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2006 VA Service Manual - aie-services

1. 2 Connect the two control cables to the A C heater control NOTE Install the control cable of bottom adjust ment lever to the front adjustment wheel of the A C heater 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 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 clock wise 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 Ibs 9 Install the center bezel onto the instrument panel Refer to 23 BODY ANSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL INSTAL LATION 10 Reconnect the negative battery cable 81119fce Fig 22 Adjusting Air Distribution Control Cables 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 ACTU ATOR DESCRIPTION This vehicle uses a two position vacuum operat
2. 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 PRO CEDURE COOLING SYSTEM FILL NOoORWD 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 counter clockwise and remove the fan from the top of the rear A C condenser housing 815f10a0 Fig 22 Rear A C Condenser Fan REAR A C CONDENSER FAN BOLT 4 REAR CONDENSER FAN SUPPRESSION FILTER FAN WIRE HARNESS CONNECTOR REAR A C CONDENSER HOUSING 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 Ibs 3 Connect the
3. 10 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION REAR RECEIVER DRIER REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 receiv er 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 con denser housing and remove the receiver d
4. 815f161c Fig 34 Rear Refrigerant Reservoir 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 refriger ant oil must be drained from the old refrigerant res ervoir 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 oOnkwWwn 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 amp 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 Ibs 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 refrig erant oil and install it onto the rear receiver drier fit ting Use only the specified O ring
5. 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 Ibs 3 If servicing the right instrument panel duct install the passenger air bag module and bracket Refer to 8 ELECTRICAL RESTRAINTS PASSEN GER AIRBAG INSTALLATION 4 Install the floor distribution ducts Refer to 24 HEATING amp AIR CONDITIONING DISTRIBU TION FLOOR DISTRIBUTION DUCTS INSTAL LATION 5 Install the defroster ducts Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION DE FROSTER DUCTS INSTALLATION 6 Install the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION akon 24 52 DISTRIBUTION REAR DISTRIBUTION REAR TABLE OF CONTENTS page A C CONDENSER COVER REMOVAL 2 2065444 vee ba Mad eed MEA Sa 52 INSTALLATION 0 0 cee ee 52 A C CONDENSER HOUSING REMOVAL e eeee24s8 09a ae ad ee ee s 52 INSTALLATION 0 0 0 0 c eee ee 54 A C EVAPORATOR COVER REMOVAL lt lt esseceacn deen ksd Ptaamadca dd 55 INSTALLATION 0 0 ec ee 55 A C CONDENSER COVER REMOVAL 1 Unlock the six quick release fasteners by turn ing them 90 degrees in either direction Fig 1 2 Remove the rear A C condenser cover from the rear A C condenser housing 815e9d82 Fig 1 Rear A C Condenser Cover 1 QUICK RELEASE FASTEN
6. REAR REFRIGERANT RESER VOIR REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI PLUMBING 24 95 TIONING DISTRIBUTION DENSER 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 A C CON
7. SUPPRESSION FILTER WIRE CONNECTOR REAR CONDENSER FAN SUPPRESSION FILTER INSTALLATION 1 Position the rear condenser fan suppression fil ter 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 Ibs 3 Install the rear condenser fan Refer to 24 HEATING amp 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION 6 Reconnect the negative battery cable AUN VA DISTRIBUTION FRONT 24 45 DISTRIBUTION FRONT TABLE OF CONTENTS page page AIR FILTER FLOOR DISTRIBUTION DUCTS REMOVAL ccc ee ee 45 REMOVAL s seated e 608455804558 84 2a eon 47 INSTALLATION eass aagana dea ana aE 45 INSTALLATION 1 1 ce yiii 48 AIR OUTLETS HVAC HOUSING REMOVAL 2 reas eco See ae ad eee ne aides 45 REMOVAL lt lt sce ead obo eed eee eet eae 48 INSTALLATION 1 0 2 ee ee 46 DISASSEMBLY aoaia a a a e a i aa 49 BLOWER MOTOR ASSEMBLY Laga 25 4244654404448 34 Sere bard 50 REMOVAL neces hedauedeanc deaa a 47 INSTALLATION 1 2 ce agadi 50 INSTALLATION 1 0 2 eee ee 47 INSTRUMENT PA
8. 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 Ibs 5 Install the defroster ducts Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION DE FROSTER DUCTS INSTALLATION 6 Install the instrument panel Refer to 23 BODY INSTRUMENT PANELANSTRUMENT PANEL ASSEMBLY INSTALLATION AUN HVAC HOUSING REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com 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 precau tions could result in accidental airbag deployment WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible perso
9. 6 eee ee 21 RECIRCULATION DOOR ACTUATOR DESCRIPTION eee ee 22 OPERATION e aeaa e ann a 22 REMOVAL sect eet seepra Se eae ee 22 INSTALLATION 1 ee 23 VA 812295b1 Fig 1 A C Compressor Clutch 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 e A C switch on the A C heater control panel e Evaporator temperature sensor e A C pressure transducer e Air temperature sensor e CAN bus messages The compressor clutch is de energized under any of the following conditions e Blocked compressor thermal fuse in the pulley e Low pressure in the system e Low evaporator temperature e Hard acceleration WOT e High coolant temperatures NOoORONDM CONTROLS FRONT 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 proce dure 1
10. BLOWER MOTOR WIRE CONNECTOR 4 SCREW 5 REAR BLOWER MOTOR SUPPRESSION FILTER 2 INSTALLATION 1 Position the rear blower motor suppression fil ter being serviced to the rear A C evaporator hous ing 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 Ibs 3 Connect the two suppression filter wire har ness connectors 4 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR 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 volt age spikes which may be generated by the rear con denser 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 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 con denser fan CONTROLS REAR 24 44 81614428 Fig 23 Rear Condenser Fan Suppression Filter 1 REAR CONDENSER FAN SUPPRESSION FILTER 2 WIRE CONNEC
11. gaged Check the serpentine drive belt condition and tension as described in Cooling before beginning this procedure 1 Select a quiet area for testing Duplicate the complaint conditions as much as possible Switch the compressor on and off several times to clearly iden tify the compressor noise Listen to the compressor while the clutch is engaged and disengaged Probe the compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to bet ter localize the source of the noise 2 Loosen all of the compressor mounting hard ware and retighten Tighten the compressor clutch mounting nut Be certain that the clutch coil is mounted securely to the compressor and that the clutch plate and pulley are properly aligned and have the correct air gap Refer to 24 HEATING amp AIR CONDITIONING CONTROLS A C COMPRESSOR CLUTCH INSTALLATION 3 To duplicate a high ambient temperature condi tion high head pressure restrict the air flow through the condenser Install a manifold gauge set to be certain that the discharge pressure does not exceed 2760 kPa 400 psi 4 Check the refrigerant system plumbing for incorrect routing rubbing or interference which can cause unusual noises Also check the refrigerant lines for kinks or sharp bends that will restrict refrigerant flow which can cause noises Refer to 24 HEAT ING amp AIR CONDITIONING PLUMBING CAU TION REFRIGERANT HOSES LINES TUBES PRECAUT
12. 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 suc tion line fitting VA 815e5c2f Fig 10 Rear A C Low Pressure Switch 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 akon 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 Ibs 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 7 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 8 Install the cover onto the rear A C
13. 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 damp securely 5 Check exhaust pipe exhaust end placement and make any final adjustments 6 Lower the vehicle FUEL DOSING PUMP DESCRIPTION The dosing pump is a combined delivery dosing and shut off system for the fuel supply to the supple mental cabin heater from the vehicle fuel tank OPERATION The dosing pump is an electrically operated pump that receives its operation instructions from the sup plemental 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 amp AIR CONDITION ING CABIN HEATER FUEL LINE REMOVAL Fig 2 2 Disconnect the fuel line between the dosing pump and the cabin heater unit VA CABIN HEATER 24 107 80bf93c6 Fig 2 Cabin Heater Dosing Pump Fuel Line 1 FUEL LINE 2 RETAINING CLAMP 3 DOSING PUMP 4 HEATER AIR INTAKE PIPE NOTE Position and retain the heater fuel line to
14. 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 electrome chanical device that uses a low current input to con trol 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 omit 8086f035 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 pres sure 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 electromag netic interference that can be
15. A C Specification Label 3 3 amps 12V 0 5V 21 C 70 F 0 35 0 60 mm 0 014 0 024 in Input to rear A C control module con denser inlet tube mounted cycles clutch off above 2551 kPa 370 psi R 134a refrig erant 24 8 CONTROLS FRONT CONTROLS FRONT TABLE OF CONTENTS page A C COMPRESSOR CLUTCH DESCRIPTION egga tae anata aad Re ae 8 OPERATION saosan ne maaria ge bid ioe eed 9 STANDARD PROCEDURE A C COMPRESSOR CLUTCH AIR GAP 9 A C COMPRESSOR CLUTCH BREAK IN 9 REMOVAL sagdrpborini erada yiki ttti 9 INSPECTION 2cccevauanesanawbaaae ete eens 11 INSTALLATION 2 ee 11 A C COMPRESSOR CLUTCH COIL DIAGNOSIS AND TESTING A C COMPRESSOR CLUTCH COIL 12 A C HEATER CONTROL DESCRIPTION sessed ade eae ce drii 12 OPERATION 0 ee 13 REMOVAL 2224 e0s80e e4000 000 sd eat eee 13 INSTALLATION 1 eee ee 13 A C PRESSURE TRANSDUCER DESCRIPTION lt aascadadcaateranaed of aa eaa 14 OPERATION cise b eevee wag ee dae bake eee e se 14 DIAGNOSIS AND TESTING A C PRESSURE TRANSDUCER 14 REMOVAL in cutee wacgute eh ale au ice eee 15 INSTALLATION 1 cee ee 15 AIR OUTLET TEMPERATURE SENSOR DESGRIPTION isc eaagutere any Pda are et bye 16 OPERATION ssscceue dead ee dada w bee ae eae 16 REMOVAL sasian paa Soph tad S aae nace Son s 16 INSTALLATION 1 eee ee 16 AMBIENT TEMPERATURE SENSOR DESCRIPTION 2 crscrsieiecericericeriss 17 OPERATION sapi paina pup motta aei E 17 A C
16. Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 refriger ant oil and install them onto the rear liquid line fit tings 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 Ibs 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 refrig erant reservoir Tighten the nut to 35 N m 26 ft Ibs 6 Reconnect the negative battery cable 7 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 24 94 PLUMBING 8 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 9 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION
17. PROCEDURE COOLING SYSTEM CLEANING REVERSE FLUSHING 24 Refill the engine cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE COOLANT SYSTEM FILL 25 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 26 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM 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 amp AIR CONDITIONING DISTRIBUTION DEFROSTER DUCTS REMOVAL 3 Remove the floor distribution ducts Refer to 24 HEATING amp AIR CONDITIONING DISTRIBU TION FLOOR DISTRIBUTION DUCTS REMOVAL DISTRIBUTION FRONT 24 51 4 If removing the right instrument pane duct remove the passenger air bag module and bracket Refer to 8 ELECTRICAL RESTRAINTS PASSEN GER 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 ikea Uy 81130de6 Fig 10 Instrument Panel Duct RH Shown LH Typical RH DEFROSTER DUCT SCREW 2 RH INSTRUMENT PANEL DUCT RH FLOOR DISTRIBUTION DUCT CENTER FLOOR DISTRIBUTION DUCT
18. 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 con trol to each temperature position Resistance should be present and should change for each position CONTROLS REAR 24 39 5 If OK test and repair the rear A C tempera ture 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 supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com 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 precau tions could result in accidental airbag deployment NOTE The rear A C temperature conirol 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 INSTRU MENT PANEL ACCESSORY SWITCH BEZEL REMOVAL 3 Disconnect the wire harness connector from the rear A C temperature control Fig 18 4
19. Using feeler gauges measure the air gap between the clutch plate and the clutch pulley fric tion surfaces 2 If the air gap is not between specifications Refer to 24 HEATING amp AIR CONDITIONING SPECIFICATIONS add or subtract shims until the desired air gap is obtained 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 posi tion 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 d
20. 1 Recover the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM RECOVERY 2 Disconnect and isolate the negative battery cable 3 Remove the routing clip retaining nut and dis engage 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 6 Disconnect the A C suction and liquid lines from the A C expansion valve and remove and dis card the O ring seals 7 Install plugs in or tape over the opened liquid and suction line fittings and both expansion valve ports 8113732f Fig 19 A C Expansion Valve EVAPORATOR TUBE TAPPING PLATE O RING SEAL 2 AIC EXPANSION VALVE BOLT 2 AIC SUCTION LINE NUT A C LIQUID LINE O RING SEAL 2 ONOnORWNM 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 suc tion line fitting and the compressor suction port 11 Remove the A C suction line from the engine compartment VA 81136df5 Fig 20 A C Compressor Refrigerant Lines A C COMPRESSOR O RING SEAL A C
21. 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIG ERANT 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 amp AIR CONDITIONING PLUMBING STANDARD PRO CEDURE 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 e Doors or windows open e Transmission in Park e A C heater controls set to outside air full cool panel mode high blower and with A C compressor engaged CAUTION A leak detector only designed for R 12 refrigerant will not detect leaks in a R 134a refriger ant 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 Fit tings lines or components that appear to be oily usu ally 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
22. 45 DISTRIBUTION REAR 52 PLUMBING es e seg eine ae eee Dees 60 CABIN HEATER 005 104 8112da5a Fig 1 Ventilation Housing NUT 5 WASHER 5 VENTILATION HOUSING HOUSING COVER AUN All vehicles are also equipped with a common heater housing Fig 2 mounted under the instru ment panel which includes e Heater core e Evaporator core Evaporator temperature sensor Expansion valve Air outlet temperature sensor Mode doors HEATING amp AIR CONDITIONING 24 2 til 1 811303a1 Fig 2 Heater Housing SCREW 12 UPPER HOUSING AIC EVAPORATOR EVAPORATOR O RING SEAL 2 EVAPORATOR GASKET VENTILATION HOUSING GASKET LOWER HOUSING WIRING HARNESS BOLT 3 10 HEATER CORE 11 HEATER CORE TUBE ASSEMBLY 12 HEATER CORE TUBE GASKET 13 HEATER CORE TUBE O RING SEAL 2 ODNDOAARWDY 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 81379213 Fig 3 Denso 10S17 A C Compressor 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 compartme
23. C com pressors 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 recy cling operation always replenish the refrigerant sys tem 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 contami nation 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 com pressor is dispersed throughout the refrigerant sys tem 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 lubrica tion 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
24. C wire harness to the rear A C discharge line at the ceiling and position the wire harness out of the way Fig 28 VA ma Se SS BAG o 815f3e15 Fig 28 Rear A C Wire Harness REAR A C EVAPORATOR HOUSING REAR A C DISCHARGE LINE RETAINING STRAP REAR A C WIRE HARNESS AUN 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 open ing 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 con denser tube PLUMBING 24 89 PLUMBING 24 90 VA Q 4 PPS S NDD SAAN Fig 29 Rear A C Discharge Line to Underbody 6 UNDERBODY DISCHARGE LINE REAR A C DISCHARGE LINE i 2 RETAINING CLIPS 7 RIGHT INNER QUARTER PANEL 3 TO REAR CONDENSER 8 FOAM INSULATORS 4 FOAM RUBBER SEAL 9
