HVAC Systems: Other Chrysler Pacifica CS

HEATING AND A/C SYSTEMS

A manually controlled dual zone heating-A/C system and an automatically controlled dual zone heating-A/C system with rear blower controls is available 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 COOLING for more information before opening or attempting any service to the engine cooling system.

All vehicles are equipped with a common heater, ventilation and air conditioning (HVAC) housing. (Scheme 58) The system combines air conditioning, heating, and ventilating capabilities in a single housing mounted within the passenger compartment under the instrument panel. The HVAC housing includes

1. A/C Evaporator
2. Evaporator temperature sensor
3. Blower motor
4. Recirculation-air door and actuator
5. Blower motor resistor or power module (depending on application)
6. Blend-air doors and actuators
7. Heater core
8. Mode-air doors and actuator

Scheme 58

Based upon the system and mode selected, conditioned air can exit the HVAC housing through one or a combination of the three main housing outlets: defrost, panel or floor. The defrost and the panel outlets are located on the top of the housing and, the floor outlet is located on the bottom of the housing. Once the conditioned air exits the HVAC housing, it is further directed through molded plastic ducts to the various outlets within the vehicle interior. These outlets and their locations are as follows

1. Defroster Outlet - A dual, centrally mounted outlet delivers air for defrosting the large windshield. An integral grid is molded into the center of the instrument panel top cover to prevent objects from falling into the duct.
2. Demister Outlets - There are two side window demisters that aid in defogging and defrosting the front door windows. One demister outlet is located at each outboard end of the instrument panel top pad, near the belt line at the A-pillars.
3. Instrument Panel Outlets - There are four panel outlets in the instrument panel, one located near each outboard end of the instrument panel facing the rear of the vehicle, and two located near the top of the instrument panel center bezel.
4. Front Floor Outlets - There are two front floor outlets, one located above each side of the floor panel center tunnel below the instrument panel.
5. Rear Floor Outlets Rear passenger vents are located in the center floor console and have separate blower fan control switch.

AUTOMATIC TEMPERATURE CONTROL (ATC) - DUAL ZONE

The dual zone automatic temperature control (ATC) heating-A/C system allows completely independent side-to-side temperature control of the discharge air.

The dual zone ATC system includes a dust and odor filter. The particulate air filter element is the same size as the A/C evaporator to ensure ample capacity. A door at the base of the HVAC housing below the glove box provides easy access to the particular air filter element.

FRONT A/C-HEATER CONTROL

The ATC A/C-heater control is located in the instrument panel and contains: (Scheme 59)

1. two temperature set controls for completely independent side-to-side temperature control of the discharged air. The full range of temperature that the system can produce in any mode is available on either side of the vehicle by independently adjusting the controls.
2. a power on/off switch. Allows the heating-A/C system to be completely turned Off. The display indicates only the outside temperature when the system is off.
3. a display screen to indicate the heating-A/C system operational modes and inside and outside temperatures.
4. a dual zone control. Allows the selection of either single (driver) or dual (driver and passenger) temperature control mode.
5. a separate front window defogger on/off switch. Contains an LED that illuminates to indicate when the front widow defroster is manually selected.
6. a rear window defogger on/off switch. Contains an LED that illuminates to indicate when the EBL system is On.
7. an air conditioning on/off switch. Contains an LED that illuminates to indicate when the A/C mode is manually selected.
8. an air recirculation on/off switch. Contains an LED that illuminates to indicate when the Recirculation mode is manually selected.
9. a manual mode switch. Allows the operator to manually select the air delivery mode.
10. two infrared temperature sensors which independently measure the surface temperature of the driver and front seat passenger.
11. a manual blower fan speed switch. Allows the operator to manually select six different fan speeds.
12. a outside temperature switch. Allows the operator to select either outside air or passenger set temperatures.
13. a rear blower fan switch. Allows the operator to set the rear blower fan speed to AUTO for automatic speed adjustment, or to REAR to give control to the intermediate seat occupants, or OFF to shut the rear blower motor down.
14. an auto high and an auto low switch. Allows various modes of automatic temperature control operation. Contains LEDs that illuminate to indicate when operational.

The Computer logic remembers the settings of the A/C-heater controls when the ignition is turned to Off and, retains those settings after a restart, etc. The computer logic also provides variable air recirculation under high temperature and humidity conditions. Recirculation mode is initially accompanied by outside air to help remove any humidity within the passenger compartment and will gradually approach full recirculation over a broad range of temperatures.

Scheme 59

REAR A/C-HEATER CONTROL

Primary controls for the rear compartment is on the instrument panel. The front A/C-heater control allows the driver to set the rear compartment blower fan speed, turn the rear unit off, or to give control to the intermediate seat occupants by switching to the REAR position. When the rear system is controlled from the instrument panel, rear blower fan speed is automatically controlled based on the front A/C-heater control temperature setting. Air flow through the floor console is directed through upper or lower outlets based on the front mode settings.

The rear rotary blower fan control is centrally mounted on the center floor console between the second row seats and allows control of the rear blower fan speed by intermediate seat passengers.

MANUAL TEMPERATURE CONTROL (MTC) - DUAL ZONE

The dual zone manual temperature control (MTC) heating-A/C system allows completely independent side-to-side temperature control of the discharge air.

The MTC A/C-heater control is located in the instrument panel and contains: (Scheme 60)

1. a power on/off switch. Contains an LED that illuminates to indicate when the heating-A/C system is On.
2. a rear window defogger on/off switch. Contains an LED that illuminates to indicate when the EBL system is On.
3. slide controls for completely independent side-to-side temperature control of the discharged air. The full range of temperature that the heating-A/C system can produce in any mode is available on either side of the vehicle by independently positioning the slide controls on the instrument panel.
4. an air recirculation on/off switch. Contains an LED that illuminates to indicate when the heating-A/C system is in the Recirculation mode.
5. an air conditioning on/off switch. Contains an LED that illuminates to indicate when the heating-A/C system is in the A/C mode.
6. a rotary control to manually select the air delivery mode.
7. a rotary control to manually select the blower fan speed.

Scheme 60

Both the dual zone manual temperature control (MTC) and the dual zone automatic temperature control (ATC) heating-A/C systems are blend-air type systems. In a blend-air heating-A/C system. (Scheme 61), a blend-air door controls the amount of conditioned air that is allowed to flow through, or around, the heater core. In the dual zone systems used on this model, two blend-air doors are used to provide completely independent side-to-side temperature control of the discharge air. The temperature controls determines the discharge air temperatures by operating the two blend door actuators, which move the blend-air doors. This design allows almost immediate control of output air temperatures.

Scheme 61

The heating-A/C systems pulls outside (ambient) air through the cowl opening at the base of the windshield, then into the air inlet housing above the heating, ventilation and air conditioning (HVAC) housing. From the air inlet housing the air passes through the A/C evaporator and then can be directed either through or around the heater core. This is done by adjusting the blend-air doors with the temperature controls located on the front A/C-heater control in the instrument panel. The air flow can then be directed from the panel, floor and defrost outlets in various combinations using the mode control located on the A/C-heater control. Air flow velocity can be adjusted with the blower fan speed control located on the A/C-heater control.

