Heating & Air Conditioning - Service Information: Other Dodge Avenger II facelift

A/C PERFORMANCE

The A/C system is designed to provide the passenger compartment with low temperature and low humidity air. The A/C evaporator, located in the HVAC housing is cooled to temperatures near the freezing point. As warm damp air passes over the fins of the A/C evaporator, the air transfers its heat to the refrigerant in the evaporator coils and the moisture in the air condenses on the evaporator fins. During periods of high heat and humidity, an A/C system will be more effective in the Recirculation mode (max-A/C). With the system in the Recirculation mode, only air from the passenger compartment passes through the A/C evaporator. As the passenger compartment air dehumidifies, the A/C system performance levels rise.

Humidity has an important bearing on the temperature of the air delivered to the interior of the vehicle. It is important to understand the effect that humidity has on the performance of the A/C system. When humidity is high, the A/C evaporator has to perform a double duty. It must lower the air temperature, and it must lower the temperature of the moisture in the air that condenses on the evaporator fins. Condensing the moisture in the air transfers heat energy into the evaporator fins and coils. This reduces the amount of heat the A/C evaporator can absorb from the air. High humidity greatly reduces the ability of the A/C evaporator to lower the temperature of the air.

However, evaporator capacity used to reduce the amount of moisture in the air is not wasted. Wringing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers. Although, an owner may expect too much from their A/C system on humid days. A performance test is the best way to determine whether the system is performing up to design standards. This test also provides valuable clues as to the possible cause of trouble with the A/C system. The ambient air temperature in the location where the vehicle will be tested must be a minimum of 21° C (70° F) for this test.

HEATER PERFORMANCE

Before performing the following tests, refer to ENGINE COOLING SYSTEM for the procedures to check the engine coolant level and flow, engine coolant reserve/recovery system operation, accessory drive belt condition and tension, radiator air flow and the fan drive operation.

If vehicle has been run recently, wait 15 minutes before removing the radiator cap. Place a rag over the cap and turn it to the first safety stop. Allow pressure to escape through the overflow tube. When the system pressure stabilizes, remove the cap completely.

MAXIMUM HEATER OUTPUT

Engine coolant is delivered to and from the heater core through two heater hoses. With the engine idling at normal operating temperature, set the temperature control to the full hot position, the mode control to the floor position, and the blower motor control to the highest speed position. Using a test thermometer, check the temperature of the air being discharged at the front floor outlets. Compare the test thermometer reading to the Heater Temperature Reference chart.

HEATER TEMPERATURE REFERENCE

If the heater outlet air temperature is below the minimum specification, refer to FLOW CHECK . Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than the coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine coolant flow obstruction in the cooling system.

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow are as follows

1. Low coolant level
2. Inoperative water pump
3. Inoperative thermostat
4. Pinched or kinked heater hoses
5. Improper heater hose routing
6. Plugged heater hoses or supply and return ports at the cooling system connections
7. Plugged heater core

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

MECHANICAL PROBLEMS

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

1. Obstructed cowl air intake
2. Obstructed heater system outlets
3. Inoperative engine thermostat
4. Inoperative blower motor system
5. Inoperative A/C-heater control
6. Inoperative blend door actuator
7. Inoperative, obstructed or improperly installed blend-air door

TEMPERATURE CONTROL

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

1. Inoperative A/C-heater control
2. Inoperative blend door actuator
3. Inoperative, obstructed or improperly installed blend-air door
4. Improper engine coolant temperature

STANDARD PROCEDURE - A/C EVAPORATOR CLEANING

Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the A/C cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor may result.

If the vehicle operator experiences a musty odor when operating the A/C system, perform the following procedure.