25. COMPRESSOR CLUTCH DESCRIPTION The A C compressor dutch 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 dutch field coil are available for service replace ment VA page REMOVAL 240g edweet syd Saye ee ed p Aia 17 INSTALLATION 2i cecdaae n cee ee Gaee oa 17 BLOWER MOTOR RESISTOR DESCRIP HON acack deco netn eee ee eee eee ers 17 OPERATION ge ga wef a he eS ioe dee Eee a 18 DIAGNOSIS AND TESTING BLOWER MOTOR RESISTOR 18 REMOVAL waccunagd cevodad qd nireki d E 18 INSTALLATION 1 eee ee 18 BLOWER MOTOR SWITCH DESCRIPTION cadi oe eed aes ed eb eg Soe 19 OPERATION fe cnaede ceed ee eee eet eeee ee 19 DIAGNOSIS AND TESTING BLOWER MOTOR SWITCH 19 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION eee ee 19 OPERATION 0 eee ee 19 REMOVAL 22 uyegande entip ai ede eee ee Pes 20 INSTALLATION 2 0 eee ee 20 IN CAR TEMPERATURE SENSOR DESCRIPTION scadeeng nana eee ee eae gee es 21 OPERATION 1c fwd os he Bw eee ed wae ee 21 DIAGNOSIS AND TESTING IN CAR TEMPERATURE SENSOR 21 MODE DOOR CABLES REMOVAL se dataa tw yd Peed ae pe ee eee 21 INSTALLATION
26. Ibs 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 amp AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION INSTALLATION NOTE High pressures are produced in the refriger ant system when the A C compressor is operating Extreme care must be exercised to make sure that each of the refrigerant system connections is pres sure tight and leak free 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 hous ing to the dash panel Tighten the screws to 4 5 N m 40 in Ibs 3 Connect the HVAC housing wire harness con nectors 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 amp 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 opene
27. Install the rear air filter Refer to 24 HEAT ING amp 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 spe A 8112004f 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 posi tion a temperature command signal is sent to the VA rear A C control module The temperature of the cir culated internal air of the rear compartment is mea sured 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
28. Instrument Panel Air Outlets 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 Ibs 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 Ibs 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 Ibs 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 Ibs 6 If servicing the passenger side air outlets install the passenger side airbag Refer to 8 ELEC TRICAL RESTRAINTS PASSENGER AIRBAG INSTALLATION 7 If servicing the driver side air outlets install the instrument cluster bezel Refer to 23 BODY IN STRUMENT PANEL CLUSTER BEZEL INSTAL LATION 8 Reconnect the battery negative cable aonhWNM VA BLOWER MOTOR REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the engine
29. Lubricate a new O ring seal with clean refrig erant oil and install it onto the rear liquid line fit ting Use only the specified O ring seal as it is made of a special material for the R 134a system Use only 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 receiv er drier Tighten the nut to 35 N m 26 ft Ibs 6 Lubricate a new O ring seal with clean refrig erant 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 Ibs 8 Reconnect the negative battery cable 9 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 10 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 11 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 12 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION
30. SYS TEM EVACUATE 15 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM 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 STAN DARD PROCEDURE DRAINING COOLING SYS TEM 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 PLUMBING 24 83 810d98ca Fig 21 Heater Water Valve 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 Ibs
31. 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 Screws 6 Remove the blower motor assembly from the ventilation housing retaining 8112c31c Fig 4 Blower Motor Assembly VENTILATION HOUSING SCREWS 3 WIRE HARNESS CONNECTOR BLOWER MOTOR INSULATION BLANKET INSTALLATION 1 Install the blower motor assembly into the ven tilation housing 2 Install the three blower motor retaining screws Tighten the screws to 2 N m 17 in Ibs 3 Connect the wire harness connector to the blower motor 4 Install the ventilation housing insulation blan ket 5 Install the engine air cleaner cover Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 6 Reconnect the negative battery cable AOUN DISTRIBUTION FRONT 24 47 DEFROSTER DUCTS REMOVAL 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 hous ing 8112cfb6 Fig 5 Defroster Du
32. 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 CONTROLS FRONT 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 com pressor The bevel side of the snap ring must be fac ing 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 fail ure and severe damage to the compressor front cover 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 compres sor 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 surfa
33. 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 kilopas cals 14 to 18 pounds per square inch Do not remove or loosen the coolant pressure cap cylin der 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 min utes before opening the cooling system for service Failure to observe this warning can result in seri ous 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 sysiem 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 refrig
34. 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 precau tions could result in accidental airbag deployment VA WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Remove the HVAC housing Refer to 24 HEATING amp AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Disassemble the HVAC housing to access the A C evaporator Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION HVAC HOUSING DISASSEMBLY 3 Lift the A C evaporator out of the lower half of the HVAC housing Fig 9 i 7 811303a1 Fig 9 HVAC Housing SCREW 12 UPPER HOUSING AIC EVAPORATOR EVAPORATOR O RING SEAL 2 EVAPORATOR GASKET VENTILATION HOUSING GASKET LOWER HOUSING WIRING HARNESS 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
35. 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION ARAON REAR A C EVAPORATOR REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau 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 amp 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 amp 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 amp AIR CONDITIONING DISTRIBUTION REAR BLOWER MOTOR REMOVAL CAUTION Be careful when drilling out
36. connection Fig 4 80c0b19e Fig 4 Cabin Heater Flexible Air Intake Line CABIN HEATER AND SPLASH SHIELD DOSING PUMP DOSING PUMP FUEL LINE FLEXIBLE INTAKE LINE CLAMP STEEL INTAKE PIPE ONRAN 5 Remove the two retaining screws and remove pipe assembly Fig 5 24 112 CABIN HEATER 80c0b1 9c Fig 5 Cabin Heater Air Intake And Heater Pipe Assembly 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 Ibs 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 connec tion 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 AOUN VA
37. ddulcchannveeivesea ys 96 INSTALLATION 223 cadca ins castes Beas 98 REFRIGERANT LINE COUPLER DESCRIPTION at cata yethneayet shoes 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 lay ers is used for the R 134a air conditioning system on this vehicle This nylon tube helps to further contain the R 134a refrigerant which has a smaller molecu lar structure than R 12 refrigerant The ends of the refrigerant hoses are made from lightweight alumi num or steel and commonly use braze less fittings Any kinks or sharp bends in the refrigerant plumb ing will reduce the capacity of the entire air condi tioning system Kinks and sharp bends reduce the flow of refrigerant in the system A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose In addition the flexible hose refrigerant lines should be routed so they are at least 80 millimeters 3 inches from the exhaust manifold OPERATION High pressures are produced in the refrigerant sys tem when the air conditioning compressor is operat ing Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure tight and leak free It is a good practice to inspect all flexible hose refrigerant lines at least
38. 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 dis charge 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 fit ting and discard PLUMBING 24 71 11 Install plug in or tape over the opened dis charge line fitting and the compressor discharge port 12 Disconnect the discharge line from the retain ing clip and remove the discharge line from the vehi cle 81136df5 Fig 7 A C Compressor Refrigerant Lines 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 plumb ing will reduce the capacity of the entire air condi tioning system Kinks and sharp bends reduce the flow of refrigerant in the system A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose In addition the flexible hose refrigerant lines should be routed so they are at least 80 millimeters 3 inches from the exhaust manifold 1 Position the discharge line into the engine com partment 2 Remove the tape or plugs
39. evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION CONTROLS REAR 24 33 BLOWER MOTOR RELAY DESCRIPTION The three rear blower motor relays used for the rear A C system are International Standards Organi zation 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 elec tromechanical 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 amp AIR CON DITIONING CONTROLS BLOWER MOTOR SWITCH DESCRIPTION The rear blower motor relays are located in the relay block in the rear A C evaporator housing 8086f035 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 cur rent input from the rear blower motor switch to con trol 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 nor
40. evaporator tube 2 Lubricate new O ring seals with clean refriger ant oil and install them onto the rear suction line fit tings 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 retain ing 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 Ibs 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 Ibs 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 12 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALL
41. generated as the elec tromagnetic 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING 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 CONTROLS REAR 24 28 815e181d VA Fig 4 Rear A C Condenser Fan Relay 4 BLOWER MOTOR RELAY K201 5 REAR CONDENSER FAN RELAY K205 6 REAR COMPRESSOR RELAY K206 1 REAR A C EVAPORATOR HOUSING 2 BLOWER MOTOR RELAY K204 3 BLOWER MOTOR RELAY K203 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 recepta cle and push
42. 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 ELECTRICALANSTRUMENT CLUSTER INSTAL LATION 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 VA IN CAR TEMPERATURE SEN SOR DESCRIPTION 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 TETE REST 811252c5 Fig 20 In Car Temperature Sensor 1 AYC 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 C heater control then makes adjustments to maintain the selected passenger compartment temperature The in car temperature sensor cann
43. is flowing unre stricted 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 amp AIR CONDITIONING CABIN HEAT ER 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 VA CABIN HEATER 24 109 80bf93c6 Fig 3 Cabin Heater Dosing Pump Fuel Line 1 FUEL LINE 2 RETAINING CLAMP 3 DOSING PUMP 4 HEATER AIR INTAKE PIPE 3 Remove clamp from the fuel line at the fuel tank connection and separate the line from the tank 4 Remove any retaining dips 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 operat ing 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 he
44. 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 amp AIR CONDI VA TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 2 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 3 Raise and support the vehicle 4 Using the proper A C line disconnect tool dis connect the underbody discharge line spring lock cou pler from the compressor section of the underbody discharge line and remove and discard the O ring seal Refer to 24 HEATING amp AIR CONDITION ING 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 crossmem ber Refer to 13 FRAME amp BUMPERS FRAME REAR CROSSMEMBER TRANSMISSION REMOVAL 10 Remove the underbody discharge line from the vehicle Push the discharge line fo
45. 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 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 refriger ant oils used in an R 12 refrigerant system R 134a refrigerant system service ports service tool couplers and refrigerant dispensing bottles have 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 vehi cle and on the compressor identifying to service tech nicians that the air conditioning system is equipped with R 134a REFRIGERANT OIL DESCRIPTION The refrigerant oil used in R 134a refrigerant sys tems 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
46. of the A C heater control 3 Connect the two control cables to the A C heater control NOOBRWNDM NOTE Install the control cable of bottom adjust ment lever to the front adjustment wheel of the A C heater control 4 Position the A C heater control into the instru ment panel 24 14 CONTROLS FRONT 5 Install the two A C heater control retaining screws Tighten the screws to 2 N m 17 in Ibs 6 Install the center bezel onto the instrument panel Refer to 23 BODY ANSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL INSTAL LATION 7 Reconnect the negative battery cable A C PRESSURE TRANS DUCER DESCRIPTION The A C pressure transducer is installed on the liq uid 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 termi nals 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 81608ad8 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 pres sures in the high side of the refrigerant system VA through its connecti
47. 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 PLUMBING 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 compres sor then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor REFRIGERANT OIL CAPACITIES A C Evaporator Drain and measure the oil A C Compressor from the old compressor see text SUCTION LINE REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death
48. 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 per formed by qualified service personnel Severe per sonal 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 PLUMBING 24 61 OPERATION eee ngea io ida i a p 98 REMOVAL esccn ad ax de qin named erna E 99 INSTALLATION sedare iana a ee 99 UNDERBODY LINES REMOVAL eso idee ew pe Daad ede ys Danad 100 INSTALLATION 1 2 eee 102 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 recom mended 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 suf focation and death WARNING The evaporation rate of R 134a refriger ant
49. order to meet vehicle cooling requirements Con trolling the refrigerant flow through the A C evapo rator 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 dam aged 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 mois ture is found in the A C system recycle the refriger ant 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 expan sion valve If excessive moisture is found recyde 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 e
50. re age aes 71 REAR A C EVAPORATOR INSTALLATION 1 eee eee 71 REMOVAL surpat enc ene eee ene e lee nek 84 A C EVAPORATOR INSTALLATION eee ee 85 DESCRIPTION ieii sani n gai ee 72 REAR A C EXPANSION VALVE OPERATION iesereuriiwioriviiui irere 72 DESCRIPTION ceriiecoresriservrevisets 85 REMOVAL sites einai beat a n Ra aR Ri 72 OPERATION sarc ace se hea dauere ae ei 85 INSTALLATION 1 eee ee 73 REMOVAL earren praag nie diaii aeeed ee 86 A C EXPANSION VALVE INSTALLATION 1 aiei 87 DESCRIPTION sie seuyewe eee pada 73 REAR DISCHARGE LINE OPERATION e ciqedacee tana a meeeata dd aes 73 DESCRIPTION cscdteigde ea qa erecting dd na n 88 DIAGNOSIS AND TESTING REMOVAL gece g mideja g 4 wig iepa E KAA 88 A C EXPANSION VALVE 1 6 ee eee 74 INSTALLATION 2 1 eee ee 90 REMOVAL precs dedeetee ee i ran papa 74 REAR LIQUID LINE INSTALLATION 44 34 oq aivenatdaadie ge endhate 74 DESCRIPTION ac adeeikes dae nr kiA Diasa 91 ELECTRIC COOLANT PUMP REMOVAL cea c eeu ebadg adage baee ates das 91 DESCRIPTION 3 sedeceeeeea cde ea eee sitis 75 INSTALLATION 1 ee ee 93 OPERATION 0 cee ee 75 REAR RECEIVER DRIER REMOVAL 2ese cnc tvr et ie aad ae yee ee 75 REMOVAL 2 e 2 coer een adadee sedi eee ees 94 INSTALLATION 1 eee eee 76 INSTALLATION 0 eee ee 94 VA REAR REFRIGERANT RESERVOIR REMOVAL coiucnrcaahitantuncweesacean 95 INSTALLATION deresini eai e an 95 REAR SUCTION LINE DESCRIPTION onnaa onnaa 96 REMOVAL sites cna