On all models, the outside air intake can be shut off by selecting the Recirculation Mode. This will operate a electrically actuated recirculation-air door that closes off the fresh air intake and recirculates the air that is already inside the vehicle.

The A/C compressor can be engaged in any mode by pressing the snowflake, A/C on/off button. It can also be engaged by placing the mode control in the mix to defrost positions. This will remove heat and humidity from the air before it is directed through or around the heater core. The mode control on the A/C-heater control is used to also direct the conditioned air to the selected system outlets. The mode control uses an electric actuator to control the mode-air doors.

The defroster outlet receives airflow from the HVAC housing through the molded plastic defroster duct, which connects to the HVAC housing defroster outlet. The airflow from the defroster outlets is directed by fixed vanes in the defroster outlet grille and cannot be adjusted.

The side window demister outlets receive airflow from the HVAC housing through the molded plastic defroster duct and molded plastic demister ducts. The airflow from the side window demister outlets is directed by fixed vanes in the demister outlet grilles and cannot be adjusted. The demisters direct air from the HVAC housing through the outlets located on the top corners of the instrument panel. The demisters operate when the mode control knob is positioned in the floor-defrost and defrost-only settings. Some air may be noticeable from the demister outlets when the mode control is in the bi-level to floor positions or when in automatic mode (depending on application).

The panel outlets receive airflow from the HVAC housing through a molded plastic main panel duct, center panel duct and two end panel ducts. The two end panel ducts direct airflow to the left and right instrument panel outlets, while the center panel duct directs airflow to the two center bezel outlets. Each of these outlets can be individually adjusted to direct the flow of air.

The floor outlets receive airflow from the HVAC housing through the floor distribution duct. The front floor outlets are integral to the molded plastic floor distribution duct, which is secured to the bottom of the housing. The front floor outlets cannot be adjusted. When equipped, the rear console outlets receive air flow through a duct which is integral to the floor console. The floor console outlets can be individually adjusted to direct the flow of air.

Note. It is important to keep the air intake opening clear of debris. Leaf particles and other debris that is small enough to pass through the cowl opening screen can accumulate within the HVAC housing. The closed, warm, damp and dark environment created within the housing is ideal for the growth of certain molds, mildews and other fungi. Any accumulation of decaying plant matter provides an additional food source for fungal spores, which enter the housing with the fresh intake-air. Excess debris, as well as objectionable odors created by decaying plant matter and growing fungi can be discharged into the passenger compartment during heater-A/C operation if the air intake opening is not kept clear of debris.

The A/C system on models so equipped is designed for the use of non-CFC, R-134a refrigerant and uses an A/C expansion valve to meter the flow of refrigerant to the A/C evaporator. The A/C evaporator cools and dehumidifies the incoming air prior to blending it with the heated air. To maintain minimum evaporator temperature and prevent evaporator freezing, an evaporator temperature sensor is used to supply an evaporator temperature message to the A/C-heater control. In turn, the powertrain control module (PCM) cycles the A/C compressor clutch off and on as necessary to protect the A/C system from evaporator freezing and optimize A/C system performance.

The dual zone automatic temperature control (ATC) system automatically maintains the interior comfort level desired by the driver and front seat passenger. This is accomplished by using two infrared sensors within the A/C-heater control which is located at the center of the instrument panel. The two infrared sensors independently measure the surface temperature of the driver and front seat passenger. Based on the sensor input, the system automatically adjusts the air temperature, the airflow volume, the airflow distribution, and amount of inside air recirculation to maintain front seat occupant comfort, even under changing outside weather conditions.

When DUAL is displayed on the A/C-heater control, the driver and passenger air outlet temperatures can be individually adjusted from the two independent TEMP buttons. When a front seat passenger is not present, pressing the DUAL button will

1. disable the passenger side infrared sensor and control the entire system based only on the driver side temperature setting.
2. replace the passenger side temperature setting in the display to the outside temperature reading.

Pressing the DUAL button a second time or adjusting the passenger side TEMP button will

1. reactivate the passenger side infrared sensor.
2. return the system to dual independent temperature operation.

This ATC system offers several manual override features. The indicator light in both the AUTO HI or AUTO LO buttons will turn off when the system is being used in the manual mode. The fan speed, airflow distribution, and outside air/recirculated air can be manually adjusted.

The front blower fan control can be set to any fixed blower fan speed by pressing the rocker switch up or down. This allows the front occupants to control the volume of air circulated in the vehicle and cancel the auto mode. The fan will now operate at a fixed speed until additional speeds are selected or until either the AUTO HI or AUTO LO buttons are pressed. The system will continue to automatically adjust air temperature and airflow distribution.

When the outside air contains smoke, odors, high humidity, or if rapid cooling is desired, interior air can be recirculated by pressing the recirculation button. The recirculate symbol will illuminate in the display when this button is selected.

The outside temperature can be shown in the A/C-heater control display by pressing the OUTSIDE TEMP button. After pressing this button, the front seat passenger side temperature setting display will be replaced with the current outside temperature. Pressing the OUTSIDE TEMP button again or pressing the passenger side TEMP button will return the display to the passenger side temperature setting.

1. The system automatically adjusts the temperature, mode and fan speed.
2. When the heating- A/C system is off, the recirculation door is automatically closed to prevent outside air from entering the passenger compartment.
3. Air conditioning is available in any mode by pressing the snowflake, A/C on/off, button.

To provide maximum comfort in the automatic mode during cold start-ups, the blower fan will remain off and DELAY will appear in the display until the engine warms up. The estimated the time remaining until the DELAY is complete will appear periodically in the display. However, the fan will engage immediately if the defrost mode is selected or by pushing the blower switch and manually adjusting the fan speed.

1. The two slide controls enable continuously variable proportioning of the conditioned air.
2. The mode control knob enables continuously variable proportioning of air flow between modes and has detents adjacent to each icon.
3. The blower control provides four separate speeds and an Off position.
4. When the heater-A/C system is off, the HVAC computer closes the recirculation door to prevent outside air from entering the passenger compartment.
5. Interior air may be recirculated to speed up heating or cooling in all modes except defrost and mix by pressing the Recirculate button on the A/C-heater control.
6. To reduce humidity for rapid defogging, the A/C compressor runs automatically in modes from "mix" to full defrost when outside temperatures are above freezing.
7. Air conditioning is available in any mode by pressing the snowflake, A/C on/off button.

MANUAL TEMPERATURE CONTROL

The blower fan speed must be set to High and the evaporator temperature sensor must be greater than 13° C (55° F) or the test will fail immediately. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than five seconds. The A/C and PWR button LEDs will blink on and off until the test is complete. If the LEDs stop blinking before two minutes, then the cool down test has been completed successfully. If the two minutes expire without the expansion valve temperature reaching -6° C (20° F) less than the outside air temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the LEDs will continue to blink until the vehicle has been driven for greater than 13 km (8 miles).

