVAL
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
NOTE: Have an approved fuel holding device ready
to capture any diesel fuel that drains from the fuel
line or cabin heater unit.
(2) Remove clamps on dosing pump end of fuel line
and separate line from the pump (Fig. 3).
VA
CABIN HEATER
VA
24 - 109
Fig. 3 Cabin Heater Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP
(3) Remove clamp from the fuel line at the fuel
tank connection and separate the line from the tank.
(4) Remove any retaining clips and remove the
fuel line from vehicle.
INSTALLATION
WARNING: Do not operate the diesel supplemental
cabin heater in an enclosed area such as a garage
that does not have exhaust ventilation facilities.
Always vent the cabin heater exhaust when operating the cabin heater. Allow the diesel supplemental
cabin heater to cool before performing any service
procedures to the cabin heater. Verify that all diesel
supplemental cabin heater fuel lines are securely
fastened to their respective components before performing any service procedures to the cabin heater.
Failure to follow these warnings may result in possible personal injury or death.
NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle’s fuel tank before performing this
procedure. Add fuel, if necessary.
(1) Install the cabin heater fuel supply line into
vehicle and fuel line retainers.
(2) Install the fuel line connection at the fuel tank
and tighten the connection securely.
3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
(3) Install the fuel line at the dosing pump and
tighten the connection securely.
(4) Lower the vehicle.
NOTE: Failure to prime the dosing pump after draining the supplemental cabin fuel line will prevent
cabin heater activation during the first attempt to
start the cabin heater. This will also set a diagnostic
trouble code (DTC) in the cabin heater control’s
memory. Do not perform the Dosing Pump Priming
procedure if an attempt was made to start the cabin
heater without priming the dosing pump first. This
will put excess fuel in the cabin heater and cause
smoke to emit from the cabin heater exhaust pipe
when cabin heater activation occurs.
(5) Connect the DRBIIIt scan tool to the diagnostic link connector.
(6) Turn the ignition to the ON position.
NOTE: Do not activate the dosing pump prime more
than one time. This will put excess fuel in the supplemental cabin heater and cause smoke to emit
from the cabin heater exhaust pipe when cabin
heater activation occurs.
NOTE: A clicking noise heard coming from the dosing pump indicates that the pump is operational.
24 - 110
CABIN HEATER
(7) With the DRBIIIt scan tool in Cabin Heater,
select System Tests and Dosing Pump Prime. Allow
the dosing pump to run for the full 45 second cycle
time. When the 45 second cycle is complete, press
Page Back on the DRBIIIt scan tool key pad to exit
the Dosing Pump Prime. The Dosing Pump Priming
procedure is now complete.
HEATER UNIT
REMOVAL
HEATER UNIT
WARNING: Do not operate the diesel supplemental
cabin heater in an enclosed area such as a garage
that does not have exhaust ventilation facilities.
Always vent the cabin heater exhaust when operating the cabin heater. Allow the diesel supplemental
cabin heater to cool before performing any service
procedures to the cabin heater. Verify that all diesel
supplemental cabin heater fuel lines are securely
fastened to their respective components before performing any service procedures to the cabin heater.
Failure to follow these warnings may result in possible personal injury or death.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Drain the engine cooling system (Refer to 7 COOLING - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the cabin heater and the
hose and tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board crossmember at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe-board crossmember and
rail.
(7) Remove the wiring harness from the toe-board
crossmember (Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT REMOVAL - WIRE HARNESS).
(8) Open the fuel filler cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
VA
(9) Loosen the two fasteners at the rail. Take care
to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the flexible section of the cabin
heater exhaust tube from the exhaust tube by loosening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to crossmember.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable support device under the
cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the
crossmembers.
(14) Remove the loosened fasteners that support
the cabin heater while supporting the weight of the
heater.
(15) Swing the cabin heater mounting bracket
from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.
(16) Remove the cabin heater from the vehicle.
WIRE HARNESS
(1) Raise and support the vehicle while taking note
of the location of the flexible exhaust tube section.
(2) Disconnect the cabin heater wire harness connector from the vehicle wiring harness.
(3) Disconnect the cabin heater wire harness connector from the dosing pump.
(4) Disconnect the two cabin heater wire harness
connectors from the cabin heater controller.
(5) Remove two wiring harness retainers from the
underbody.
(6) Remove two wiring harness retainers from the
cabin heater shield.
(7) Carefully route the cabin heater wire harness
out the left side between the heater unit and the
heater shield.
INSTALLATION
HEATER UNIT
(1) Install the cabin heater mounting bracket
between the exhaust bracket and the rail mounting
location.
(2) Support the cabin heater and install the fasteners that secure the cabin heater to the mounting
bracket.
(3) Install the three fasteners to the crossmembers. Tighten the M6 fasteners to 7 N·m (62 in. lbs.).
CABIN HEATER
VA
(4) Position the two spacer washers between the
body and the rubber grommets for the two mounting
points on the rail.
(5) Tighten the remaining M6 fasteners to 7 N·m
(62 in. lbs.) and the M8 fasteners to 23 N·m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.
(6) Install the seat hex nut at the heater mounting
flange to the crossmembers. Tighten the nut to 60
N·m (44 ft. lbs.)
(7) Install the flexible section of the cabin heater
exhaust tube to the exhaust tube. Tighten the M6
bolt of the clamp securley. Install the hose to the
exhaust tube.
(8) Tighten the two M8 fasteners at the rail to 23
N·m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.
(9) Install the wiring harness (Refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION - WIRE
HARNESS).
(10) Tighten the hose and tube assembly to the
toe-board crossmember at two locations.
(11) Install the second hose to the underbody hose
and tube assembly.
(12) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(13) Remove the cabin heater support device from
under the vehicle.
(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).
(16) Verify function of the heater unit.
24 - 111
INLET HOSE
REMOVAL
NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.
(1) Drain the engine cooling system (Refer to 7 COOLING - STANDARD PROCEDURE - DRAINING
COOLING STSTEM).
(2) Remove clamps from the cabin heater tubes at
the lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the cabin
heater air intake muffler connection (Refer to 24 HEATING & AIR CONDITIONING/CABIN HEATER/INLET MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 4).
WIRE HARNESS
(1) Carefully route the cabin heater wire harness
from the left side between the heater unit and the
heater shield.
(2) Install the two wiring harness retainers to the
cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retainers to the underbody.
(4) Connect the two cabin heater wire harness connectors to the cabin heater controller.
(5) Connect the cabin heater wire harness to the
dosing pump.
(6) Connect the cabin heater wire harness connector to the vehicle wiring harness.
(7) Lower the vehicle.
(8) Verify function of the heater unit.
Fig. 4 Cabin Heater Flexible Air Intake Line
1
2
3
4
5
6
-
CABIN HEATER AND SPLASH SHIELD
DOSING PUMP
DOSING PUMP FUEL LINE
FLEXIBLE INTAKE LINE
CLAMP
STEEL INTAKE PIPE
(5) Remove the two retaining screws and remove
pipe assembly (Fig. 5).
24 - 112
CABIN HEATER
Fig. 5 Cabin Heater Air Intake And Heater Pipe
Assembly
1
2
3
4
5
-
INTAKE TUBE AIR INTAKE
INTAKE PIPE
RETAINING SCREWS
INTAKE HEATER LINE
RETURN HEATER LINE
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N·m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
clamp securely.
(4) Install the cabin heater tubes to the lower
heater connection and the lower EGR cooler connection and tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).
(7) Verify function of the heater unit.
VA
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