51. receiver drier acts as a reservoir to store surplus refrigerant 24 80 PLUMBING The receiver drier cannot be repaired If the receiv er 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING amp AIR CONDITION ING 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 receiv er 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 com partment an 8113854 Fig 18 Receiver Drier RECEIVER DRIER A C LIQUID LINE REAR SECTION A C PRESSURE TRANSDUCER A C LIQUID LINE FRONT SECTION CLAMP AOUN V
52. 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 volt age test the clutch coil feed circuit for excessive volt age drop and repair as necessary 5 For the acceptable A C clutch coil current draw specifications refer to 24 HEATING amp AIR CONDI TIONING SPECIFICATIONS Specifications apply for a work area temperature of 21 C 70 F If volt age 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
53. rivets to pre vent damage to the rear A C components 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 815f11e5 Fig 23 Rear A C Evaporator REAR A C EVAPORATOR HOUSING RIVET 12 COVERS REAR A C EVAPORATOR SCREW AND WASHER 5 CONDENSATE DRAIN PAN ONR UN VA 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 mea sured 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 compres sor 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 evap orator 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 evap orator and install eight new rivets 4 Install the left blower motor onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDITI
54. the refrigerant system Use only refrigerant oil of the OMDNDONARWDY PLUMBING 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 amp AIR CONDITIONING DISTRIBUTION HVAC HOUSING ASSEMBLY 3 Install the HVAC housing Refer to 24 HEAT ING amp 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 81613fcd 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 low temperature 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
55. 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 tem perature 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 REMOVAL INSTALLATION HEATER UNIT REMOVAL HEATER UNIT WIRE HARNESS INSTALLATION HEATER UNIT WIRE HARNESS INLET HOSE REMOVAL INSTALLATION 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 kilome ter 5 mph and the fuel tank volume exceeds 1 8 of a tank The heater should start if the coolant temper ature 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 start up DIAGNOSIS AND TESTING SUPPLEMENTAL CABIN HEATER Refer to the Symptoms Diagnosis table for basic checks of the diesel fueled supplemental cabin heater va CABIN HEATER 24 105 SYMPTOMS DIAGNOSIS Symptom Possible Causes Smell of diesel fuel Check cabin heater system integration in vehicle s f
56. the A C evaporator The sensor will change its internal resistance in response to the tem peratures it monitors The A C heater control is con nected to the sensor through a sensor ground circuit and a sensor signal circuit As the evaporator tem perature increases the resistance of the sensor decreases and the voltage monitored by the A C heater 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 tempera ture sensor reads between 1 C 33 F and 3 5 C 38 F to protect the A C evaporator from freezing AUN 24 20 CONTROLS FRONT 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 DRBIII 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 BODYANSTRUMENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 5 Remove the instrument clu
57. 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 refrig erant 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 rub ber 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 815f3718 Fig 35 Rear A C Suction Line 1 REAR A C SUCTION LINE 2 TO UNDERBODY SUCTION LINE 3 RETAINING CLIPS 4 LEFT INNER QUARTER PANEL 5 TO REAR A C EVAPORATOR REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover
58. the ATC Function Test using the DRBIII 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 har ness routing and retention connector pin out infor mation 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 supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com 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 precau tions could result in accidental airbag deployment 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 con nect the positive lead of the ohmmeter to terminal 9 and the negative lead to terminals 3 and 5
59. the rear A C evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING 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 hous ing and remove the control module CONTROLS REAR 24 29 CONTROLS REAR 24 30 81522460 VA Fig 6 Rear A C Control Module 3 WIRE HARNESS CONNECTOR 4 SCREW 2 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 Ibs 3 Connect the wire harness connector to the rear A C control module 4 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 5 Reconnect the negative battery cable A C HIGH PRESSURE SWITCH DESCRIPTION The rear A C high pressure switch provides a sig nal to the rear A C control module to control rear A C compr
60. the retainer that secures the compres sor 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 amp AIR CONDI TIONING 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 electri cal 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 DRBIII 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 amp 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
61. to the rear sec tion of the liquid line 10 Install the grille Refer to 23 BODY EXTE RIOR GRILLE INSTALLATION 11 Reconnect the negative battery cable 12 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE 13 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RE FRIGERANT 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 compart ment 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 receiv er 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 con taminating the A C expansion valve Refrigerant enters the receiver drier as a high pressure low tem perature 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
62. up to a full charge 14 Remove the jumper wire from the low pres sure 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 com pressor 81608376 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 sys tem uses theDenso 10S17C ten cylinder doubleact ing 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 812c0f81 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 refrig
63. 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 REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING amp AIR CONDITION ING 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 PLUMBING 24 99 9324 5 Fig 38 Refrigerant Line Spring Lock Coupler Disconnect 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 s
64. 0 psi The rear A C high pressure switch contacts close when the rear discharge line pressure drops to approxi mately 1860 to 2275 kPa 270 to 330 psi The rear A C high pressure switch is factory cali brated 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 opene
65. 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 cali brated 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the insulating tape from around the area of the rear A C low pressure switch Fig
66. 6 eee ee 44 The rear A C dutch relay is located in the relay block in the rear A C evaporator housing VA 8086f035 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 elec tromechanical 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 con tact This action allows high current to flow to the A C clutch field coil When the relay coil is de energized spring pres sure 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 electromag netic interference that can be generated as the elec tromagnetic 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 wi
67. 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 10 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE UNDERBODY LINES REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The underbody refrigerant lines for the optional rear A C system are serviced in five sec tions Two sections are connected the A C compres sor 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 dis charge line uses a spring
68. A 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 fit tings 5 Connec the front and rear sections of the liq uid line to the receiver drier 6 Install the bolts that secures the liquid line fit tings to the receiver drier Tighten the bolts to 7 N m 62 in Ibs 7 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 8 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE REFRIGERANT DESCRIPTION The refrigerant used in this air conditioning sys tem 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 flam mable clear and colorless liquefied gas Even though R 134a does
69. ATION REFRIGERANT LINE COUPLER DESCRIPTION A spring lock type refrigerant line coupler is used to connect the front section of the underbody dis charge 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 cou pler 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 VA 80a7 e303 Fig 37 Spring Lock Coupler Typical MALE HALF SPRING LOCK COUPLER FEMALE HALF SPRING LOCK COUPLER SECONDARY CLIP CONNECTION INDICATOR RING COUPLER CAGE GARTER SPRING COUPLER CAGE O RING SEALS ONOaRWNDM Two O rings on the male half of the fitting are used to seal the connection These O rings are com patible with R 134a refrigerant and must be replaced with O rings made of the same material Secondary clips are installed over the two con nected 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
70. BUTION FRONT 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 amp 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 CS O 5 N Qr a 8112d98c Fig 8 Heater Housing HEATER HOUSING AIR TEMP SENSOR WIRE CONNECTOR WIRE HARNESS WIRE HARNESS CONNECTOR BOLT 4 EVAP TEMP SENSOR WIRE CONNECTOR EVAPORATOR DRAIN TUBE DISASSEM BLY 1 Remove the HVAC housing from the vehicle Refer to 24 HEATING amp 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 NOoORWD 24 50 DISTRIBUTION FRONT 3 Remove the gasket located at the A C evapora tor and heater core tubes and the gasket that seals the ventilation housing to the HVAC housing Fig 9 4 Remove
71. C 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 compres sor 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 81613fb9 Fig 8 Front A C Evaporator 1 A C EVAPORATOR 2 EVAPORATOR TUBES 3 TAPPING BLOCK OPERATION Refrigerant enters the evaporator from the expan sion 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 vapor ize 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 supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com ponent diagnosis or service Disconnect and isolate the battery negative ground
72. 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 The low side pressure is too 1 Accessory drive belt slip 1 Inspect the accessory drive belt condition high and the high side pres ping sure is too low 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 Re place the A C compressor if required The low side pressure is too 1 Restricted refrigerant flow 1 See Liquid Line Suction Line and Dis low and the high side pres through the refrigerant lines charge Line in this group Inspect the refriger sure is too high ant lines for kinks tight bends or improper routing Correct the routing or replace the re frigerant line if required 2 Restricted refrigerant flow 2 See A C Expansion Valve in this group through the A C expansion Replace the valve if required valve 3 Restricted refrigerant flow 3 See A C Condenser in this group Replace through the A C condenser the restricted A C condenser if required HEATER PERFOR
73. Denso 7SBU16C A C Compressor A C COMPRESSOR O RING SEAL A C SUCTION LINE BOLT RETAINING CLIP BOLT A C DISCHARGE LINE O RING SEAL DENSO 10817 A C COMPRESSOR WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death ONOaARWND NOTE The A C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system Dis charging is not necessary if servicing the compres sor 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 amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 2 Disconnect and isolate the negative battery cable 3 Raise and support the vehicle 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 compresso
74. Disengage the retaining tabs and remove the rear A C temperature control from the accessory switch panel Za ye Y oe NA Kes 4 WY s 81614556 EA OS LISS lt S IS T EANN ZTA gt ce X aN 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 connec tor The rear temperature sensor is located in the rear A C evaporator housing 8152997 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 resis tance in the sensor changes as air temperature changes Based upon the resistance in the sensor a specific voltage on the temperature sensor signal cir cuit is ret
75. E 3 REAR REFRIGERANT RESERVOIR 4 REAR A C HIGH PRESSURE SWITCH 5 REAR CONDENSER OUTLET TUBE 6 SUCTION LINE 7 NUT AND WASHER 8 8 REAR A C WIRE HARNESS 9 REAR BLOWER MOTOR SUPPRESSION FILTER 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 mea sured 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 compres sor 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 con denser 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 Ibs 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 refrig erant oil and install it onto the rear liquid line fit ting Use only the specified O ring seal as it is made
76. E Be certain to check the refrigerant oil level if the A C compressor is being replaced See Refriger ant 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 com partment and loosely install the three compressor PLUMBING 24 69 retaining bolts Tighten the bolts using the following sequence to 20 N m 14 ft Ibs e The upper bolt at the front of the compressor e The lower bolt at the front of the compressor e 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 suc tion and discharge lines to the A C compressor Tighten the bolts to 21 N m 15 ft Ibs 6 Connect the wire harness connector to the A C compressor clutch coil 7 Install the accessory drive belt Refe
77. ER AND WASHER 6 2 RUBBER DAMPING WASHER 6 3 REAR CONDENSER COVER 4 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 VA page A C EVAPORATOR HOUSING REMOVAL ocxndaude end Adee eee eae ec 55 INSTALLATION ee ee ee 57 AIR FILTER REMOVAL ssisredi rie pede needa de 58 INSTALLATION wesana saaana a dual ars 58 BLOWER MOTOR REMOVAL xsccanaad dactmad aagi nRa aE E 58 INSTALLATION eee ee 59 A C CONDENSER HOUSING REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the co
78. G amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 2 Disconnect and isolate they negative batter cable 3 Remove the grille Refer to 23 BODY EXTE RIOR 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 con denser 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 dis engage 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 amp 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 811385f4 Fig 16 Receiver Drier 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
79. IGERANT SYS TEM EVACUATE 17 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 18 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 19 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 connec tor 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 evapo rator 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 DISTRIBUTION REAR 24 55 815eb14b Fig 3 Rear A C Evaporator Cover 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 c
80. IONS 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 HEAT ING amp AIR CONDITIONING PLUMBING STAN DARD PROCEDURE REFRIGERANT RECOVERY Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIG ERANT SYSTEM EVACUATE Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE If the high pressure relief valve still does not seat properly replace the a c compressor Refer to 24 HEATING amp AIR CONDITIONING PLUMBING A C COMPRESSOR REMOVAL 6 If the noise is from liquid slugging on the suc tion line check the refrigerant oil level and the refrigerant system charge Refer to 24 HEATING amp AIR CONDITIONING PLUMBING REFRIGER PLUMBING 24 67 ANT OIL STANDARD PROCEDURE Refer to 24 HEATING amp 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The A C compresso