1. On models equipped with a particulate air filter, remove the filter and inspect for dirt and debris. Refer to «FILTER, PARTICULATE AIR, REMOVAL»(ref-485480-S02461733742012071300000) . Discard the used particulate filter if required.
2. Remove the cowl panel cover. Refer to «COVER, COWL PANEL»(ref-485483-S39328540002012071300000) .
3. Clean any dirt and debris that may be present at the HVAC fresh air inlet screen and at the top of the cowl panel.
4. Install the cowl panel cover.
5. Raise and support the vehicle.
6. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may be blocking the drain and repair as necessary.
7. Once drain operation has been verified; when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an appropriate pair of heater hose pliers. when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or plug and temporarily cap or plug the drain tube.
8. Lower the vehicle.
9. Place a protective cover over the front passenger side floor and seat area.
10. Remove the blower motor. Refer to «MOTOR, BLOWER, REMOVAL»(ref-485480-S05001860412012071300000) .
11. Remove the blower motor power module. Refer to «MODULE, POWER, BLOWER MOTOR, REMOVAL»(ref-485480-S09733768152012071300000) .
12. Clean any dirt and debris that may be present inside the HVAC blower motor housing and all readily accessible areas inside the HVAC housing. If necessary, use a vacuum with a small flexible hose, and take caution not to damage the evaporator core fins.
13. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C evaporator with three bottles of Mopar® Cooling Coil Cleaner through the blower motor and power module or resistor openings. Be sure to use all of the coil cleaner in each container.
14. Allow the vehicle to sit for 30 minutes.
15. Raise and support the vehicle. WARNING: Excess cooling coil cleaner will drain from the evaporator housing when the clamp, cap or plug is removed from the evaporator drain hose or tube. Always use eye protection, rubber gloves and protective clothing. Avoid continuous breathing of vapors from evaporator coil cleaning fluid. Avoid contact with skin and eyes. Failure to follow these instruction may result in possible serious or fatal injury.
16. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow excess coil cleaner to drain from the HVAC housing.
17. Lower the vehicle.
18. Refill the three empty coil cleaner bottles with clean tap water.
19. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely rinse the entire surface of A/C evaporator with the three bottles of clean tap water through the blower motor and power module or resistor openings. Be sure to use all of the water in each container.
20. Install the blower motor. Refer to «MOTOR, BLOWER, INSTALLATION»(ref-485480-S36711866772012071300000) .
21. Install the blower motor power module. Refer to «MODULE, POWER, BLOWER MOTOR, INSTALLATION»(ref-485480-S26053123762012071300000) .
22. Disconnect the wire harness connector from the A/C compressor to disable compressor operation. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-485480-S16902540862012071300000) .
23. Start the engine
24. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
25. Set the A/C-heater controls to the following: air distribution to Panel and Recirculation mode temperature to full heat
26. Allow the vehicle to run for 20 minutes.
27. Turn the engine off.
28. Raise and support the vehicle.
29. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may have blocked the drain during evaporator coil cleaning and repair as necessary.
30. Once drain operation has been verified; when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an appropriate pair of heater hose pliers. when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or plug and temporarily cap or plug the drain tube.
31. Lower the vehicle.
32. Remove the blower motor. Refer to «MOTOR, BLOWER, REMOVAL»(ref-485480-S05001860412012071300000) .
33. Remove the blower motor power module. Refer to «MODULE, POWER, BLOWER MOTOR, REMOVAL»(ref-485480-S09733768152012071300000) .
34. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C evaporator with one bottle of Mopar® Cooling Coil Coating through the blower motor and power module or resistor openings. Be sure to use all of the coil coating in the container. NOTE: Be sure to thoroughly clean out the spray delivery tool with warm water once coil coating is complete to prevent damage to the tool.
35. Refill the empty bottles with clean warm tap water and completely rinse out the PSE Flex Spray Delivery Tool 534-62637, or equivalent.
36. Allow the vehicle to sit for 30 minutes.
37. Install the blower motor. Refer to «MOTOR, BLOWER, INSTALLATION»(ref-485480-S36711866772012071300000) .
38. Install the blower motor power module. Refer to «MODULE, POWER, BLOWER MOTOR, INSTALLATION»(ref-485480-S26053123762012071300000) .
39. Raise and support the vehicle. WARNING: Excess cooling coil coating will drain from the evaporator housing when the clamp, cap or plug is removed from the evaporator drain hose or tube. Always use eye protection, rubber gloves and protective clothing. Avoid continuous breathing of vapors from evaporator coil sealing fluid. Avoid contact with skin and eyes. Failure to follow these instruction may result in possible serious or fatal injury.
40. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow excess coil coating to drain from the HVAC housing.
41. Lower the vehicle.
42. Start the engine
43. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
44. Set the A/C-heater controls to the following: air distribution to Panel and Recirculation mode temperature to full heat
45. Allow the vehicle to run for 20 minutes.
46. Turn vehicle off.
47. Remove protective cover from front passenger side floor and seat area.
48. On models equipped with a particulate air filter, install the filter. Refer to «FILTER, PARTICULATE AIR, INSTALLATION»(ref-485480-S33634836022012071300000) .
49. Connect the wire harness connector to the A/C compressor. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-485480-S12532763762012071300000) .
50. Verify proper A/C-heater system operation.