AUTOMATIC TEMPERATURE CONTROL

The ambient air temperature in the room where the vehicle will be tested must be a minimum of 21° C (70°F) for this test. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than four seconds. The snowflake icon and the DELAY text in the A/C-heater control display will blink on and off alternately until the test is complete. If the snowflake icon and the DELAY text stop blinking before two minutes, then the cool down test has been completed successfully. If the two minutes expire without the evaporator temperature reaching 11° C (20° F) less than the evaporator initial temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the snowflake icon and the DELAY text will continue to blink across ignition cycles until the vehicle has been driven for greater than 12 km (8 miles).

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow are as follows

1. Pinched or kinked heater hoses.
2. Improper heater hose routing.
3. Plugged heater hoses or supply and return ports at the cooling system connections.
4. Plugged heater core.

If proper coolant flow through the cooling system is verified, and heater outlet air temperature is insufficient, a mechanical problem may exist.

MECHANICAL PROBLEMS

Possible causes of insufficient heat due to mechanical problems are as follows

1. Faulty engine thermostat.
2. Faulty blend door actuator.
3. Obstructed fresh air intake.
4. Obstructed heater system outlets.
5. Faulty blend-air door.

TEMPERATURE CONTROL

If the heater outlet air temperature cannot be adjusted with the temperature control on the A/C-heater control panel, the following could require service

1. Faulty blend door actuator.
2. Faulty A/C-heater control.
3. Faulty related wiring harness or connectors.
4. Faulty blend-air door.

HEATING-A/C SYSTEM

A/C SYSTEM

FASTENER TORQUE

Scheme 62

Snap Ring Pliers C-4574 are required to service the A/C clutch and field coil. (Scheme 62)

A/C COMPRESSOR CLUTCH COIL

The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) through the A/C clutch relay. The A/C clutch coil can be tested by either measuring clutch field coil resistance or by measuring current draw. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.

PRELIMINARY CHECKS

1. If the A/C compressor clutch will not engage, verify the refrigerant charge level. Refer to «REFRIGERANT SYSTEM CHARGE LEVEL»(ref-245452-S16834279042006110200000) . If the refrigerant charge level is OK, go to step 2 . If the refrigerant charge level is not OK, adjust the refrigerant charge as required.
2. If the A/C compressor clutch still will not engage, disconnect the headlamp and dash wire harness connector for the A/C pressure transducer and check for battery current at the connector with the engine running and the A/C-heater control set to the A/C mode. If OK, go to «TESTS»(ref-245452-S01287089882006110200000) . If not OK, refer to «BODY DIAGNOSTIC PROCEDURES»(ref-247415) to perform further diagnosis.

TESTS

1. Verify the battery state of charge «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - DIAGNOSIS AND TESTING)»(ref-245419-S39829091822006110200000) .
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 heater-A/C control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed.
4. The compressor clutch should engage immediately, and the clutch coil voltage should be within two volts of the battery voltage. If the coil voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop. If the compressor clutch does not engage, refer to «BODY DIAGNOSTIC PROCEDURES»(ref-247415) to perform further diagnosis.
5. For the acceptable A/C clutch coil current draw specifications refer to «SPECIFICATIONS»(ref-245452-S06943598032006110200000) . Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. If the compressor clutch coil current reading is zero, the coil is open and must be replaced. If the compressor clutch coil current reading is four amperes or more, the coil is shorted and must be replaced.

A/C CLUTCH BREAK-IN

After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor 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.

A/C PRESSURE TRANSDUCER

The A/C pressure transducer is tested using a DRBIII® scan tool. Refer to BODY DIAGNOSTIC PROCEDURES for more information. Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the A/C to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicate a low or high refrigerant system pressure condition to the powertrain control module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the A/C compressor. Refer to the A/C PRESSURE TRANSDUCER VOLTAGE chart for the possible conditions indicated by the transducer voltage reading.

A/C PRESSURE TRANSDUCER VOLTAGE

FRONT BLOWER MOTOR RESISTOR

Note. For circuit descriptions and diagrams, refer to the SYSTEM WIRING DIAGRAMS .

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector from the blower motor resistor «(Refer to HEATING & AIR CONDITIONING/CONTROLS-FRONT/BLOWER MOTOR RESISTOR - REMOVAL)»(ref-245452-S29752423752006110200000) .
3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. 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.

CENTER AIR OUTLETS

Note. The two center air outlets located above the instrument panel center bezel are serviced as an assembly.

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel from the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL)»(ref-245423-S18120095492006110200000).
3. Remove the two screws that secure the bottom of the center air outlet to the instrument panel. (Scheme 63)
4. Roll the bottom of the center air outlet upward and disengage the retaining clips that secure the top of the air outlet to the instrument panel and remove the outlet.

Scheme 63

INSTRUMENT PANEL AIR OUTLETS

1. If servicing the right instrument panel air outlet, use a trim stick C-4755 or equivalent and gently pry the outer perimeter of the center trim panel from the right side of the instrument panel and remove the trim panel. If servicing the left instrument panel air outlet, remove the instrument cluster bezel «(Refer to BODY/INSTRUMENT PANEL/CLUSTER BEZEL - REMOVAL)»(ref-245423-S14808381802006110200000).
2. Remove the instrument panel end cap from the end of the instrument panel being serviced «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL END CAP - REMOVAL)»(ref-245423-S34090680022006110200000).
3. Remove the two screws that secure the instrument panel air outlet to the instrument panel and remove the outlet. (Scheme 64)

Scheme 64

1. Position the center air outlet onto the instrument panel.
2. Engage the retaining tabs at the top of the center air outlet to the top of the opening in the instrument panel, then roll the center air outlet downward.
3. Install the two screws that secure the bottom of the center air outlet to the instrument panel. Tighten the screws to 2 N.m (17 in. lbs.).
4. Install the center bezel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION)»(ref-245423-S12488567262006110200000) .
5. Reconnect the negative battery cable.

1. Position the instrument panel air outlet into opening in the instrument panel.
2. Install the two screws that secure the instrument panel air outlet to the instrument panel. Tighten the screws to 2 N.m (17 in. lbs.).
3. Install the instrument panel end cap «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL END CAP - INSTALLATION)»(ref-245423-S31086471262006110200000) .
4. If servicing the left instrument panel air outlet, install the instrument cluster bezel «(Refer to BODY/INSTRUMENT PANEL/CLUSTER BEZEL - INSTALLATION)»(ref-245423-S01917880992006110200000) . If servicing the right instrument panel air outlet, install the right trim panel firmly and evenly onto the instrument panel until the retaining tabs are fully engaged.