81. MANCE TEST Before performing the following tests perform the ATC Function Test using the DRBIII and refer to Cooling for the procedures to check the radiator cool ant level serpentine drive belt tension radiator air flow and the radiator fan operation MAXIMUM HEATER OUTPUT 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 e Temperature control in the full hot position 24 6 HEATING amp AIR CONDITIONING VA e Mode control in the floor heat position e Blower motor control in the highest speed posi tion Using a test thermometer check the temperature of the air being discharged at the floor outlets Com pare the test thermometer reading to the Tempera ture Reference chart TEMPERATURE REFERENCE CHART Ambient Temperature Minimum Floor Outlet Temperature Celsius Fahreheit Celsius Fahreheit Pts a a peg ert If the floor outlet air temperature is insufficient check for a faulty heater valve perform ATC Func tion Test and verify that the cooling system is oper ating 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 c
82. NEL DUCTS DEFROSTER DUCTS REMOVAL sasihan deli eee ee ed 51 REMOVAL sodara ia dasoa Mike d ant E a ee 47 INSTALLATION 1 0 2 eee ee 51 INSTALLATION 0 0 2 2 ee ee 47 AIR FILTER 2 Install the ventilation housing cover 3 Close the locking clips at the front and rear of REMOVAL the ventilation housing 1 Remove the insulation blanket from the venti lation 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 direc tion of the arrow shown 4 Remove the air filter 8112aaic 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 hous ing NOTE The locking tabs should retain the ventila tion housing cover securely 4 Install the insulation blanket onto the ventila tion housing AIR OUTLETS REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com ponent diagnosis or service Disconnect and isolate the battery negative ground cable then wait two minutes for the system capacitor to discharge before performing furth
83. NTROL 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 8112327d 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 instru ment panel Refer to 24 HEATING amp AIR CONDI TIONING CONTROLS A C HEATER CONTROL INSTALLATION 4 Reconnect the battery negative cable VA AMBIENT TEMPERATURE SEN SOR 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 two wire harness lead and connector of the vehicle elec trical 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 opti mum cabin temperature levels The ambient air temperature sensor is mounted to the front licence plate bracket by three integral retaining tabs 81614364 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 vari
84. NTROL REMOVAL DIAGNOSIS AND TESTING BLOWER MOTOR SWITCH The blower motor switch can be diagnosed by using the DRBIII scan tool Refer to Body Diagnostic Pro cedures For circuit descriptions and diagrams refer to the appropriate wiring information CONTROLS FRONT 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 ter minals 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 tempera ture sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A C system HU MM pi VN ggasi Obl ie S eo gt TE SERA See Be Seesaeaage lt adaa EEE _ NM M om N V N UNN AUT TN N E WN 812b0ee6 Fig 18 Sensor Evaporator Temperature EVAPORATOR TEMPERATUE SENSOR A C EVAPORATOR HVAC HOUSING WIRE CONNECTOR OPERATION The evaporator temperature sensor monitors the temperature of
85. O specifications have common physical dimensions cur rent 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 VA page REMOVAL 22 dung otiere aw ei Pare aw ed ewes 36 INSTALLATION cece scar haps eee eee eee 37 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION zesk nine saai i EE ee 37 OPERATION 20 eta ewe ee an eee ne See 37 REMOVAL ssegecaa tesira aa ae ace ave Saale aie 37 INSTALLATION 1 ee 38 TEMPERATURE CONTROL DESCRIPTION eee ee 38 OPERATION sieeavdead pene eens crecido 38 DIAGNOSIS AND TESTING REAR A C TEMPERATURE CONTROL 39 REMOVAL sige a gj take bate eae Sa eae eS 39 INSTALLATION 2 0 eee ee 40 TEMPERATURE SENSOR DESCRIPTION ee eee ee 40 OPERATION 2 ee 40 DIAGNOSIS AND TESTING REAR TEMPERATURE SENSOR 40 REMOVAL 2c 4 me eaa bide daai ah a ee 40 INSTALLATION 1 eee ee 41 SUPPRESSOR FILTER REAR BLOWER MOTOR DESCRIPTION s cia pede gee eyed ag ee sees 41 OPERATION s2tceeeebadva a tes wade dae ani 41 REMOVAL fetuy oomeeadyegiee oP ae caged as 42 INSTALLATION 2 cee eevee eves eee eee es 43 SUPPRESSOR FILTER REAR CONDENSER FAN DESCRIPTION eee ee 43 OPERATION 46 eseeee vu ws a ee ee eee ts 44 REMOVAL soitot dig eed fond Sarat Be eee 44 INSTALLATION
86. 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 evap orator 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 amp AIR CONDITIONING PLUMBING REAR A C EVAPORATOR REMOVAL VA DISTRIBUTION REAR 24 57 815eed85 Fig 5 Rear A C Evaporator Housing 10 REAR EVAPORATOR DRAIN HOSES REAR A C EVAPORATOR HOUSING 1 2 REAR A C WIRE HARNESS 11 SCREW 9 3 REAR BODY WIRE HARNESS 12 REAR DOME LAMP HARNESS 4 NUT 13 REAR A C EVAPANSION VALVE 5 POSITIVE WIRE LEAD 14 REAR LIQUID LINE FITTING 6 GROUND LEAD 15 REAR A C EVAPORATOR OUTLET TUBE 7 GROMMET 16 REAR SUCTION LINE FITTING 8 SEALING WASHER 4 17 INSULATING TAPE 9 BOLT AND WASHER 4 INSTALLATI
87. ON ground lead could result in improper operation or 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 mea sured 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 compres sor 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 evap orator 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 sup port 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 hous ing retaining bolts Failure to correctly install the possible damage to the rear A C system 4 Position the ground lead to the rear A C evap orator housing and install the four bolts and washers and four damping washers that secure the evapora tor housing to the roof panel Tighten the bolts to 25 N m 18 ft Ibs 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 Ibs 6 U
88. ONING 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 amp AIR CONDITIONING PLUMBING REAR A C EXPANSION VALVE INSTALLATION 6 Position the condensate drain pan to the bot tom 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 Ibs 7 Install the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDITIONING DISTRI BUTION 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 externally equalized 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 PLUMBING 24 85 81615489 Fig 24 Rear A C Expansion Valve 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 low temperature mixture
89. ONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 12 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR 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 refrig erant 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 Fig 26 Rear A C Discharge Line REAR A C DISCHARGE LINE RETAINING CLIPS TO REAR A C CONDENSER RIGHT INNER QUARTER PANEL TO UNDERBODY DISCHARGE LINE REMOVAL AUN WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and
90. ONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE Very specific instructions and conditions pertain to this procedure which are significantly dif ferent than procedures used in other vehicle appli cations 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 DRBIII 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 e Engine at idle at operating temperature e All doors or windows open e Transaxle in Neutral e All A C duct louvers open e A C heater controls set to fresh air NOT Recir culate 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 e Restricted compressor thermal fuse in the pul ley e Low pressure in the system e L
91. OR 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 Ibs 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 6 Reconnect the negative battery cable NOoORWONM DISTRIBUTION REAR 24 59 24 60 PLUMBING VA PLUMBING TABLE OF CONTENTS page page PLUMBING HEATER CORE DESCRIPTION ostiena dae acter naee hea peas 61 DESCRIPTION caaee idea datan koa ARTEA 76 OPERATION 0 eee 61 OPERATION gaeng eaga ete esta n aiia 76 WARNINGS es 61 REMOVAL serge de retd Enna ga eale males 76 CAUTIONS mitaani naa eta ave eee Sard 62 INSTALLATION eee ee 77 DIAGNOSIS AND TESTING LIQUID LINE REFRIGERANT SYSTEM LEAKS 62 REMOVAL oscac genet lege nag et kiia iiia 77 STANDARD PROCEDURE INSTALLATION oo e
92. PAS Dai cable PCY f 3 Disconnect the wire harness connector from the I A C pressure transducer Fig 10 8111875e 4 Using an open end wrench remove the AIC Fig 10 A C Pressure Transducer i transducer from the fitting on the liquid ANINE Hee NERSOUANEE TOR a WJ S oN KASS W A K T Q Q 1 2 A C PRESSURE TRANSDUCER 5 Remove the O ring seal from the A C pressure 3 O RING SEAL transducer and discard 4 LIQUID LINE FITTING INSTALLATION 1 Lubricate a new O ring seal with clean refrig erant oil and install it on the A C pressure trans ducer 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 Ibs 3 Reconnect the wire harness connector to the transducer 4 Reconnect the battery negative cable 5 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE 24 16 CONTROLS FRONT 6 Charge the refrigerant system Refer to 24 HEATING amp 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 tem perature of the air coming out of the heater housing unit Fig 11 The sensor is attached to heater hous ing unit directly behind the ATC heater A C control panel The thermistor wi
93. R REMOVAL 2 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING 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 sec tion of the suction line INSTALLATION DISCHARGE LINE 1 If the compressor section of the underbody dis charge 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 refrig erant 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 Ibs 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 v
94. RESSION 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 WDM 24 42 CONTROLS REAR the rear A C control module circuits and radio recep tion 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR 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 evap orator housing and remove the suppression filters as required VA VA CONTROLS REAR 24 43 8156942d Fig 22 Rear Blower Motor Suppression Filter LH shown RH similar 1 REAR A C EVAPORATOR HOUSING 2 SUPPRESSION FILTER WIRE CONNECTOR 3
95. RESSURE 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 e RECOVERY RECYCLING EVACUATION CHARGING HOSE The center manifold hose Yel low 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death A R 134a_ refrigerant recovery recycling charging station that meets SAE Standard J 2210 must be used to recover the refrigerant from an R 134a refrig erant system Refer to the operating instructions sup plied 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer t
96. Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death VA 1 Disconnect and isolate the negative battery cable 2 Remove the cover from the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 815f3e17 Fig 27 Rear A C Discharge Line to Rear Condenser 1 REAR A C CONDENSER 2 GROMMET 3 REAR A C DISCHARGE LINE 4 CONDENSER INLET TUBE 5 SCREW AND BRACKET 8 Remove the right quarter trim panel Refer to 23 BODY NNTERIOR QUARTER TRIM PANEL REMOVAL 9 Remove the retaining strap that secures the rear A
97. Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM 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 com partment 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 vanetype pump using a magnetic clutch PLUMBING 24 75 81608cbc 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 tempera ture 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 STAN DARD PROCEDURE DRAINING COOLANT SY
98. 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 ven tilation housing and engage the locking tab The housing is indexed to allow mounting in only one position 3 Reconnect the negative battery cable D A ee O e VA BLOWER MOTOR SWITCH DESCRIPTION The blower motor is controlled by a thumbwheel type 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 Utili zation REST function is selected regardless of the blower speed setting on the A C heater control 808c82b6 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 con trol 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 amp AIR CONDITIONING CONTROLS A C HEATER CO
99. S TEM 3 Disconnect the wire harness connector from the electric coolant pump Fig 13 4 Loosen both hose clamps from the electric cool ant 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 PLUMBING 24 76 AE CAE A TA ANI Fig 13 Electric Coolant Pump 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 Ibs 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 elec tric coolant pump 6 Reconnect the negative battery cable 7 Fill the engine cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE COOLING SYSTEM FILL 81137967 ouahkwonh HEATER CORE DESCRIPTION The heater core is mounted into the HVAC hous ing 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 T
100. SSURE TRANSDUCER INSTAL LATION 13 Install the grille Refer to 23 BODY EXTE RIOR GRILLE INSTALLATION 14 Reconnect the battery negative cable 15 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM EVACUATE 16 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RE FRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE REAR SECTION 1 Position the rear section of the A C liquid line into the engine compartment PLUMBING 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 expan sion valve Tighten the nut to 10 N m 89 in Ibs 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 fit ting to the receiver drier Tighten the bolt to 7 N m 62 in Ibs 9 Install the routing clip retainer
101. SUCTION LINE BOLT RETAINING CLIP BOLT A C DISCHARGE LINE O RING SEAL ONOnRWNDM INSTALLATION 1 Position the A C suction line into the engine compartment 2 Remove plugs or tape from the suction line fit ting and the compressor suction port 3 Lubricate a new rubber O ring seal with clean refrigerant oil and install it onto the suction line fit ting 4 Connect the A C suction line to the A C com pressor 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 Ibs 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 suc tion 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 Ibs 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 Ibs VA 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT
102. TE O RING SEAL 2 AIC EXPANSION VALVE BOLT 2 AIC 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 tap ping plate evaporator inlet and outlet tube fittings ONOaARWNDM VA 4 Install the two bolts that secure the A C expan sion valve to the evaporator tube tapping plate Tighten the bolts to 5 N m 45 in Ibs 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 suc tion line fittings 7 Connect the liquid line fitting to the A C expan sion 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 expan sion valve Tighten the nut to 10 N m 89 in Ibs 10 Reconnect the negative battery cable 11 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 12 Charge the refrigerant system
103. TION 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 evapora tor temperature Controlling the evaporator tempera ture 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 Neg ative Temperature Coefficient NTC thermistor in a capillary tube is inserted between the rear evapora tor coil fins to monitor evaporator temperature The switch unit contains internal control logic that mon itors 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 CONTROLS REAR 24 37 815e274d Fig 15 Rear Evaporator Temperature Sensor 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 tem perature 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 o
104. TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION PLUMBING 24 103 SUCTION LINE REAR SECTION 1 Position the rear section of the underbody suc tion 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 Ibs 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 suc tion line to the front section of the suction line and install the retaining bolt Tighten the bolt to 25 N m 18 ft Ibs 6 Connect the rear section of the underbody suc tion line to the rear A C suction line Tighten the nut to 35 N m 26 ft Ibs 7 Lower the vehicle 8 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 9 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 10 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 24 104 CABIN HEATER VA CABIN HEATER TABLE OF CONTENTS page CABIN HEATER DESCRIPTION 23s c
105. TO UNDERBODY 5 BRACKETS INSTALLATION 9 Install the right quarter trim panel Refer to 1 Remove the tape or plugs from the rear dis charge and underbody line fittings and the rear con denser tube 2 Lubricate new O ring seals with clean refriger ant 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 Ibs 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 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 Ibs 11 Install the bracket and screw that secures the rear discharge line to the right s