A/C SYSTEM

SEDAN MODEL

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

Scheme 56

Note. Typical overhead console shown in illustration. Infrared sensor location may vary by model.

1. Disconnect and isolate the negative battery cable.
2. Remove the overhead console (1) from the headliner and place it on a workbench. Refer to «CONSOLE, OVERHEAD, FRONT, REMOVAL»(ref-485483-S30043015782012071300000) .
3. Remove the screw (2) that secures the infrared sensor (3) to the back of the overhead console and remove the sensor.

Scheme 57

1. Lower the convertible top.
2. Disconnect and isolate the negative battery cable.
3. Partially remove the windshield header trim panel (1) to gain access to the infrared sensor (2). Refer to «PANEL, HEADER, REMOVAL»(ref-485483-S39005544302012071300000) .
4. Carefully disengage the retaining tabs (3) that secure the infrared sensor to the back of the header trim panel and remove the sensor from the trim panel.
5. Disconnect the wire harness connector (4) from the infrared sensor and remove the sensor from the vehicle.

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

Note. Typical overhead console shown in illustration. Infrared sensor location may vary by model.

1. Position the infrared sensor (3) onto the back of the overhead console (1). Align the slot on the front of the sensor with the tabs (4) on the console.
2. Install the screw (2) that secures the infrared sensor to the overhead console. Tighten the screw to 1.2 N.m (10 in. lbs).
3. Install the overhead console. Refer to «CONSOLE, OVERHEAD, FRONT, INSTALLATION»(ref-485483-S32080506932012071300000) .
4. Reconnect the negative battery cable.

CONVERTIBLE MODEL

1. Position the infrared sensor (2) to the windshield header trim panel (1) and connect the wire harness connector (4). NOTE: Make sure the infrared sensor is properly positioned in the header trim panel. The sensor lens must be centered in the hole in the trim panel or the sensor may not function as designed.
2. Install the infrared sensor onto the back of the header trim panel and engage the two retaining tabs (3). Make sure the retaining tabs are fully engaged to the sensor and that the sensor is properly positioned in the trim panel.
3. Install the windshield header trim panel. Refer to «PANEL, HEADER, INSTALLATION»(ref-485483-S33982010862012071300000) .
4. Reconnect the negative battery cable.
5. Raise the convertible top.

Scheme 58

Note. Typical sun sensor assembly shown in illustration.

The Automatic Temperature Control (ATC) heating and A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case with a clear lens (3), that protrudes through the center of the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness.

RIGHT FRONT FLOOR DUCT

Note. Illustration shown with instrument panel removed for clarity.

1. Connect the right floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing.
2. On LHD models, install the glove box bin. Refer to «GLOVE BOX, INSTRUMENT PANEL, INSTALLATION»(ref-485483-S21930804692012071300000) .

LEFT FRONT FLOOR DUCT

Note. Illustration shown with instrument panel removed for clarity.

1. Connect the left floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing.
2. Install the screw (4) that secures the left floor duct to the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
3. On LHD models, connect the shift interlock cable (3) to the left floor duct.
4. On RHD models, install the glove box bin. Refer to «GLOVE BOX, INSTRUMENT PANEL, INSTALLATION»(ref-485483-S21930804692012071300000) .

REAR FLOOR DISTRIBUTION DUCTS

1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing.
2. Install the rear seat floor ducts. Refer to «REAR SEAT FLOOR DUCTS»(ref-485480-S31308430002012071300000) .
3. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

REAR SEAT FLOOR DUCTS

Note. Right side rear floor duct shown in illustration. Left side duct similar.