BLOWER MOTOR

For circuit descriptions and diagrams, refer to SYSTEM WIRING DIAGRAMS . Possible causes of an inoperative front or rear blower motor include

1. Faulty fuse (the fuse is located in the integrated power module (IPM) in the engine compartment)
2. Faulty blower motor circuit wiring or wire harness connectors
3. Faulty blower motor resistor or power module (depending on application)
4. Faulty blower motor relay
5. Faulty blower motor switch
6. Faulty blower motor.

AIR DISTRIBUTION HOUSING

Note. The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

Scheme 65

Scheme 66

1. Remove the HVAC housing from the vehicle and place it on a workbench «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
2. Disconnect the HVAC wire harness connectors from the mode door actuator and the two blend door actuators located on the driver side of the air distribution housing and position the HVAC wire harness out of the way. (Scheme 65) 1 - ACTUATOR WIRE HARNESS CONNECTOR (3) 2 - MODE DOOR ACTUATOR 3 - DRIVER BLEND DOOR ACTUATOR 4 - PASSENGER BLEND DOOR ACTUATOR
3. Remove the foam seal from the heater core tubes and the flange located at the front of the HVAC housing. (Scheme 66) If the seal is deformed or damaged, it must be replaced.
4. Remove the plastic retaining strap that secures the heater core tubes to the front of the HVAC housing. NOTE: Take the proper precautions to protect against spilled engine coolant. Have absorbent toweling readily available to clean up any spills.
5. Remove the bolt that secures the heater core tube sealing plate to the heater core.
6. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened heater core ports. 1 - FOAM SEAL 2 - RETAINING STRAP 3 - HEATER CORE 4 - SEALING PLATE 5 - SCREW 6 - HVAC HOUSING 7 - HEATER CORE TUBES
8. Remove the four screws that secure the air distribution housing to the rear of the HVAC housing. (Scheme 67)
9. Tilt the top of the air distribution housing rearward to disconnect the distribution housing from the two tab-and-slot type retainers located at the bottom of the housing and remove the distribution housing.
10. If required, disassemble the air distribution housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - DISASSEMBLY)»(ref-245452-S17839813602006110200000).

Scheme 67

AIR INLET HOUSING

Note. The air inlet housing must be removed from HVAC housing for service of the recirculation-air door.

1. Remove the HVAC housing assembly «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
2. Remove the recirculation door actuator. see scheme 53«(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/RECIRCULATION DOOR ACTUATOR - REMOVAL)»(ref-245452-S18372870492006110200000).
3. Remove the recirculation door actuator wire lead from the routing clip located on the lower air inlet housing and position the wire lead aside.
4. Disconnect the blower motor wire lead connector from the blower motor resistor or power module, depending on application.
5. Remove the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing.
6. Remove the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and remove the lower HVAC housing. 1 - BLOWER MOTOR RESISTOR/POWER MODULE 2 - BLOWER MOTOR WIRE LEAD 3 - LOWER HVAC HOUSING 4 - UPPER AIR INLET HOUSING 5 - UPPER SCREW (1) 6 - LOWER AIR INLET HOUSING 7 - RECIRCULATION DOOR ACTUATOR 8 - ACTUATOR WIRE LEAD 9 - LOWER SCREW (4)
7. Push the rubber blower motor wire lead grommet through the opening in the lower air inlet housing. see scheme 46
8. Feed the blower motor wire lead through the opening in the lower air inlet housing and remove the lower air inlet housing from the vehicle. 1 - BLOWER MOTOR WIRE LEAD GROMMET
9. Carefully cut the foam seal along the parting line of the upper air inlet housing. (Scheme 68) If the seal is deformed or damaged, it must be replaced.
10. Remove the three screws that secure the upper air inlet housing to HVAC housing.
11. Remove the upper air inlet housing and recirculation-air door from the HVAC housing.
12. If required, remove the screw that secures the recirculation-air door to the upper air inlet housing and remove the air door.

Scheme 68

HVAC HOUSING

Note. The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.

Note. Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure.

Scheme 69

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-245448-S20805593812006110200000).
3. Disconnect and isolate the negative battery cable.
4. Disconnect the liquid and suction lines from the A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING/LIQUID LINE - REMOVAL)»(ref-245452-S07070833032006110200000).
5. Disconnect the heater hoses from the heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER INLET HOSE - REMOVAL)»(ref-245452-S01889769802006110200000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER RETURN HOSE - REMOVAL)»(ref-245452-S01660265192006110200000).
6. Remove the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. (Scheme 69) 1 - NUT (3) 2 - HVAC HOUSING MOUNTING STUDS 3 - DASH PANEL
7. Remove the instrument panel from the passenger compartment. «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(ref-245423-S04922067372006110200000).
8. Remove the nut and bolt that secure the HVAC housing to the passenger compartment side of the dash panel. (Scheme 70)
9. Pull the HVAC housing rearward to clear the dash panel and remove the HVAC housing from the passenger compartment.
10. If required, disassemble the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - DISASSEMBLY)»(ref-245452-S17839813602006110200000).

Scheme 70

Note. The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

1. Remove the air distribution housing from the HVAC housing and place it on a workbench «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
2. Remove the two screws that secure the heater core to the driver side of the air distribution housing and carefully remove the heater core. (Scheme 71)
3. Remove the screws that secure the mode door actuator and the two blend door actuators to the driver side of the air distribution housing and remove the actuators. 1 - AIR DISTRIBUTION HOUSING 2 - MODE DOOR ACTUATOR 3 - BLEND DOOR ACTUATOR (DRIVER) 4 - SCREW (2) 5 - SCREWS 6 - HEATER CORE 7 - BLEND DOOR ACTUATOR (PASSENGER)
4. Remove the defrost door linkage arm, instrument panel door linkage arm, mode door cam, floor door gear, driver side blend door gear and the passenger side blend door stop from the driver side of the air distribution housing. (Scheme 72) 1 - DEFROST DOOR LINKAGE ARM 2 - INSTRUMENT PANEL DOOR LINKAGE ARM 3 - MODE DOOR CAM 4 - FLOOR DOOR GEAR 5 - DRIVER SIDE BLEND DOOR GEAR 6 - PASSENGER SIDE BLEND DOOR STOP 7 - AIR DISTRIBUTION HOUSING
5. Remove the six screws that secure the floor distribution ducts to the air distribution housing and remove the ducts. (Scheme 73) 1 - SCREWS (6) 2 - FLOOR DISTRIBUTION DUCTS 3 - HVAC HOUSING
6. Remove the screw from the center of the driver side of the air distribution housing. (Scheme 74)
7. Carefully cut the foam seal along the parting line of the two halves of the air distribution housing. If the seal is deformed or damaged, it must be replaced.
8. Remove the seven screws that secure the two halves of the air distribution housing together and carefully separate the housing. 1 - SCREW 2 - AIR DISTRIBUTION HOUSING 3 - FOAM SEAL 4 - PARTING LINE 5 - SCREWS (7)
9. Push down on the retaining tab of the blend door gear and carefully pull the gear out of the blend door pivot shaft. (Scheme 75) NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced.
10. Remove the blend-air door from the driver side of the air distribution housing. 1 - BLEND-AIR DOOR (DRIVER SIDE) 2 - AIR DISTRIBUTION HOUSING 3 - GEAR RETAINING TAB 4 - BLEND DOOR GEAR
11. Remove the screw that secures the driver side air vane to the passenger side of the air distribution housing and remove the vane. (Scheme 76) NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
12. Remove the air doors and the partition from the air distribution housing. 1 - AIR VANE (DRIVER SIDE) 2 - DEFROST-AIR DOORS 3 - PANEL-AIR DOOR (DRIVER SIDE) 4 - SCREW 5 - FLOOR-AIR DOOR (DRIVER SIDE) 6 - AIR DISTRIBUTION HOUSING (PASSENGER SIDE) 7 - PARTITION
13. Remove the screw that secures the passenger side air vane to the passenger side of the air distribution housing and remove the vane. (Scheme 77) NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced.
14. Remove the air doors from the passenger side of the air distribution housing.