106. TOR TO CONDENSER FAN 3 MOUNTING BRACKET 4 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 amp 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 sup pression filter VA amp 815e9889 Fig 24 Rear Condenser Fan Suppression Filter REAR A C CONDENSER HOUSING CONDENSER FAN WIRE CONNECTOR BOLT WASHER AND NUT 2
107. VA HEATING amp AIR CONDITIONING 24 1 HEATING amp AIR CONDITIONING TABLE OF CONTENTS page HEATING amp AIR CONDITIONING DESCRIPTION ccs bets Oped eeGaae dd Read ee 1 OPERATION ssc age maia diang a aag a ee 2 DIAGNOSIS AND TESTING A C PERFORMANCE 0000 3 HEATER PERFORMANCE TEST 5 ATC FUNCTION TEST 0000 6 SPECIFICATIONS HEATING A C SYSTEM 004 6 HEATING amp AIR CONDITION ING 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 ventila tion housing Fig 1 located in the engine compart ment which includes e Blower motor e Blower motor resistor block e Recirculation door and actuator page CONTROLS FRONT 0 0005 8 CONTROLS REAR _ 000000 24 DISTRIBUTION FRONT
108. VER 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 81608ed6 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 Con trolling the rear evaporator temperature prevents condensate water on the evaporator fins from freez ing 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
109. able 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 volt age on the temperature sensor signal circuit which iS programmed to correspond to a specific tempera ture The ambient temperature sensor is diagnosed using the DRBIII scan tool Refer to Body Diagnos tic Procedures The ambient temperature sensor cannot be adjusted or repaired and if faulty or damaged it must be replaced CONTROLS FRONT 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 1 Install the ambient temperature sensor onto the front license plate bracket Make sure the retain ing 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 R
110. ading 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 com pressor Refer to the A C Pressure Transducer Volt age chart for the possible condition indicated by the transducer voltage readings va CONTROLS FRONT 24 15 A C PRESSURE TRANSDUCER VOLTAGE Voltage 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau Y R tions could result in possible personal injury or gt death l 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE SG Aik 2 Disconnect and isolate the battery negative
111. and mechanical controls These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehi cle The A C heater control is located on the instrument panel inboard of the steering column and below the VA radio Fig 7 The A C heater control contains a rota ry type temperature control a rotary type mode con trol 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 808c82b6 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 DRBIII scan tool Refer to Body Diagnostic Procedures The A C heater control is diagnosed using a DRBIII scan tool Refer to Body Diagnostic Proce dures 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 supple mental restraint system before attempting any steering wheel steering column airbag seat
112. asteners to the crossmem bers Tighten the M6 fasteners to 7 N m 62 in Ibs 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 Ibs and the M8 fasteners to 23 N m 17 ft Ibs 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 Ibs 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 Ibs 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 HEAT ING amp 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
113. ater fuel lines are securely fastened to their respective components before per forming any service procedures to the cabin heater Failure to follow these warnings may result in pos sible 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 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 drain ing 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 conirol 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 DRBIII scan tool to the diagnos tic 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 sup plemental cabin heater and cause smoke to emit fr
114. ays 4 BLOWER MOTOR RELAY K201 5 REAR CONDENSER FAN RELAY K205 6 REAR COMPRESSOR RELAY K206 1 REAR A C EVAPORATOR HOUSING 2 BLOWER MOTOR RELAY K204 3 BLOWER MOTOR RELAY K203 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 termi nals are fully seated 3 Install the rear air filter Refer to 24 HEAT ING amp 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 instru ment panel Fig 13 The rear A C blower motor switch allows the selection of one of two blower motor speeds and an Off position 8111e286 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 Wh
115. belt tensioner impact sensor or instrument panel com 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 precau tions could result in accidental airbag deployment CONTROLS FRONT 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 C heater control to the instrument pane Fig 8 4 Pull the A C heater control away from the instrument panel far enough to access the connec tions 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 con trol 808c8474 Fig 8 A C Heater Control AIC 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
116. ces of the pulley J9324 91 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 Ibs 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 dutch 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 amp AIR CONDITIONING CONTROLS A C COMPRESSOR CLUTCH STANDARD PROCE DURE 10 Install
117. condenser Tighten the nuts to 33 N m 24 ft Ibs 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 EXTE RIOR GRILLE INSTALLATION 13 Install the front fascia 14 Reconnect the negative battery cable 15 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 16 Recharge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE A C DISCHARGE LINE REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL 4 Remove the nut that secures the discharge line fitting to the condenser on the left side of the con denser 5 Disconnect the
118. 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 amp AIR CON DITIONING 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 loos ening 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 amp AIR CONDITIONING CABIN HEATER EXHAUST TUBE REMOVAL 11 Remove seat hex nut at the heater mounting flange to crossmember 12 Loosen the remai
119. ct RH Shown LH Typical HEATER HOUSING SCREW DEFROSTER DUCT o S a INSTALLATION 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 Ibs 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 amp 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 NAGI SHIFT MECHANISM REMOVAL 6 Remove center floor distribution duct from the heater housing 8112d1c0 Fig 6 Floor Distribution Duct RH Shown LH Typical 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
120. d refrigerant line fittings 10 Lubricate two new rubber O ring seals with clean refrigerant oil and install them onto the evap orator core fittings 11 Connect the refrigerant line terminal block to the evaporator tubes VA 12 Install the two bolts that secure the refriger ant line terminal block to the A C evaporator Tighten the bolts to 5 N m 45 in Ibs 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 Ibs 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 hous ing Refer to 24 HEATING amp AIR CONDITION ING 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
121. d rear dis charge line fitting CONTROLS REAR 24 31 an Fig 8 Rear A C High Pressure Switch REAR A C CONDENSER WIRE HARNESS CONNECTOR REAR A C HIGH PRESSURE SWITCH REAR DISCHARGE LINE FITTING WD INSTALLATION 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 Fail ure to replace the sealing tape could result in a rear refrigerant system leak 1 Remove the tape or plug from the rear dis charge 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 pres sure switch to 10 N m 88 in Ibs 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 6 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 7 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 8 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER CO
122. dd30c Fig 1 Manifold Gauge Set Typical 1 HIGH PRESSURE GAUGE 2 VALVE 3 VACUUM REFRIGERANT HOSE YELLOW W BLACK STRIPE 4 HIGH PRESSURE HOSE RED W BLACK STRIPE 5 LOW PRESSURE HOSE BLUE W BLACK STRIPE 6 VALVE 7 LOW PRESSURE GAUGE MANIFOLD GAUGE SET CONNECTIONS CAUTION Do not use an R 12 manifold gauge set on an R 134a system The refrigerants are not com patible and system damage will result 24 64 PLUMBING FRONT A C SYSTEM e 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 e 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 reciver drier e RECOVERY RECYCLING EVACUATION CHARGING HOSE The center manifold hose Yel low 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 e 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 ser vice port e HIGH P
123. down firmly on the relay until the ter minals are fully seated 3 Install the rear air filter Refer to 24 HEAT ING amp 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 3 81562021 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 bat tery power through the rear blower switch The con trol 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
124. dy 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 20 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 21 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 22 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 disen gaging the velcro type retainers 4 Carefully clean the rear particulate air filter using compressed air VA 815
125. e the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 o SS oe 3 1 EN 0 O Q ENG 4 Na 815eed87 Fig 4 Rear A C Wire Harness Condenser Side REAR CONDERSER FAN SUPPRESSION FILTER REAR A C HIGH PRESSURE SWITCH REAR A C WIRE HARNESS GROMMET RETAINING STRAPS AUN 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 connec tor 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 posi tion 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
126. e9e01 Fig 6 Rear Particulate Air Filter QUICK RELEASE FASTENER 8 REAR A C EVAPORATOR COVER REAR PARTICULATE AIR FILTER REAR AIR INLET GRATE INSTALLATION AUN 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 turn ing 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR 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 a Yo ai pee co Ss Too oo P pne JIN LES ull fg SOD CCQO OD 00 00 00 0000 GEES OO 00 OO OO OO OO OOOO MOO OO 0050S 815eb539 Fig 7 Rear Blower Motors LH shown RH similar REAR BLOWER MOT
127. econnect 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 resis tor wires contained within a ceramic heat sink 24 18 CONTROLS FRONT The blower motor resistor is accessed for service without removing any other components 81614504 Fig 15 Front Blower Motor Resistor 1 MOUNTING PLATE 2 WIRE CONNECTOR RECEPTACLE 3 CERAMIC HEAT SINK OPERATION The blower motor resistor block has multiple resis tor 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 pa
128. ection 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 sec tion of the suction line 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 PLUMBING 24 102 Nf a Sm SB Q If M A A SS Fig 40 Underbody Suction Line Front Section 1 UNDERBODY SUCTION LINE FRONT SECTION 2 BOLT 3 UNDERBODY SUCTION LINE REAR SECTION 4 SUCTION LINE COMPRESSOR SECTION 5 SCREW AND BRACKET 2 VA 7 81 5f7b6a Fig 41 Underbody Suction Line Rear Section REAR A C DISCHARGE LINE UNDERBODY SUCTION LINE REAR SECTION SCREW AND BRACKET 3 BOLT UNDERBODY SUCTION LINE FRONT SECTION AUN SUCTION LINE REAR SECTION 1 Remove the cover from the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REA
129. ed 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 oOuahwWh VA mounted on the outboard side of the ventilation housing above the blower motor in the engine com partment 81608ed1 Fig 23 Recirculation Door Actuator 1 RECIRCULATION DOOR ACTUATOR 2 VACUUM CONNECTOR 3 ELECTRONIC CONTROL SOLENOID OPERATION The recirculation door actuator uses engine vac uum which is controlled by an integral electrical solenoid The electrical solenoid is connected to the A C heater control through the vehicle electrical sys tem 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 recircu lation 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 w
130. ee ee 79 REFRIGERANT SYSTEM SERVICE RECEIVER DRIER EQUIPMENT 3 icc dee eee ware ieee ee ee 63 DESCRIPTION 2 cee esc eee eee eee edie 79 REFRIGERANT SYSTEM RECOVERY 64 OPERATION peagi aed Va eee ee OE wee 79 REFRIGERANT SYSTEM EVACUATE 64 REMOVAL wee ccee cece ene ee eae geen eee ee 80 REFRIGERANT SYSTEM CHARGE 64 INSTALLATION 1 eee ee 80 A C COMPRESSOR REFRIGERANT DESCRIPTION 1 ee ee 66 DESCRIPTION na a aea ee 80 OPERATION sac eenla tee eve ead eee aa eee 66 OPERATION ae ceee eevee aes ea wee ee eee ee 80 DIAGNOSIS AND TESTING REFRIGERANT OIL A C COMPRESSOR NOISE 66 DESCRIPTION aega auye Sere daw ee Sede de 81 REMOVAL OPERATION j6is4achagen aii eueed Sao dX 81 DENSO 7SBU16C A C COMPRESSOR _ 67 STANDARD PROCEDURE DENSO 10817 A C COMPRESSOR 68 REFRIGERANT OIL LEVEL 81 INSTALLATION SUCTION LINE DENSO 7SBU16C A C COMPRESSOR _ 68 REMOVAL 2c 2arcdiaethee dG stoked Saale 81 DENSO 10817 A C COMPRESSOR 69 INSTALLATION oo eee ee 82 A C CONDENSER WATER VALVE DESCRIPTION sacs d pede wany paue damni bee 69 REMOVAL isiass peers tee Sake dae ee eee 83 OPERATION sssceeue deedee awd bee ae eae 69 INSTALLATION 6 1 ee es 83 REMOVAL sasani odia gtd dae dad aani 70 REAR A C CONDENSER FAN INSTALLATION 11 eee eee 70 REMOVAL ecc eevev ers bar seeds chess ee 83 A C DISCHARGE LINE INSTALLATION 0 eee ee ee 84 REMOVAL 0e c enced ae
131. ehicle Tighten the screws to 8 N m 70 in Ibs 4 Engage the fuel lines to the retaining clips located near the transmission 5 Install the rear transmission crossmember Refer to 13 FRAME amp BUMPERS FRAME REAR CROSSMEMBER TRANSMISSION INSTALLA TION 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 spring lock coupler to the compressor section of the dis charge line and install the secondary retaining dip if equipped Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING REFRIGERANT LINE COU PLER INSTALLATION VA 9 Connect the rear A C discharge line to the underbody discharge line Tighten the nut to 35 N m 26 ft Ibs 10 Lower the vehicle 11 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 12 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 13 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION SUCTION LINE FRONT SECTION 1 If the compressor section of the underbody suc tion line was removed from the A C co
132. eiver drier and includes the high side service port and the A C pressure trans ducer 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 fit ting to the receiver drier Tighten the bolt to 7 Nem 62 in Ibs 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 Ibs 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 refrig erant oil and install it on the liquid line fitting 10 Connect the liquid line fitting to the con denser outlet port on the right side of the condenser 11 Install the nut that secures the liquid line fit ting to the condenser Tighten the nut to 17 N m 12 ft Ibs 12 Reinstall the A C pressure transducer Refer to 24 HEATING amp AIR CONDITIONING CON TROLS A C PRE
133. en 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 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 DIAGNOSIS AND TESTING REAR BLOWER MOTOR SWITCH Before testing the rear blower motor switch verify that the front A C system is functional by performing the ATC Fuction Test using the DRBIII 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 har ness routing and retention connector pin out infor mation 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 supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com 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 prop
134. eparated from the garter spring and cage on the male fitting within the dis connect tool NOTE The garter spring may not release if the A C line disconnect tool is cocked while pushing it into the coupler cage opening 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 cou pler fitting 24 100 PLUMBING CAUTION Use only the specified O rings as they are made of a special material for the R 134a sys tem 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 refrig erant oil Use only refrigerant oil of the type recom mended for the compressor in the vehicle 5 Fit the female half of the coupler fitting over the male half of the fitting