1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other.
2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 N.m (20 in. lbs.).
3. Reinstall the carpet. Refer to «CARPET, FLOOR, INSTALLATION»(ref-485483-S11179845052012071300000) .
4. Install the front seat to the side of the vehicle being serviced. Refer to «SEAT, INSTALLATION»(ref-485483-S26704587492012071300000) or «SEAT, FRONT, INSTALLATION»(ref-485483-S42530389282012071300000) .
5. Install the center floor console. Refer to «INSTALLATION»(ref-485483-S26788681212012071300000) .

OUTER DUCTS

Note. Passenger side shown in illustration. Driver side similar.

1. Connect each outer instrument panel duct (2) to the center instrument panel duct (3). Make sure the ducts are fully engaged to each other.
2. Position each outer instrument panel duct to the instrument panel top cover (5).
3. Install the screw (4) that secures each outer instrument panel duct to the instrument panel top cover. Tighten the screws to 2.2 N.m (20 in. lbs.).
4. Install the left and right instrument panel air outlets (1). Refer to «OUTLET, AIR, INSTALLATION»(ref-485480-S30355844832012071300000) .
5. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

CENTER DUCT

1. Position the center instrument panel duct (2) to the instrument panel top cover (2) and engage the duct to the center of the cover. Make sure the center duct is fully engaged to the cover.
2. Install the screws (3) that secure the center instrument panel duct to the instrument panel top cover. Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Install the defroster duct. Refer to «DUCT, DEFROSTER, INSTALLATION»(ref-485480-S03491884252012071300000) .
4. Install the demister ducts. Refer to «DUCT, INSTRUMENT PANEL DEMISTER, INSTALLATION»(ref-485480-S42823544152012071300000) .
5. Install the instrument panel top pad. Refer to «PAD, INSTRUMENT PANEL, INSTALLATION»(ref-485483-S23106404972012071300000) .
6. Install the outer instrument panel ducts. Refer to «OUTER DUCTS»(ref-485480-S37227803972012071300000) .
7. Install the left and right instrument panel air outlets. Refer to «OUTLET, AIR, INSTALLATION»(ref-485480-S30355844832012071300000) .
8. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

DRIVER SIDE

1. Position the driver side demister duct (2) to the instrument panel top cover (3) and connect it to the defroster duct (4). Make sure the ducts are fully engaged to each other.
2. Install the two screws (1) that secure the driver side demister duct (2) to the instrument panel top cover (3). Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Install the instrument panel top pad. Refer to «PAD, INSTRUMENT PANEL, INSTALLATION»(ref-485483-S23106404972012071300000) .
4. Install the outer instrument panel ducts. Refer to «DUCT, INSTRUMENT PANEL, INSTALLATION»(ref-485480-S37108459512012071300000) .
5. Install the left and right instrument panel air outlets. Refer to «OUTLET, AIR, INSTALLATION»(ref-485480-S30355844832012071300000) .
6. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

PASSENGER SIDE

1. Position the passenger side demister duct (1) to the instrument panel top cover (2) and connect it to the defroster duct (3). Make sure the ducts are fully engaged to each other.
2. Install the two screws (4) that secure the passenger side demister duct (2) to the instrument panel top cover (3). Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Install the instrument panel top pad. Refer to «PAD, INSTRUMENT PANEL, INSTALLATION»(ref-485483-S23106404972012071300000) .
4. Install the outer instrument panel ducts. Refer to «DUCT, INSTRUMENT PANEL, INSTALLATION»(ref-485480-S37108459512012071300000) .
5. Install the left and right instrument panel air outlets. Refer to «OUTLET, AIR, INSTALLATION»(ref-485480-S30355844832012071300000) .
6. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

Scheme 59

Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin.

The filter should be replaced at least once a year or every 24, 000 km (15, 000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter.

HOUSING-AIR DISTRIBUTION

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

Note. LHD model shown in illustrations. RHD model similar.