Scheme 77

Note. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

1. Remove the HVAC housing from the vehicle and place it on a workbench «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
2. Remove the air distribution housing from the HVAC housing. see scheme 65«(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000).
3. Remove the air inlet housing from the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR INLET HOUSING - REMOVAL)»(ref-245452-S09911585562006110200000). 1 - HVAC HOUSING 2 - AIR INLET HOUSING 3 - AIR DISTRIBUTION HOUSING
4. Remove the A/C expansion valve from the A/C evaporator. «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C EXPANSION VALVE - REMOVAL)»(ref-245452-S34487089282006110200000).
5. Disconnect the HVAC wiring harness from the blower motor resistor or power module (depending on application). (Scheme 78)
6. Disengage the HVAC wire harness from the routing clips on the HVAC housing and remove the wire harness from the housing.
7. If required, remove three screws that secure the blower motor to the HVAC housing and remove the blower motor.
8. If required, remove two screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove the resistor or module.
9. If required, remove two screws that secure the support bracket to the HVAC housing and remove the bracket.
10. Remove the thirteen screws that secure the upper HVAC housing half to the lower half of the HVAC housing.
11. Separate the two halves of the HVAC housing.
12. Carefully lift the A/C evaporator and insulator out of the lower half of the HVAC housing.

Scheme 78

Note. The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

1. Install the air doors into the passenger side of the air distribution housing as required. Align the air doors with the pivot shaft holes in the housing.
2. Install the air vane and retaining screw to the passenger side of the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
3. Align the air door pivot shafts with the pivot holes in the center partition and install the partition onto the passenger side of the air distribution housing.
4. Install the driver side air vane and retaining screw to the center partition. Tighten the screw to 2 N.m (17 in. lbs.).
5. Install the blend-air door to the driver side of the air distribution housing. Align the air door with the pivot shaft hole in the housing.
6. Align and install the blend door gear into the pivot shaft of the driver side blend-air door. Make sure that the retaining tab on the door gear is securely engaged to the pivot shaft.
7. Align the air door pivot shafts to each other and carefully install the driver side half of the air distribution housing to the passenger side half of the housing.
8. Install the seven screws that secure the two halves of the air distribution housing together. Tighten the screws to 2 N.m (17 in. lbs.).
9. Inspect the foam seal, especially at the parting line. If the seal is deformed or damaged, it must be replaced.
10. Install the screw to the center of the driver side air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
11. Position the floor distribution ducts onto the air distribution housing.
12. Install the six screws that secure the floor distribution ducts to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.). NOTE: Align the guide pin on the linkage arms with the guides on the mode door cam during installation of the floor door gear and linkage arms.
13. Install the passenger side blend door stop, driver side blend door gear, floor door gear, mode door cam, instrument panel door linkage arm and the defrost door linkage arm onto the driver side of the air distribution housing.
14. Position the mode door and blend door actuators onto the driver side of the air distribution housing. If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those in the air door linkage.
15. Install the two screws that secure each actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
16. Carefully install the heater core into the driver side of the air distribution housing.
17. Install the two screws that secure the heater core to the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.).
18. Install the air distribution housing onto the HVAC housing. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .

1. Install the A/C evaporator into the lower half of the HVAC housing. Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator around the A/C evaporator is properly installed.
2. Install the upper half of the HVAC housing onto the lower half of the HVAC housing.
3. Install the thirteen screws that secure the two halves of the HVAC housing together. Tighten the screws to 2 N.m (17 in lbs.).
4. If removed, install the support bracket and the two retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
5. If removed, install the blower motor resistor or power module (depending on application) and the two retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
6. If removed, install the blower motor and the three retaining screws. Tighten the screws to 2 N.m (17 in lbs.).
7. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers.
8. Engage the HVAC wire harness into the routing clips on the HVAC housing.
9. Connect the HVAC wire harness connector to the blower motor resistor or power module (depending on application).
10. Install the A/C expansion valve. «(Refer to HEATING & AIR CONDITIONING/PLUMBING/A/C EXPANSION VALVE - INSTALLATION)»(ref-245452-S21293697682006110200000) .
11. Install the air inlet housing onto the HVAC housing. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR INLET HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .
12. Install the air distribution housing onto the HVAC housing. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .
13. Install the HVAC housing into the vehicle. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .

Note. The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.

1. Install the air distribution housing onto the rear of the HVAC housing by inserting the two tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing and tipping the distribution housing forward until it is properly aligned with the HVAC housing.
2. Install the four screws that secure the air distribution housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Remove the tape or plugs from the heater core ports.
4. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system.
5. Position both heater core tubes and the sealing plate simultaneously onto the heater core. NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed.
6. Index both heater core tubes to the heater core ports.
7. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.).
8. Install the plastic retaining clamp that secures the heater core tubes to the front of the HVAC housing.
9. Install the foam seal onto the heater core tubes and the flange located at the front of the HVAC housing.
10. Position the HVAC wire harness onto the air distribution housing.
11. Connect the HVAC wire harness connectors to the mode door actuator and the two blend door actuators located on the driver side of the air distribution housing.
12. Install the HVAC housing assembly. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .

Note. The air inlet housing must be removed from HVAC housing for service of the recirculation-air door.

1. If removed, install the recirculation-air door into the upper air inlet housing and install the retaining screw. Tighten the screw to 2 N.m (17 in. lbs.).
2. Position the air inlet housing and recirculation-air door onto the HVAC housing. CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seats.
3. Install the three screws that secure the upper air inlet housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
4. Inspect the foam seal along the parting line. If the seal is deformed or damaged, it must be replaced.
5. Feed the blower motor wire lead through the opening in the lower air inlet housing and seat the rubber grommet into the lower air inlet housing.
6. Position the recirculation-air door pivot into the lower air inlet housing.
7. Install the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and the lower HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.).
9. Connect the blower motor wire lead connector to the blower motor resistor or power module, depending on application.
10. Install the recirculation door actuator wire lead into the routing clip located on the lower air inlet housing.
11. Install the recirculation door actuator. «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/RECIRCULATION DOOR ACTUATOR - INSTALLATION)»(ref-245452-S16163684232006110200000) .
12. Install the HVAC housing assembly. «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-245452-S08736913792006110200000) .