135. er diagnosis or service This is the only sure way to disable the supplemental restraint system Failure to take the proper precau tions could result in accidental airbag deployment 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 IN STRUMENT PANEL CLUSTER BEZEL REMOVAL 3 If servicing the passenger side air outlets remove the passenger side airbag Refer to 8 ELEC TRICAL RESTRAINTS PASSENGER AIRBAG REMOVAL 24 46 DISTRIBUTION FRONT 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 81119381 Fig 2 Passenger Side Air Nozzle Cover FRONT SCREWS 2 BRACKET BRACKET SCREWS NOZZLE COVER INSTRUMENT PANEL AUN 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 VA 8112bb78 Fig 3
136. er precau tions 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 con nect 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 posi tions and the Off position There should be continu ity 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 posi tions and the Off position There should be continu VA 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 REMOVAL WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner
137. erant The A C compressor draws in low pressure refrig erant vapor from the A C evaporator through its suc tion 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 compres sor clutch pulley and bearing assembly and clutch field coil are available for service If an internal fail ure of the A C compressor has occurred the receiver drier must also be replaced DIAGNOSIS AND TESTING A C COMPRESSOR NOISE When investigating an air conditioning related noise you must first know the conditions under which the noise occurs These conditions include weather vehicle speed transmission in gear or neu tral engine speed engine temperature and any other special conditions Noises that develop during air conditioning operation can often be misleading For example What sounds like a failed front bearing or connecting rod may be caused by loose bolts nuts VA mounting brackets or a loose compressor clutch assembl y 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 disen
138. erant oils are not compatible and dam age to the A C system will result CAUTION The use of A C system sealers may result in damage to A C refrigerant recovery evacu ation 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 dis charged Never open or loosen a connection before recovering the refrigerant CAUTION If equipped do not remove the second ary retention clip from any spring lock coupler con nection 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 dis charged 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 refrigeran
139. es datade edhe boearss 104 OPERATION aa ccpens sta gete ete iaaii 104 DIAGNOSIS AND TESTING SUPPLEMENTAL CABIN HEATER 104 EXHAUST TUBE REMOVAL 2c ieee ead ebb pee pete ee 105 INSTALLATION 6 eee 106 FUEL DOSING PUMP DESCRIPTION oc eta ei eee erusin 106 OPERATION piesio pies take d oiai 106 REMOVAL ssreccrrnri peed eae Rede ee 106 INSTALLATION 0 ee 107 FUEL LINE STANDARD PROCEDURE CLEANING eee 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 oper ates 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 pas senger compartment The supplemental cabin heater system is interfaced to the vehicles on board com puter systems and DRBIII 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 con trol The supplemental cabin heater is activated when the temperature control is set to or above
140. essor 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 pres sure 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 con denser The rear refrigerant system must be discharged prior to removing the rear A C high pressure switch 81608ed6 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 VA rear A C compressor operation when the rear dis charge line pressure approaches high levels and also reduces electrical surging from rear A C dutch 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 dis charge 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 49
141. f this equipment PARTIAL CHARGE METHOD The partial charge method is used to add a partial charge to a refrigerant system that is low on refrig erant To perform this procedure the evaporator inlet and outlet tube temperatures are measured The temperature difference is measured with a tempera ture 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 amp 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 e 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 e 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 PLUMBING 24 65 erant line connector fittings The probes must make c
142. 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 fit ting 4 Connect the discharge line fitting to the com pressor 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 Ibs ONOnRWNDY 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 fit ting 8 Connect the discharge line fitting to the con denser inlet port 9 Install the nut that secures the discharge line fitting to the condenser Tighten the nut to 33 N m 24 ft Ibs 10 Install the grille Refer to 23 BODY EXTE RIOR GRILLE INSTALLATION 11 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 12 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM 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 instru ment panel Fig 8 The A C evaporator is positioned within the HVA
143. 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 com ponents 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 Fail ure 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 CABIN HEATER 24 106 aS jat O L DF 4 VA 80bf6712 Fig 1 Cabin Heater Exhaust System 4 FLEXIBLE HEATER EXHAUST PIPE 5 HEATER SHIELD 6 EXHAUST PIPE MOUNTING CLIP 3 1 MOUNTING SCREW 3 2 STEEL HEATER EXHAUST PIPE 3 EXHAUST CLAMP 2 3 Remove the clamp at the flexible pipe connec tion 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 vehi de 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
144. function of the heater unit 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 con nectors to the cabin heater controller 5 Connect the cabin heater wire harness to the dosing pump 6 Connect the cabin heater wire harness connec tor to the vehicle wiring harness 7 Lower the vehicle 8 Verify function of the heater unit CABIN HEATER 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 amp AIR CONDITIONING CABIN HEAT ERANLET MUFFLER REMOVAL 4 Remove the clamp at the flexible tube to steel tube
145. ge A C CLUTCH RELAY DESCRIPTION viata na due cgtee nies pea eee 24 OPERATION es d2 cetera a cede babe bee 25 REMOVAL sui stag tannoes eR een eM ek nee s 25 INSTALLATION 12 eee ee 26 A C CONDENSER FAN RELAY DESCRIPTION sg geeca day etaphte ye vee 26 OPERATION sscadawadeeintue eee nesday 26 REMOVAL imepaa agria aed 2 ne ees 27 INSTALLATION 1 0 eee eee 28 A C CONTROL MODULE DESCRIPTION eh eicdesuede dee da eadude es 28 OPERATION weve ees eee fo eee es 28 REMOVAL yee eecrevee ed haan esas Gente Se 29 INSTALLATION 1 cee ee 30 A C HIGH PRESSURE SWITCH DESCRIPTION pesis ngsisrisngurri isteku 30 OPERATION soeaemeeg be bbe a eet eae etd 30 REMOVAL j daca Gansdids naaa ae ene eas 31 INSTALLATION 1 cee eee 31 A C LOW PRESSURE SWITCH DESCRIPTION 4 0 sieu ace oar ee wpe than 32 OPERATION staire enia lan aid va wale ate dd sate 32 REMOVAL 4 6 idae peatideg dae g wedi bag de bade 32 INSTALLATION 1 eee ee 33 BLOWER MOTOR RELAY DESCRIPTION see eseee edd ea teeta eee ee 33 OPERATION 0 id so dap ee 33 REMOVAL ics ee ednaesa eed dba daead caer 34 INSTALLATION 1 eee ee 35 BLOWER MOTOR SWITCH DESCRIPTION miutan a eee 35 OPERATION ssceeet a bee ew eee ee ee eee 35 DIAGNOSIS AND TESTING REAR BLOWER MOTOR SWITCH 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 IS
146. h 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 compart ment To maintain minimum evaporator temperature and prevent evaporator freezing an evaporator tempera ture 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 passen ger 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 Recircula tion mode only air from the passenger compartment passes through the A C evaporator As the passenger compartment air dehumidifies the A C system per formance levels rise Humidity has an important bearing on the temper ature
147. he heater core is serviced by removing and disas sembling the HVAC housing VA 81613fa6 Fig 14 Front Heater Core HEATER CORE BOLT 3 HEATER CORE TUBES O RING SEALS Ron 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 WARNING To avoid personal injury or death on vehicles equipped with airbags disable the supple mental restraint system before attempting any steering wheel steering column airbag seat belt tensioner impact sensor or instrument panel com 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 precau tions could resu
148. he 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 com pressor Fig 5 Fig 5 Clutch Coil Snap Ring 1 SNAP RING PLIERS 2 CLUTCH COIL 3 SNAP RING 4 COMPRESSOR INSPECTION Compressor clutch components should always be inspected closely before they are reinstalled The clutch plate and clutch pulley are mated at the fac tory 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 pul ley and the clutch plate for wear The clutch pulley and clutch plate should be replaced if there is exces sive wear or scoring 2 Examine the friction surfaces of the clutch pul ley 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
149. hen no vacuum is supplied through the electrical solenoid The recirculation door actuator can be diagnosed by performing the ATC Function Test using a DRBIII scan tool Refer to Body Diagnostic Proce dures 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 VA 2 Disconnect the wire harness connector from the recirculation door actuator Fig 24 3 Disconnect the vacuum line from the recircula tion door actuator 4 Remove the two screws that secure the recircu lation door actuator to the ventilation housing 5 Disconnect the actuator shaft from the recircu lation door pivot lever and remove the actuator from the vehicle 8111d8ea Fig 24 Recirculation Door Actuator 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 recircu lation door actuator to the ventilation housing Tighten the screws to 2 N m 17 in Ibs 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 ONARAN CONTROLS FRONT 24 23 24 24 CONTROLS REAR CONTROLS REAR TABLE OF CONTENTS pa
150. i tT 815f3548 Fig 32 Rear Liquid Line Reservoir to Expansion Valve 1 GROMMET 2 LIQUID LINE TO EXPANSION VALVE 3 REAR REFRIGERANT RESERVOIR 4 REAR A C 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 refriger ant oil and install them onto the rear liquid line fit tings 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 receiv er drier Tighten the nut to 35 N m 26 ft Ibs 4 Connect the rear liquid line to the rear A C condenser Tighten the nut to 35 N m 26 ft Ibs 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 8 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 9 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 10
151. ide of the rear con denser housing Tighten the screw securely 12 Reconnect the negative battery cable 13 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 14 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 15 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR INSTALLATION 16 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER INSTALLATION VA REAR LIQUID LINE DESCRIPTION The rear liquid line is the refrigerant line that car ries 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 refrig erant 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 rub ber 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 t
152. impact sensor or instrument panel com 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 precau tions could result in accidental airbag deployment 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 INSTRU MENT 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 VA 81614548 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 DESCRIP
153. 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 Ibs 3 Install the heater core into the bottom half of the HVAC housing 4 Assemble the HVAC housing Refer to 24 HEATING amp 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 RE VERSE FLUSHING 5 Install the HVAC housing Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION HVAC HOUSING INSTALLATION LIQUID LINE REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The A C liquid line is serviced in two sec tions 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 HEATIN
154. l sor Freeze up Con Evaporator tem HVAC hous trol perature sensor ing mounted input to A C heater control operating range of 10 C 14 F to 40 C 104 F VA ltem Description Notes Low psi Control High psi Con trol Refrigerant Charge Capaci ty A C Clutch Coil Draw A C Clutch Air Gap A C Pressure Transducer High Pressure Relief Valve Refer to the A C Underhood Spec ification Label located in the engine compart ment 2 0 3 7 amps 12V 0 5V 21 C 70 F 0 020 0 035 in REAR A C SYSTEM Liquid line mounted input to PCM operating range of 200 kPa 29 psi to 2799 kPa 406 psi Receiver drier mounted opens at a discharge pressure over 3999 kPa 580 psi R 134a refrig Item Description Notes A C Compres sor Freeze up Con trol Low psi Control Evaporator Tem perature Sensor A C Low Pres sure Switch Denso 10S17 ND 8 PAG oil 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 Input to rear A C control module suc tion line mounted cycles clutch off below 30 kPa 4 4 psi HEATING amp AIR CONDITIONING 24 7 ltem Description Notes High psi Con trol Refrigerant Charge Capaci ty A C Clutch Coil Draw A C Clutch Air Gap A C High Pres sure Switch Refer to the Rear
155. ll change resistance as the temperature changes 81608b8e 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 hous ing unit The sensor will change its internal resis tance 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 resis tance of the sensor decreases and the voltage moni tored 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 tem perature The ATC control module makes adjust ments to maintain the requested interior temperature by cycling both the A C compressor and solenoid heater valve on and off VA The air outlet temperature sensor is diagnosed by performing the ATC Function Test using the DRBIII 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 instru ment panel Refer to 24 HEATING amp AIR CONDI TIONING CONTROLS A C HEATER CO
156. lt in accidental airbag deployment VA WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Remove the heater housing Refer to 24 HEATING amp AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Disassemble the HVAC housing to access the heater core Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION HVAC HOUSING DIS ASSEMBLY 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 811303a1 Fig 15 HVAC Housing SCREW 12 UPPER HOUSING AIC EVAPORATOR EVAPORATOR O RING SEAL 2 EVAPORATOR GASKET VENTILATION HOUSING GASKET LOWER HOUSING WIRING HARNESS BOLT 3 10 HEATER CORE 11 HEATER CORE TUBE ASSEMBLY 12 HEATER CORE TUBE GASKET 13 HEATER CORE TUBE O RING SEAL 2 OMONDARWNDY PLUMBING 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
157. mally 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 deenergized spring pres sure 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 electromag netic interference that can be generated as the elec tromagnetic field of the relay coil collapses The rear blower motor relay terminals are con nected to the vehicle electrical system through recep tacles 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 diag nosis 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Reach up into the rear A C evaporator housing and remove the rear blower motor relays as neces sary from the relay block Fig 12 VA VA 815e181d CONTROLS REAR 24 35 Fig 12 Rear Blower Motor Rel
158. move the nuts and washers that secure the ventilation housing to the body and remove the ven tilation housing from the vehicle Fig 7 VA 8112da5a Fig 7 Ventilation Housing NUT 5 WASHER 5 VENTILATION HOUSING HOUSING COVER RON 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 fit tings 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 BODYANSTRUMENT PANEL REMOVAL 17 Remove the defroster floor distribution and instrument panel ducts Refer to 24 HEATING amp AIR CONDITIONING DISTRIBUTION DEFROSTER DUCTS REMOVAL Refer to 24 HEATING amp AIR CONDITIONING DISTRIBUTION FLOOR DIS TRIBUTION DUCTS REMOVAL and Refer to 24 HEATING amp AIR CONDITIONING DISTRIBUTION INSTRUMENT PANEL DUCTS REMOVAL 18 Disconnect the two bulkhead ground connec tions near instrument cluster area 19 Remove the passenger airbag bracket Refer to 8 ELECTRICAL RESTRAINTS PASSENGER AIRBAG REMOVAL DISTRI