Scheme 60

Scheme 61

1. Remove the HVAC housing assembly and place it on a workbench. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
2. Remove the floor distribution ducts from the HVAC housing assembly. Refer to «DUCT, FLOOR DISTRIBUTION, REMOVAL»(ref-485480-S06283377012012071300000) . NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (7).
4. Remove the screw (8) that secures the flange to the HVAC housing and remove the flange.
5. Remove the screws (3) that secure the heater core tube retaining brackets (6) to the air distribution housing (4).
6. On RHD models, remove the air distribution housing from the HVAC housing. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
7. Carefully pull the heater core (5) out of the air distribution housing.
8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4).
9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing.
10. Remove the air distribution housing from the rear of the HVAC housing.
11. If required, disassemble the air distribution housing. Refer to «HOUSING, HVAC, DISASSEMBLY»(ref-485480-S07294919802012071300000) .

HOUSING-AIR INLET

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

Note. LHD model shown in illustration. RHD model similar.

Scheme 62

1. Remove the HVAC housing assembly and place it on a workbench. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
2. If equipped, remove the particulate air filter. Refer to «FILTER, PARTICULATE AIR, REMOVAL»(ref-485480-S02461733742012071300000) .
3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3).
4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and remove the inlet housing from the HVAC housing.
5. If required, disassemble the air inlet housing. Refer to «HOUSING, HVAC, DISASSEMBLY»(ref-485480-S07294919802012071300000) .

HOUSING-HVAC

Note. The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors.

Note. LHD model shown in illustrations. RHD model similar.

Scheme 63

Scheme 64

Scheme 65

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
3. Partially drain the engine cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
4. Remove the top nut (2) that secures the heat shield (3) to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal. Complete removal of the two bottom heat shield retaining nuts is not required.
5. Reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required.
6. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
7. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.
8. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
9. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal. NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle.
10. Remove the instrument panel. Refer to «PANEL, INSTRUMENT, REMOVAL»(ref-485483-S19587481862012071300000) .
11. Remove the rear floor ducts. Refer to «DUCT, FLOOR DISTRIBUTION, REMOVAL»(ref-485480-S06283377012012071300000) .
12. Remove the condensation drain tube. Refer to «TUBE, CONDENSATION DRAIN, REMOVAL»(ref-485480-S04184923352012071300000) .
13. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3). NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.
14. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.

SCREEN-AIR INLET

Note. LHD model shown in illustration. RHD model similar.

Scheme 66

1. Remove the cowl grille screen. Refer to «COVER, COWL PANEL, REMOVAL»(ref-485483-S06040071802012071300000) .
2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen.

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

Note. LHD model with A/C shown in illustrations. RHD and heater-only models similar.

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Remove the HVAC housing assembly and place it on a workbench. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
2. Remove the air distribution housing (2) from the HVAC housing (1). Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
3. Remove the heater core from the air distribution housing. Refer to «CORE, HEATER, REMOVAL»(ref-485480-S28576740062012071300000) .
4. Remove the screws (1) that secure the blend door actuator (2) to the left side of the air distribution housing (3) and remove the actuator.
5. Remove the blend door lever (1) from the left side of the air distribution housing (2). NOTE: To remove the blend door pivot lever, disengage the retaining tab on the lever and pull the lever straight off the pivot shaft.
6. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4). NOTE: It is not necessary to remove the mode door actuator from the bracket when servicing the air distribution housing.
7. Remove the three screws (1) that secure the mode door actuator (2) and bracket (3) to the right side of the air distribution housing (4) and remove the actuator and bracket as an assembly.
8. Remove the mode door cam (1) from the right side of the air distribution housing (2). NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
9. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced.
10. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.
11. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
12. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5). NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing.
13. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).

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

Note. LHD model shown in illustrations. RHD model similar.

Scheme 75

Scheme 76

1. Remove the HVAC housing assembly and place it on a workbench. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
2. Remove the air inlet housing (3) from the HVAC housing (1). Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air inlet housing (3) and remove the actuator.
4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft. NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced. NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.
5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.

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

Note. LHD model shown in illustrations. RHD model similar.