Note. The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.

1. Position the HVAC housing against the dash panel in the passenger compartment with the three mounting studs located in their proper holes. Make sure that the condensate drain tube protrudes through its opening.
2. Loosely install the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel.
3. Install the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. Tighten the nuts to 7 N.m (62 in. lbs.).
4. Tighten the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel to 3 N.m (26 in. lbs.).
5. Install the instrument panel. «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION)»(ref-245423-S29845757912006110200000) .
6. Connect the heater hoses to the heater core. «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER INLET HOSE - INSTALLATION)»(ref-245452-S09811747112006110200000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER RETURN HOSE - INSTALLATION)»(ref-245452-S02838414402006110200000) .
7. Connect the suction and liquid lines to the A/C expansion valve. «(Refer to HEATING & AIR CONDITIONING/PLUMBING/LIQUID LINE - INSTALLATION)»(ref-245452-S05355814892006110200000) .
8. Reconnect the negative battery cable.
9. If the heater core is being replaced, flush the cooling system. «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING)»(ref-245448-S20805593812006110200000) .
10. Refill the engine cooling system. «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-245448-S20805593812006110200000) .
11. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
12. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .
13. Calibrate the A/C-heater control. «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C HEATER CONTROL - STANDARD PROCEDURE -A/C-HEATER CONTROL CALIBRATION)»(ref-245452-S15299216602006110200000) .

4 PASSENGER SEATING

1. Remove the front and rear center floor console covers. «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the body wire harness connectors from the rear blower motor power module, floor console mode door actuator and the hands-free module. (Scheme 79)
4. Remove the body wire harness bracket from the console support bracket.
5. Remove the gear shift assembly. «(Refer to POWER TRANSFER UNIT & 41AE/TE TRANSAXLE/SHIFT MECHANISM - REMOVAL)»(ref-245428-S13406965292006110200000).
6. If necessary, remove the two support brackets, the rear blower motor housing and the hands-free module from the floor console base and duct assembly.
7. Remove the nine nuts and two bolts that secure the floor console base and duct assembly to the center floor panel and remove the base and duct assembly.

Scheme 79

Scheme 80

1. Remove the two screws that secure the rear floor outlet assembly to the rear of the center floor console and remove the floor outlet assembly. (Scheme 80) 1 - CENTER FLOOR CONSOLE 2 - REAR FLOOR OUTLET ASSEMBLY 3 - SCREW (2)
2. Remove the center floor console cover. «(Refer to BODY/INTERIOR/CENTER CONSOLE - REMOVAL)»(ref-245423-S35687059132006110200000).
3. Remove the gear shift assembly. «(Refer to POWER TRANSFER UNIT & 41AE/TE TRANSAXLE/SHIFT MECHANISM - REMOVAL)»(ref-245428-S13406965292006110200000).
4. Remove the five nuts and two bolts that secure the floor console base and duct assembly to the floor panel and remove the base and duct assembly. (Scheme 81)

Scheme 81

1. Position the floor console base and duct assembly into the vehicle.
2. Install the nine nuts and two bolts that secure the floor console base and duct assembly to the center floor panel. Tighten the nuts and bolts to 5 N.m (45 in. lbs.).
3. If removed, install the two support brackets, the rear blower motor housing and the hands-free module. Tighten the screws to 2 N.m (17 in. lbs.).
4. Install the gear shift assembly. «(Refer to POWER TRANSFER UNIT & 41AE/TE TRANSAXLE/SHIFT MECHANISM - INSTALLATION)»(ref-245428-S16251062962006110200000) .
5. Install the body wire harness bracket onto the console support bracket.
6. Connect the body wire harness connectors to the rear blower motor power module, floor console mode door actuator and the hands-free module.
7. Reconnect the negative battery cable.
8. Install the front and rear center floor console covers. «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .

5 PASSENGER SEATING

1. Position the floor console base and duct assembly into the vehicle.
2. Install the five nuts and two bolts that secure the floor console base and duct assembly to the center floor panel. Tighten the nuts and bolts to 5 N.m (45 in. lbs.).
3. Install the gear shift assembly. «(Refer to POWER TRANSFER UNIT & 41AE/TE TRANSAXLE/SHIFT MECHANISM - INSTALLATION)»(ref-245428-S16251062962006110200000) .
4. Install the center floor console cover. «(Refer to BODY/INTERIOR/CENTER CONSOLE - INSTALLATION)»(ref-245423-S27588691282006110200000) .
5. Install the rear floor outlet assembly onto the rear of the center floor console.
6. Install the two screws that secure the rear floor outlet assembly to the center floor console. Tighten the screws to 2 N.m (17 in. lbs.).

WARNINGS

CAUTIONS

REFRIGERANT SYSTEM LEAKS

If the A/C system is not cooling properly, determine if the refrigerant system is fully-charged. Refer to REFRIGERANT SYSTEM CHARGE LEVEL .

If the refrigerant system is low or empty; a leak at a refrigerant line, connector fitting, component, or component seal is likely. While an oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement. An electronic leak detector designed for R-134a refrigerant is recommended for locating and confirming refrigerant system leaks. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the results of the refrigerant system charge level test.

SYSTEM EMPTY

1. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .
3. Proceed to «SYSTEM LOW»(ref-245452-S28772295262006110200000) procedures.

SYSTEM LOW

1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following conditions for five minutes, then turning the engine off. Front windows are open. Transaxle in Park. Front heater-A/C controls set to outside air, panel mode, blower high, and compressor engaged.
3. Wait five to seven minutes and, with the engine not running, use a electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components.
4. To inspect an evaporator for leaks, insert the electronic leak detector probe into a floor outlet or the recirculation air intake.

REFRIGERANT SYSTEM CHARGE LEVEL

Note. Always refer to the underhood HVAC Specification Label for the refrigerant fill capacity of the vehicle being serviced.

The procedure that follows should be used to determine whether the refrigerant system contains the proper refrigerant charge. Symptoms of an improper refrigerant charge (low) include: poor A/C performance, fog emitted from the air outlets, a hissing sound from the A/C expansion valve/evaporator area. There are two different methods with which the refrigerant charge level may be tested

1. Using a DRBIII® scan tool, a thermocouple and the Charge Determination Chart. (Scheme 82) Refer to «BODY DIAGNOSTIC PROCEDURES»(ref-247415) for more information.
2. Using a manifold gauge set, a thermocouple and the Charge Determination Chart. (Scheme 82)

A temperature probe is required to measure liquid line temperature. The clamp-on, Type K thermocouple temperature probe used in this procedure is available through the DaimlerChrysler Professional Service Equipment (PSE) program. This probe (PSE #66-324-0014 or #80PK-1A) is compatible with temperature-measuring instruments that accept Type K thermocouples, and have a miniature connector input. Other temperature probes are available through aftermarket sources; however, all references in this procedure will reflect the use of the probe made available through the PSE program.