159. mpressor remove plugs or tape from the suction line fitting lubricate a new rubber O ring seal with clean refrig erant 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 Ibs 2 Position the front section of the underbody suc tion 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 Ibs 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 suc tion line to the compressor section of the suction line Tighten the nut to 35 N m 26 ft Ibs 7 Connect the front section of the underbody suc tion line to the rear section of the suction line and install the retaining bolt Tighten the bolt to 25 N m 18 ft Ibs 8 Lower the vehicle 9 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 10 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 11 Install the cover onto the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI
160. nal injury or death NOTE The HVAC housing must be removed from the vehicle and the two halves of the housing sep arated for service access of the heater core A C evaporator and each of the various mode doors 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 2 Partially drain the engine cooling system Refer to 7 COOLING ENGINE COOLANT STAN DARD PROCEDURE DRAINING COOLING SYS TEM 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 hous ing Refer to 24 HEATING amp AIR CONDITION ING DISTRIBUTION AIR FILTER REMOVAL 7 Disconnect the wire harness and vacuum con nectors from the recirculation door actuator Refer to 24 HEATING amp AIR CONDITIONING CONTROLS RECIRCULATION DOOR ACTUATOR REMOVAL 8 Disconnect the wire harness connector from the blower motor resistor block Refer to 24 HEATING amp AIR CONDITIONING CONTROLS BLOWER MOTOR RESISTOR BLOCK REMOVAL 9 Disconnect the wire harness connector from the blower motor Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION BLOWER MOTOR REMOVAL 10 Re
161. ners and bracket 12 Remove the four condenser retaining screws 13 Carefully remove the condenser from the vehi de lower bracket VA 81133502 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 con denser Tighten the screws to 2 N m 17 in Ibs 3 Install the lower auxiliary fan bracket and retaining nuts Tighten the nuts to 5 N m 45 in Ibs 4 Install the auxiliary fan and upper bracket assembly Tighten the screws to 5 N m 45 in Ibs 5 Connect the wire harness connector to the aux iliary 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 VA 9 Install the nuts that secure the A C discharge and liquid lines to the A C
162. ng 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 thermo couple measurements Record the temperature differ ence 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 Tempera 16 C 21 C 27 C 32 C 38 C 43 C ture 60 F 70 F 80 F 90 F 100 F 110 F 1378 kPa 1516 kPa 1723 kPa 1930 kPa 2206 kPa 2413 kPa 200 psi 220 psi 250psi 280 psi 320 psi 350 psi Compressor Dis charge Pressure 24 66 PLUMBING 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 temper ature is 10 C 50 F Subtract the inlet tube tem perature from the outlet tube temperature The difference is 2 C 4 F With a 2 C 4 F tem perature differential at 21 C 70 F ambient tem perature the system is fully charged 13 Add enough refrigerant to bring the refriger ant system
163. ning 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 con nector from the vehicle wiring harness 3 Disconnect the cabin heater wire harness con nector 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 fasten ers that secure the cabin heater to the mounting bracket 3 Install the three f
164. nplug 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 evap orator tube ports 8 Lubricate a new O ring seal with clean refrig erant oil and install it onto the rear liquid line fit ting 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 Ibs 24 58 DISTRIBUTION REAR 10 Lubricate a new O ring seal with clean refrig erant oil and install it onto the rear suction line fit ting 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 evap orator outlet tube Tighten the suction line nut to 35 N m 26 ft Ibs 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 bo
165. nser fins that might obstruct proper air flow Also any factory installed air seals or shrouds must be properly reinstalled following radia tor 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 3 Remove the front fascia 4 Remove the grille Refer to 23 BODY EXTE RIOR 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 assembl y 11 Remove the auxiliary fan retai
166. nt quickly when requested by the operator Fig 4 81115663 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 obstruc tions for the HVAC system to receive a sufficient vol ume 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 temper ature control switch The electric pulsed heater valve is then energized depending on the requested quan tity of heat and an electrically operated water pump gives a nearly constant water flow for exact temper ature 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 hig
167. o 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 com pressor head pressure will rise above acceptable operating levels This will reduce the performance of the air conditioner and damage the compressor Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature To evacuate the refrigerant sys tem use the following procedure 1 Connect a R 134a refrigerant recovery recy cling charging station that meets SAE Standard J 2210 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 suc tion gauge reads 88 kPa 26 in Hg vacuum or greater close all of the valves and turn off the vac uum pump a If the refrigerant system fails to reach the specified vacuum the system has a leak that must be corrected Refer to 24 HEATING amp AIR CON DITIONING PLUMBING DIAGNOSIS AND TESTING REFRIGERANT SYSTEM LEAKS b If the refrigerant system maintains the spec ified vacuum for five minutes restart the vacuum pump open the suction and discharge valves and evacuate the system fo
168. o be leak ing or damaged it must be replaced 81573471 Fig 30 Rear A C Liquid Lines REAR A C CONDENSER REAR LIQUID LINE FROM CONDENSER REAR RECIEVER DRIER AND RESERVOIR REAR LIQUID LINE TO EXPANSION VALVE REMOVAL ROD WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death PLUMBING 24 91 CONDENSER TO RECEIVER DRIER 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING DISTRIBUTION REAR AIR FILTER REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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
169. 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 refrig erant reservoir outlet Tighten the liquid line nut to 35 N m 26 ft Ibs 8 Remove the tape or plugs from the rear dis charge line fitting and rear condenser port 9 Lubricate a new O ring seal with clean refrig erant 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 Ibs 11 Install the bracket and screw that secures the rear discharge line to the right side of the rear con denser 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 amp AIR CONDITIONING PLUMBING REAR RECEIVER DRIER INSTALLATION VA 15 Reconnect the negative battery cable 16 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFR
170. 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 Control ling the refrigerant flow through the A C evaporator ensures that none of the refrigerant leaving the evap orator 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 WD 24 86 PLUMBING REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the cover from the rea
171. of the air delivered to the interior of the vehi de 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 temper ature 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 temper ature of the air However evaporator capacity used to reduce the amount of moisture in the air is not wasted Wring ing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers Although an owner may expect too much from their A C system on humid days A performance test is the best way to determine whether the system is per forming up to design standards This test also pro vides valuable clues as to the possible cause of HEATING amp AIR CONDITIONING 24 3 trouble with the A C system The ambient air tem perature 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 fol lowing operation Refer to 24 HEATING amp AIR CONDITI
172. om the cabin heater exhaust pipe when cabin heater activation occurs NOTE A clicking noise heard coming from the dos ing pump indicates that the pump is operational 24 110 CABIN HEATER 7 With the DRBIII 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 DRBIII 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 supplemenial cabin heater in an enclosed area such as a garage that does not have exhaust ventilation facilities Always vent the cabin heater exhaust when operat ing 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 per forming any service procedures to the cabin heater Failure to follow these warnings may result in pos sible 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
173. on to a fitting on the liquid line The transducer will change its internal resistance in response to the pressures it monitors The ATC con trol 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 engag ing 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 per forming the ATC Function Test using the DRBIII 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 The A C pressure transducer is tested using a DRBIII scan tool Refer to Body Diagnostic Proce dures 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 pres sure transducer voltage re
174. only DaimlerChrysler approved refrigerant dye STANDARD PROCEDURE REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING Eye protection must be worn when ser vicing 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 warn ings may result in possible personal injury WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer PLUMBING 24 63 to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death When servicing the air conditioning system a R 134a_ refrigerant recovery recycling charging sta tion that meets SAE Standard J 2210 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 80a
175. ontact with the bottom surfaces of the evaporator inlet and outlet tubes 3 Open all of the windows or doors of the passen ger 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 refrig erant 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 e f 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 e f dual probes are used record the temperatures of both the evaporator inlet and outlet tubes Then subtract the inlet tube temperature readi
176. oolant flow obstruction in the heater system POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW e Pinched or kinked heater hoses e Improper heater hose routing e Plugged heater hoses or supply and return ports at the cooling system connections e noperative or stuck heater water valve e 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 INSUFFI CIENT HEAT e An obstructed cowl air intake e Obstructed heater system outlets e 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 follow ing could require service e Faulty A C heater control switch e Faulty temperature sensor e Faulty A C heater control cable or actuator e 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 DRBIII scan tool to confirm that the A C system is performing satisfactorily This test provides a quick confirmation of heating and A C system perfor mance to the service technician Refer to Body Diag nostic Procedures for the appropriate diagnostic information SPECIFICATIONS HEATING A C SYSTEM FRONT A C SYSTEM ltem Description Notes A C Compres Denso 7SBU16C ND 8 PAG oi
177. ot be adjusted or repaired and if faulty or damaged the A C heater control must be replaced Refer to 24 HEATING amp AIR CONDITIONING CONTROLS A C HEATER CONTROL REMOVAL DIAGNOSIS AND TESTING IN CAR TEMPERATURE SENSOR The in car temperature sensor is diagnosed by per forming the ATC Function Test using the DRBIII scan tool Refer to Body Diagnostic Procedures For circuit descriptions and diagrams refer to the appro priate wiring information CONTROLS FRONT 24 21 MODE DOOR CABLES REMOVAL 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 amp 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 81119958 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
178. over 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 evap orator housing 3 Install the six screws that secure the rear A C evaporator cover to the front of the evaporator hous ing Tighten the screws to 2 2 N m 21 in Ibs 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 NOoORWD A C EVAPORATOR HOUSING REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remov
179. ow evaporator temperature e Hard acceleration WOT e 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 amp 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 amp 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 Possible Causes Rapid A C compressor clutch cycling ten or more cycles per minute Equal pressures but the compressor clutch does not engage Normal pressures but A C Performance Test air temper atures at center panel outlet are too high Very low refrigerant system charge 1 No refrigerant in the refrig erant system 2 Faulty fuse 3 Faulty A C compressor clutch coil 4 Improperly installed or faulty evaporator temperature sensor 5 Fa
180. plosion causing property damage per sonal 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 meet ing 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 Refrig erant System Charge Level test Refer to 24 HEAT ING amp AIR CONDITIONING PLUMBING DIAGNOSIS AND TESTING REFRIGERANT SYS TEM 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 refriger ant 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
181. 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 pull ing the connector away from the pump 4 Remove the dosing pump from the rubber iso lator INSTALLATION 1 Install the dosing pump onto the rubber isola tor 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 amp AIR CONDITIONING CABIN HEATER FUEL LINE INSTALLATION 4 Connect the wire harness connector to the fuel pump by depressing the integral spring and pushing the connector towards the dosing pump Pull the con nector towards the cabin heater to verify the instal lation 5 Verify function of the supplemental heater cabin FUEL LINE STANDARD PROCEDURE CLEANING 1 Remove the cabin heater fuel line Refer to 24 HEATING amp AIR CONDITIONING CABIN HEAT ER 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
182. r 7 Disconnect the underbody suction and dis charge lines from the A C compressor and remove and discard the O ring seals 8 Install plugs in or tape over the opened refrig erant line fittings and the compressor ports 9 Remove the bolts that secure the A C compres sor to the mounting bracket 10 Remove the A C compressor from the engine compartment Fig 5 Denso 10S17 A C Compressor REFRIGERANT LINES WIRE HARNESS CONNECTOR BOLTS 3 AIC COMPRESSOR INSTALLATION DENSO 7SBU16C A C COMPRESSOR NOTE Be certain to check the refrigerant oil level if the A C compressor is being replaced See Refriger ant Oil Level in this group for the procedures Use only refrigerant oil of the type recommended for the A C compressor in the vehicle WOM 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 com partment and loosely install the three compressor retaining bolts Tighten the bolts using the following sequence to 20 N m 15 ft Ibs VA e The upper bolt at the front of the compressor e The lower bolt at the front of the compressor e 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 HEAT ING amp AIR CONDITIONING PLUMBING A C COM PRESSOR INSTALLATION DENSO 10S17 3 Lower the vehicle 4 Remove
183. r A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING 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 dis card 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 VA NE o PLUMBING 24 87 815effOf Fig 25 Rear A C Expansion Valve 5 RETAINING CLAMP 1 INSULATING TAPE 2 REAR LIQUID LINE 6 SENSING BULB AND CAPILLARY TUBE 3 REAR A C EXPANSION VALVE 7 EQUALIZER TUBE 4 REAR A C EVAPORATOR INLET TUBE 8 REAR A C EVAPORATOR OUTLET TUBE INSTALLATION 6 Connect the equalizer tube to the rear evapora 1 Remove the tape or plugs from the rea