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Remove the HVAC housing assembly and place it on a workbench. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
2. Remove the air distribution housing (2) from the HVAC housing (1). Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) .
3. Remove the air inlet housing (3) from the HVAC housing. Refer to «HOUSING, HVAC, REMOVAL»(ref-485480-S34419782402012071300000) . NOTE: Manual temperature system shown in illustration. Automatic system similar.
4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket.
5. Remove the two screws (5) that secure the blower motor power module (6) to the bottom of the HVAC housing and remove the module.
6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
7. Carefully remove the foam seal (2) from the front of the two halves of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced.
8. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together.
9. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
10. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced.
11. If required, remove the seal (4) from around the evaporator tube tapping block (5).

Note. LHD model with A/C shown in illustrations. RHD and heater-only models similar.

1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing. NOTE: Properly position the air doors within the air distribution housing by first aligning the four mode door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the mode door levers with the UP mark on each air door facing toward the top of the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on each air door facing toward the top of the housing.
3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged.
4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 N.m (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced. NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam.
6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (1) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam.
7. Position the mode door actuator (2) and bracket (3) onto the right side of the HVAC air distribution housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door cam.
8. Install the screws (1) that secure the mode door actuator bracket to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft. NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever.
10. Install the blend door lever (1) onto the air distribution housing. Make sure the levers are correctly aligned to each other.
11. Position the blend door actuator (2) onto the left side of the air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door lever.
12. Install the screws (1) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
13. Install the heater core into the air distribution housing. Refer to «CORE, HEATER, INSTALLATION»(ref-485480-S20159287592012071300000) .
14. Install the air distribution housing onto the HVAC housing (1). Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .
15. Install the HVAC housing assembly. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .

Note. LHD model shown in illustrations. RHD model similar.

1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet housing. NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end of the recirculation door pivot shaft.
2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation air-door. Make sure the adapter is fully engaged to the pivot shaft.
3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4).
4. Install the air inlet housing (3) onto the HVAC housing (1). Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .
5. Install the HVAC housing assembly. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .

Note. LHD model shown in illustrations. RHD model similar.

1. If removed, install the seal (4) onto the evaporator tube tapping block (5). NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3).
3. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1). Make sure the retaining tabs are fully engaged.
4. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 N.m (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves.
5. Install the foam seal (2) onto the front of the two HVAC housing halves.
6. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing. NOTE: Manual temperature system shown in illustration. Automatic system similar.
7. Position the blower motor (3) into the bottom of the HVAC housing (4).
8. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
9. Position the blower motor power module (6) into the HVAC housing.
10. Install the two screws (5) that secure the power module to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
11. Install the air inlet housing (3) onto the HVAC housing (1). Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .
12. Install the air distribution housing (2) onto the HVAC housing. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) . NOTE: If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
13. Install the HVAC housing assembly. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .

Note. LHD model shown in illustrations. RHD model similar.

1. Position the air distribution housing (2) onto the rear of the HVAC housing (4).
2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the HVAC housing.
3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
4. Carefully install the heater core (5) into the side of the air distribution housing (4).
5. On RHD models, install the air distribution housing onto the HVAC housing (7). Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .
6. Install the heater core tube brackets (6) and retaining screws (3). Tighten the screws to 1.2 N.m (10 in. lbs.)
7. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing.
8. Install the screw (8) that secures the flange to the HVAC housing. Tighten the screw to 1.2 N.m (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
9. Install the foam seal (1) onto the flange.
10. Install all of the floor distribution ducts onto the air distribution housing. Refer to «DUCT, FLOOR DISTRIBUTION, INSTALLATION»(ref-485480-S41185156782012071300000) . NOTE: If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
11. Install the HVAC housing assembly. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .

Note. LHD model shown in illustration. RHD model similar.

1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic retaining tabs (4). Make sure the retaining tabs are fully engaged.
2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. If equipped, install the particulate air filter. Refer to «FILTER, PARTICULATE AIR, INSTALLATION»(ref-485480-S33634836022012071300000) .
4. Install the HVAC housing assembly. Refer to «HOUSING, HVAC, INSTALLATION»(ref-485480-S28317155452012071300000) .

Note. LHD model shown in illustrations. RHD model similar.