In order to use the temperature probe, a digital thermometer will also be required. If a digital thermometer is not available, an adapter is available through the PSE program that will convert any standard digital multimeter into a digital thermometer. This adapter is designed to accept any standard Type K thermocouple. If a digital multimeter is not available, this tool is also available through the PSE program.

Note. When connecting the service equipment couplings to the refrigerant system service ports, be certain that the valve of each coupling is fully closed. This will reduce the amount of effort required to make the connection.

1. Remove the caps from the refrigerant system service ports and attach a manifold gauge set or a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 to the refrigerant system.
2. Attach a clamp-on thermocouple to the A/C liquid line. The thermocouple must be placed as close to the A/C pressure transducer as possible to accurately observe liquid line temperature.
3. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run at idle under the following conditions for five minutes. Front windows are open. Transaxle in Park. Front A/C-heater controls set to fresh air, full cool, panel mode, high blower speed and the A/C compressor engaged.
4. Raise the liquid line (discharge) pressure to about 1793 kPa (260 psi) by placing a piece of cardboard over part of the front of the A/C condenser. To place the cardboard properly, remove the upper radiator sight shield from the front fascia. Cover only enough of the A/C condenser to raise and maintain the liquid line pressure at the specified level.
5. Observe the liquid line (discharge) pressure and liquid line temperature. Using the Charge Determination Chart. (Scheme 82), determine whether the refrigerant system is operating within the proper charge range. If the refrigerant system is operating in the undercharged area of the chart, add 0.057 kilogram (0.125 pound or 2 ounces) of R-134a refrigerant to the system. If the refrigerant system is operating in the overcharged area of the chart, reclaim 0.057 kilogram (0.125 pound or 2 ounces) of refrigerant from the system.
6. Recheck the refrigerant system charge level following each refrigerant level adjustment. Continue this process until the refrigerant system readings are in the proper charge range area on the Charge Determination Chart. (Scheme 82)

Scheme 82

REFRIGERANT SYSTEM SERVICE EQUIPMENT

RECOVERY/RECYCLING STATION

When servicing the A/C system, a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 must be used. (Scheme 83) 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.

Scheme 83

MANIFOLD GAUGE SET

A manifold gauge set may be needed with some recovery/recycling/charging equipment. (Scheme 84) The manifold gauge set should have manual shut-off valves, or automatic back-flow valves located at the service port connector end of the manifold gauge set hoses. This will prevent refrigerant from being released into the atmosphere.

Scheme 84

MANIFOLD GAUGE SET CONNECTIONS

1. LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to the suction (low side) service port. This port is on the A/C suction line located near the A/C expansion valve at the rear of the engine compartment.
2. HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to the discharge (high side) service port. This port is on the liquid line fitting located at the top of the receiver/drier near the right strut tower.
3. RECOVERY, RECYCLING, EVACUATION AND CHARGING HOSE - The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.

REFRIGERANT SYSTEM RECOVERY

A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment.

REFRIGERANT SYSTEM EVACUATE

Note. Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.

If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time, it is recommended that the refrigerant oil be drained and replaced with new oil or a new compressor be used. This will eliminate the possibility of contaminating the A/C refrigerant system.

If the refrigerant system has been open to the atmosphere, it must be evacuated before the refrigerant system can be filled. Moisture and air mixed with the refrigerant system will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to evacuate the refrigerant system. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. To evacuate the refrigerant system, use the following procedure

Note. When connecting the service equipment couplings to the refrigerant system service ports, be certain that the valve of each coupling is fully closed. This will reduce the amount of effort required to make the connection.

1. Recover the refrigerant system «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY)»(ref-245452-S23385733282006110200000) .
2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment.
3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture within the refrigerant system. When the suction gauge reads -88 kPa (-26 in. Hg) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the refrigerant system fails to reach the specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes.
4. Close all valves. Turn off and disconnect the vacuum pump.
5. Charge the refrigerant system «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE)»(ref-245452-S23385733282006110200000) .

REFRIGERANT SYSTEM CHARGE

Note. Always refer to the A/C Underhood Specification Label for the refrigerant fill capacity of the vehicle being serviced.

After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, always refer to the A/C Underhood Specification Label located in the engine compartment. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

CHARGING PROCEDURE

1. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
2. A manifold gauge set and a R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should still be connected to the A/C refrigerant system.
3. Measure the proper amount of R-134a refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment.
4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system.
5. When the transfer of refrigerant has stopped, close both the suction and discharge valves.
6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the A/C-heater controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 RPM). If the A/C compressor will not engage, test the compressor clutch control circuit and repair as required.
7. Open the suction valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time.
8. Close the suction valve and test the A/C system performance «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST)»(ref-245452-S01326498202006110200000)
9. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
10. Install the caps onto the refrigerant system service ports.
11. Run the HVAC Control Cool down test to verify proper operation «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C COOL DOWN TEST)»(ref-245452-S20143311062006110200000) .

HIGH PRESSURE RELIEF VALVE

A high pressure relief valve is located on the rear of the A/C compressor. This mechanical valve is designed to vent refrigerant from the A/C system to protect against damage to the compressor and other system components, caused by condenser air flow restriction or an overcharge of refrigerant.

A/C COMPRESSOR

The A/C compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. The A/C compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant.

The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor. The A/C compressor pumps the high-pressure refrigerant vapor to the A/C condenser through the compressor discharge port.

The A/C compressor cannot be repaired and, if faulty or damaged, the entire compressor assembly must be replaced. The compressor clutch, pulley and clutch coil are available for service.

The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The relief valve closes when a minimum discharge pressure of 2756 kPa (400 psi) is reached.

The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the A/C system. If the relief valve vents refrigerant, it does not necessarily mean that the valve is faulty.

The high pressure relief valve is a factory-calibrated unit. The relief valve cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The relief valve is only serviced as a part of the A/C compressor assembly.

A/C EXPANSION VALVE

Note. The A/C expansion valve should only be tested following testing of the A/C compressor.

Note. Liquid CO 2 is required to test the A/C expansion valve. This material is available from most welding supply facilities. Liquid CO 2 is also available from companies which service and sell fire extinguishers.