184. r an additional ten minutes 3 Close all of the valves and turn off the charg ing station vacuum pump 4 The refrigerant system is now ready to be charged with R 134a refrigerant Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE REFRIGERANT SYSTEM CHARGE WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death VA CAUTION A small amount of refrigerant oil is removed from the A C system each time the refrig erant 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 infor mation After the refrigerant system has been tested for leaks and evacuated a refrigerant charge can be injected into the system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING SPECIFICA TIONS CHARGE CAPACITY A R 134a_ refrigerant recovery recycling charging station that meets SAE Standard J 2210 must be used to charge the refrigerant system with R 134a refrigerant Refer to the operating instructions sup plied by the equipment manufacturer for proper care and use o
185. r may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system Dis charging is not necessary if servicing the compres sor 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 amp AIR CONDITION ING 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 refrig erant 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 amp AIR CONDI TIONING 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 81136df5 Fig 4
186. r refrig erant line and evaporator tube fittings and the rear expansion valve ports 2 Lubricate a new O ring seal with clean refrig erant 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 Nm 26 ft Ibs 4 Lubricate a new O ring seal with clean refrig erant oil and install it onto the rear liquid line fit ting 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 Ibs tor outlet tube Tighten the nut to 10 N m 88 in Ibs 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 amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITI
187. r 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 evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING 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 RONM CONTROLS REAR 24 38 VA 815e281e 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 sen sor to the rear A C evaporator housing 2 Install the two screws that secure the rear evaporator temperature sensor to the rear A C evap orator housing Tighten the screws to 2 N m 17 in Ibs 3 Install the sensor probe into the rear A C evap orator 4 Connect the two wire harness connectors to the rear evaporator temperature sensor 5
188. r 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 amp AIR CONDITIONING PLUMBING RECEIVER DRIER REMOVAL and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RE CEIVER DRIER INSTALLATION 10 Reconnect the negative battery cable 11 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 12 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM 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 con denses When the refrigerant leaves the condenser it has become a high pressure liquid refrigerant The volume of air flowing over the condenser fins is crit ical to the proper cooling performance of the air con ditioning system Therefore it is important that 24 70 PLUMBING there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the conde
189. 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 zn N Fig 31 Rear Liquid Line Condenser to Receiver drier 1 REAR RECEIVER DRIER 2 LIQUID LINE FROM CONDENSER 3 REAR A C CONDENSER 4 RETAINING STRAPS VA 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 amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 3 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the cover from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER COVER REMOVAL 5 Disconnect the rear liquid line from the reser voir 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 VA PLUMBING 24 93 E yc fi
190. refrigerant system Refer to 24 HEATING amp AIR CONDITION ING PLUMBING REFRIGERANT STANDARD PROCEDURE REFRIGERANT SYSTEM RECOV ERY 2 Disconnect and isolate the negative battery cable 3 Remove the grille Refer to 23 BODY EXTE RIOR GRILLE REMOVAL akon 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 dis card the O ring seals 6 Disengage the routing clip retainer from the rear section of the A C liquid line 8113732f Fig 17 A C Expansion Valve EVAPORATOR TUBE TAPPING PLATE O RING SEAL 2 AIC EXPANSION VALVE BOLT 2 AIC SUCTION LINE NUT A C LIQUID LINE O RING SEAL 2 ONOaARWNDY 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 VA INSTALLATION NOTE The A C liquid line is serviced in two sec tions The front section connects between the A C condenser and the rec
191. rier 8 Install plugs into or tape over the opened rear liquid line fitting and reservoir and receiver drier ports VA 815f15a1 Fig 33 Rear Receiver Drier 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 refriger ant oil of the type recommended for the rear A C compressor in the vehicle aonkWNM 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 receiv er drier and measure the refrigerant oil Fill the new receiver drier with the same amount of new refriger ant 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 direc tion 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 Ibs 3 Remove the tape or plugs from the rear liquid line fitting and reservoir and receiver drier ports 4
192. ring 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 evapo rator housing Refer to 24 HEATING amp AIR CON CONTROLS REAR 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 CONTROLS REAR 24 26 815e181d VA Fig 2 Rear A C Clutch Relay 4 BLOWER MOTOR RELAY K201 5 REAR CONDENSER FAN RELAY K205 6 REAR COMPRESSOR RELAY K206 1 REAR A C EVAPORATOR HOUSING 2 BLOWER MOTOR RELAY K204 3 BLOWER MOTOR RELAY K203 INSTALLATION 1 Position the rear A C dutch 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 HEAT ING amp 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
193. rom the bracket VA 81522942 CONTROLS REAR 24 41 Fig 20 Rear Temperature Sensor 1 REAR A C EVAPORATOR HOUSING 2 TEMPERATURE SENSOR 3 BRACKET 4 WIRE HARNESS CONNECTOR INSTALLATION 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 HEAT ING amp 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 prop agation of RF interference into the vehicles electrical system by the rear blower motors to ensure interfer ence free radio reception The rear blower motor suppression filters are located near the rear blower motors in the rear A C evaporator housing N Zea 816142de Fig 21 Rear Blower Motor Suppression Filter REAR BLOWER MOTOR SUPP
194. roup Inspect the blend air door s for proper operation and sealing Repair if required VA HEATING amp AIR CONDITIONING 24 5 Possible Causes The low side pressure is 1 Low refrigerant system normal or slightly low and charge the high side pressure is too low 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 2 See A C Evaporator in this group Replace A C evaporator is restricted the restricted A C evaporator if required 3 Faulty A C compressor 3 See A C Compressor in this group Re place the A C compressor if required The low side pressure is 1 A C condenser air flow re 1 Check the A C condenser for damaged normal or slightly high and stricted the high side pressure is too high 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 2 See Receiver Drier in this group Replace receiver drier is restricted the restricted receiver drier if required 3 Inoperative radiator cooling 3 Test the radiator cooling fan and replace if fan required Refer to Group 7 Cooling 4 Refrigerant system over 4 See Refrigerant System Charge in this charged group Recover the refrigerant from the refrig erant system
195. rward 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 VA PLUMBING 24 101 So 22e oss S22 eeo N S 90000000 20000 Socogee Soco ji 4 BE ee _ Zo fi N O Ore Fig 39 Underbody Discharge Line UNDERBODY DISCHARGE LINE FUEL LINES REAR A C DISCHARGE REAR TRANSMISSION CROSSMEMBER OND 5 SCREW AND BRACKET 2 6 DISCHARGE LINE COMPRESSOR SECTION 7 RETAINING CLIP SUCTION LINE FRONT SECTION 1 Remove the cover from the rear A C evaporator housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C EVAPORA TOR COVER REAR REMOVAL 2 Recover the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING 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 conn
196. 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 Ibs 7 Lubricate a new O ring seal with clean refrig erant oil and install it onto the rear liquid line fit ting 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 refrig erant reservoir Tighten the nut to 35 N m 26 ft Ibs 9 Reconnect the negative battery cable 10 Evacuate the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the rear refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 12 Install the rear air filter Refer to 24 HEAT ING amp AIR CONDITIONING DISTRIBUTION REAR AIR FILTER INSTALLATION 13 Install the cover onto the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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
197. ster Refer to 8 ELECTRICALANSTRUMENT 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 instru ment panel Refer to 24 HEATING amp AIR CONDI TIONING 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 VA 811193a2 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 evap orator 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 amp AIR CONDITIONING CONTROLS A C HEATER CONTROL INSTALLATION 7 Install the center section of the
198. t oil is used Abnormal amounts of dirt moisture or air can upset the chemical stability This may cause operational troubles or even seri ous damage if present in more than very small quantities Before disconnecting a component clean the outside of the fittings thoroughly to pre vent 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 ser vice 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 immedi ately after using Store refrigerant oil only in a clean airtight and moisture free container CAUTION Do not overcharge the refrigerant sys tem 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 mix tures are potentially dangerous and may result in fire or ex
199. th to battery volt age 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 pin out and location views for the various wire harness connectors splices and grounds 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 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 ATT 4 AY AY S 808c83be Fig 16 Blower Motor
200. the 12 screws that secure the two housing halves together 5 Seperate the two housing halves 6 Remove the heater core from the lower hous ing 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 811303a1 Fig 9 HVAC Housing SCREW 12 UPPER HOUSING AIC EVAPORATOR EVAPORATOR O RING SEAL 2 EVAPORATOR GASKET VENTILATION HOUSING GASKET LOWER HOUSING WIRING HARNESS 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 hous ing 2 Remove the tape or plugs from the heater core fittings OONDNARWN 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 Ibs 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 hous ing halves together Tighten the screws to 2 N m 17 in
201. the refrigerant from the rear refriger ant system Refer to 24 HEATING amp AIR CONDI TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT RECOVERY 4 Remove the insulating tape from around the area of the rear A C suction line and evaporator out let 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 evapora tor tube PLUMBING 24 97 24 98 PLUMBING VA Fig 36 Rear A C Suction Line REAR A C SUCTION LINE RETAINING CLIPS EVAPORATOR OUTLET TUBE UNDERBODY SUCTION LINE RON 5 FOAM RUBBER SEAL 6 FOAM INSULATORS 7 LEFT INNER QUARTER PANEL INSTALLATION 1 Remove the tape or plugs from the rear suction and underbody line fittings and the rear
202. the tape or plugs from the opened suc tion 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 Ibs 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 compres sor is being replaced due to an internal failure Refer to 24 HEATING amp AIR CONDITIONING PLUMB ING RECEIVER DRIER REMOVAL and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING RECEIVER DRIER INSTALLATION 11 Reconnect the negative battery cable 12 Evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 13 Charge the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE DENSO 10817 A C COMPRESSOR NOT
203. uel 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 exter nal 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 op Check cabin heater operation with DRBIII scan tool and replace eration components as required Continuous white smoke from heater Check cabin heater operation with DRBIII scan tool and replace exhaust during combustion operation components as required White smoke is typical in extreme weather conditions Heater can not be switched off Check cabin heater operation with DRBIII scan tool and replace components as required Heater does not operate Diagnosis cabin heater control module using the DRBIII scan tool and the procedures listed in Vehicle Performance under Cabin Heater Diagnosis in Group 18 Loss of coolant Leakage or heater Inspect coolant hoses for leakage kinks or loose hose connection develops smoke during combustion Inspect the exhaust tube assembly for continuous flow if OK there is operation and exhaust has an ex an internal heater leak and cabin heater should be inspected and tremely sweet smell components should be replaced as required Loss of
204. ulty A C pressure trans ducer 6 Faulty engine Control Mod ule ECM 1 Excessive refrigerant oil in system 2 Blend door cable improperly installed or faulty 3 Blend air door s inoperative or sealing improperly See Refrigerant System Leaks in this group Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 1 See Refrigerant System Leaks in this group Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 2 Check the fuses in the Power distribution block and junction block Repair the shorted circuit or component and replace the fuses if required Refer to Group 8 3 See A C Compressor Clutch Coil in this group Test the compressor clutch coil and replace if required 4 See Evaporator Temperature Sensor in this group Test the sensor and replace if re quired 5 See A C Pressure Transducer in this group Test the sensor and replace if re quired 6 Refer to Group 9 Engine Electrical Diag nostics for testing of the ECM Test the ECM and replace if required 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 See Mode Door Cables in this group In spect the cable for proper operation and re place if required 3 See HVAC Housing in this g
205. urned to the rear A C control module which is programmed to correspond to a specific tem perature The rear A C temperature sensor cannot be adjusted or repaired and if faulty or damaged it must be replaced 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 cir cuit descriptions and for complete HVAC wiring dia grams If not OK replace the faulty temperature sensor Refer to 24 HEATING amp AIR CONDITION ING CONTROLS REAR TEMPERATURE SENSOR REMOVAL REMOVAL 1 Disconnect and isolate the negative battery cable 2 Remove the air filter from the rear A C evapo rator housing Refer to 24 HEATING amp AIR CON DITIONING 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 f
206. utch 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 dutch plate to aid in bolt removal 24 10 CONTROLS FRONT on INN amp es So oy fs O A De I ASS JANIN 19324 89 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 mal let 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 com pressor Fig 4 VA Fig 4 Pulley Snap Ring 1 SNAP RING 8 Remove the screw that secures the clutch coil wire harness connector bracket and ground dip to t
207. ver from the rear A C condenser housing Refer to 24 HEATING amp AIR CONDI TIONING DISTRIBUTION REAR A C CON DENSER 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 con denser 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 refrig erant 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 con denser 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 DISTRIBUTION REAR 24 54 815ed61e Fig 2 Rear A C Condenser Housing 1 REAR A C CONDENSER HOUSING 2 LIQUID LIN
208. xpansion valve and the receiver drier REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING amp AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING amp AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death 1 Recover the refrigerant from the A C system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIG ERANT 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 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 expan sion valve to the evaporator tube tapping plate 8 Remove the expansion valve from the evapora tor 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 evap orator inlet and outlet tube fittings and both expan sion valve ports 8113732f Fig 11 A C Expansion Valve EVAPORATOR TUBE TAPPING PLA

2006 VA Service Manual - aie-services

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