When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve

1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level.
2. Close all doors, windows and vents to the passenger compartment.
3. Set the A/C-heater controls so that the A/C compressor is operating, the temperature control is in the highest temperature position, the mode-air doors is directing air output to the floor and the blower motor operating is operating at the highest speed.
4. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the A/C evaporator.
5. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 965 kPa to 1655 kPa (140 psi to 240 psi). The suction (low pressure) gauge should read 138 kPa to 207 kPa (20 psi to 30 psi). If OK, go to step 6 . If not OK, replace the faulty A/C expansion valve. WARNING: Protect the skin and eyes from exposure to liquid CO 2 or personal injury can result.
6. If the suction (low pressure) gauge reads within the specified range, freeze the A/C expansion valve for 30 seconds using liquid CO 2 or another suitable super-cold material. Do not spray R-134a or R-12 refrigerant on the A/C expansion valve for this test. The suction (low pressure) gauge reading should drop by 69 kPa (10 psi). If OK, go to step 7 If not OK, replace the faulty A/C expansion valve.
7. Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 138 kPa to 207 kPa (20 psi to 30 psi). If not OK, replace the faulty A/C expansion valve.
8. When expansion valve testing is complete, test the overall A/C system performance «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C PERFORMANCE TEST)»(ref-245452-S19301435982006110200000) .

HEATER CORE TUBES

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-245448-S20805593812006110200000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the heater hoses from the heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER INLET HOSE - REMOVAL)»(ref-245452-S01889769802006110200000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER RETURN HOSE - REMOVAL)»(ref-245452-S01660265192006110200000).
4. Remove the silencer from beneath the driver side end of the instrument panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills.
5. Remove the bolt that secures the heater core tube sealing plate to the heater core. (Scheme 85)
6. Push both heater core tubes simultaneously toward the dash panel to disengage the tubes from the heater core and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports.
8. Pull both heater core tubes simultaneously away from the distribution housing and rearward to disengage tubes from the dash panel seal and remove the tubes.

Scheme 85

HEATER CORE

1. Remove the silencer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside.
2. Remove the brake lamp switch from its mounting bracket. «(Refer to LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - REMOVAL)»(ref-245432-S24338820862006110200000)
3. Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm. «POWER BRAKE BOOSTER»(ref-245442-S36962946292006110200000). NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills.
4. If equipped with power adjustable pedals, remove the adjustable pedal assembly. Refer to «PEDALS - ADJUSTABLE»(ref-245442-S36116002112006110200000).
5. Remove the heater core tubes. «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER CORE - HEATER CORE TUBES - REMOVAL)»(ref-245452-S42419027462006110200000).
6. Remove the two screws that secure the heater core mounting plate to the HVAC air distribution housing.
7. While pulling the accelerator pedal upward and pushing the brake pedal downward for clearance, remove the heater core from the air distribution housing. (Scheme 86)and (Scheme 87).

Scheme 86

Scheme 87

1. Remove the plugs or tape from both heater core tube fittings and both heater core ports.
2. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system.
3. Position the heater core tubes and sealing plate to the dash panel, below the instrument panel.
4. Install both heater core tubes simultaneously through the dash panel seal.
5. Position both heater core tubes and the sealing plate simultaneously onto the heater core. NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed.
6. Index both heater core tubes to the heater core ports.
7. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.).
8. Install the silencer under the driver side end of the instrument panel.
9. Connect the heater hoses to the heater hose tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER INLET HOSE - INSTALLATION)»(ref-245452-S09811747112006110200000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER RETURN HOSE - INSTALLATION)»(ref-245452-S02838414402006110200000) .
10. Reconnect the negative battery cable.
11. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-245448-S20805593812006110200000) .

1. If NOT equipped with power adjustable pedals, pull the accelerator pedal upward and push the brake pedal downward for clearance to install the heater core into the HVAC air distribution housing.
2. While pushing the brake pedal downward and pulling the accelerator pedal upward for clearance, install the heater core into the HVAC air distribution housing.
3. Install the two screws that secure the heater core to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
4. Install the heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING/HEATER CORE - INSTALLATION)»(ref-245452-S04081295952006110200000) .
5. If equipped with power adjustable pedals, install the adjustable pedal assembly. Refer to «PEDALS - ADJUSTABLE»(ref-245442-S36116002112006110200000) .
6. Connect the power brake booster input rod (push rod) to the pin on the brake pedal arm «(Refer to POWER BRAKE BOOSTER»(ref-245442-S20157463122006110200000) .
7. Install the brake lamp switch into its mounting bracket «(Refer to LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION)»(ref-245432-S37012686682006110200000) .
8. Install the silencer boot around the base of the lower steering shaft on the dash panel.
9. Reconnect the negative battery cable.
10. If the heater core is being replaced, flush the cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING)»(ref-245448-S20805593812006110200000) .
11. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-245448-S20805593812006110200000) .

REAR SECTION

1. Recover the refrigerant from the refrigerant system. «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY»(ref-245452-S36829399792006110200000).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
4. Remove the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER - REMOVAL)»(ref-245452-S00149754582006110200000).
5. Remove the nut that secures the suction and liquid line to the A/C expansion valve. see scheme 98
6. Disconnect the suction and liquid line from the A/C expansion valve and remove the O-ring seals.
7. Remove the bolt that secures the rear section of the A/C liquid line to the receiver/drier.
8. Disconnect the rear section of the A/C liquid line from the receiver/drier and the A/C expansion valve and remove and discard the O-ring seals.
9. Install plugs in, or tape over the opened liquid and suction line fittings, the receiver/drier port and both expansion valve ports.
10. Remove the rear section of the A/C liquid line from the engine compartment.

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 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 A/C liquid line to the receiver/drier.
5. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (100 in. lbs.).
6. Engage the front section of the A/C liquid line into the routing clip on top of the right frame rail.
7. Remove the tape or plugs from the condenser port and the liquid line fitting.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
9. Connect the A/C liquid line to the A/C condenser.
10. Install the nut that secures the A/C liquid line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.).
11. Install the right side radiator air seal and the air seal retaining pins.
12. Install the radiator sight shield and the sight shield retaining pins.
13. Install the front fascia. «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-245440-S02961106272006110200000) .
14. Install the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
15. Reconnect the negative battery cable.
16. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
17. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

1. Position the rear section of the A/C liquid line into the engine compartment.
2. Remove the tape or plugs from the liquid and suction line fittings, the receiver/drier port and both expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings.
4. Connect the liquid and suction lines to the A/C expansion valve.
5. Install the nut that secures the liquid and suction lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
7. connect the A/C liquid line to the receiver/drier.
8. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (100 in. lbs.).
9. Install the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS/A/C PRESSURE TRANSDUCER - INSTALLATION)»(ref-245452-S13757290472006110200000) .
10. Install the air cleaner housing. Refer to «HOUSING-AIR CLEANER»(ref-245454-S16653029582006110200000) for 3.5L or «AIR CLEANER HOUSING»(ref-245455-S35224362002006110200000) for 3.8L.
11. Reconnect the negative battery cable.
12. Evacuate the refrigerant system. «Refer to REFRIGERANT SYSTEM EVACUATE»(ref-245452-S08694777132006110200000) .
13. Charge the refrigerant system. «Refer to REFRIGERANT SYSTEM CHARGE»(ref-245452-S42943197032006110200000) .

REFRIGERANT OIL LEVEL

When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil.

It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures.

Note. Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions.

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 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 is 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 A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor.

REFRIGERANT OIL CAPACITIES