1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud.
2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 N.m (40 in. lbs.).
3. Install the condensation drain tube. Refer to «TUBE, CONDENSATION DRAIN, INSTALLATION»(ref-485480-S36418279932012071300000) .
4. Install the rear floor ducts. Refer to «DUCT, FLOOR DISTRIBUTION, INSTALLATION»(ref-485480-S41185156782012071300000) .
5. Install the instrument panel. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .
6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes.
7. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
8. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 25 N.m (18 ft. lbs.).
11. Position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment.
12. Install the three nuts (2) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in. lbs.).
13. Reconnect the negative battery cable.
14. If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
15. Refill the engine cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
16. Evacuate the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
17. Charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
18. Initiate the Actuator Calibration function using a scan tool. Refer to the appropriate Electrical Diagnostic article. .

Note. LHD model shown in illustration. RHD model similar.

1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel.
2. Install the cowl grille screen. Refer to «COVER, COWL PANEL, INSTALLATION»(ref-485483-S30272729182012071300000) .

Scheme 81

The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (2) within the HVAC air inlet housing at the selected speed.

The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing.

DEMISTER

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

Note. Right side shown in illustration. Left side similar.

Scheme 82

1. Remove the instrument panel cover (2) and place it on a workbench. Refer to «PANEL, INSTRUMENT, REMOVAL»(ref-485483-S19587481862012071300000) .
2. Remove the screw (3) that secures the demister outlet (1) to the back of the instrument panel cover and remove the outlet.

INSTRUMENT PANEL

Note. Take the proper precautions to protect the instrument panel cover and the center bezel from cosmetic damage while performing these procedures.

Note. Dodge model shown in illustration. Chrysler model similar.

Scheme 83

Scheme 84

1. If servicing a center air outlet (1 and 3): Remove the center bezel. Refer to «BEZEL, INSTRUMENT PANEL, CENTER, REMOVAL»(ref-485483-S42198523072012071300000) . Using Trim Stick (special tool #C-4755, Trim Stick) or equivalent, disengage the four retaining clips (4 and 5) that secure each air outlet to the center bezel (2) and remove the outlet.
2. If servicing an outboard air outlet (2), use Trim Stick (special tool #C-4755, Trim Stick) (1) or equivalent to disengage the five retaining clips that secure each air outlet to the instrument panel cover (3) and remove the outlet.

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

Note. Right side shown in illustration. Left side similar.

1. Position the demister duct (1) to the instrument panel cover (2).
2. Install the screw (3) that secures the demister duct to the instrument panel cover. Tighten the screw to 2.2 N.m (20 in. lbs.).
3. Install the instrument panel cover. Refer to «PANEL, INSTRUMENT, INSTALLATION»(ref-485483-S06376687882012071300000) .

Note. Take the proper precautions to protect the instrument panel cover and the center bezel from cosmetic damage while performing these procedures.

Note. Dodge model shown in illustration. Chrysler model similar.

Scheme 85

1. If servicing a center air outlet (1 and 3): Position the outlet to the center bezel (2) and engage the four plastic retaining clips (4 and 5). Install the center bezel. Refer to «BEZEL, INSTRUMENT PANEL, CENTER, INSTALLATION»(ref-485483-S02994003422012071300000) .
2. If servicing an outboard air outlet (1), position the outlet to the instrument panel cover (2) and engage the five metal retaining clips.

WARNING

CAUTION

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -8 kPa (-26 in. Hg) or greater vacuum) for at least 30 minutes. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) . CAUTION: Use only Chrysler LLC approved R-134a leak detection dye. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using low-budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.
2. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye.
3. Prepare the vehicle specific amount of R-134a refrigerant. Refer to «REFRIGERANT, SPECIFICATIONS»(ref-485480-S25756786772012071300000) . NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.
4. Dispense the leak detection dye and the correct amount of R-134a refrigerant into the evacuated refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
5. Refer to «LEAK TEST»(ref-485480-S15168832652012071300000) .

SYSTEM LOW

1. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye. NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.
2. Dispense the leak detection dye and 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
3. Refer to «LEAK TEST»(ref-485480-S15168832652012071300000) .

RECOVERY PROCEDURE

1. If use of aftermarket A/C system sealant is suspected, the A/C system should be tested for sealant prior to refrigerant system recovery. See the operating instructions supplied by the equipment manufacturer for proper use and care of this equipment.
2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system.
3. Recover the A/C refrigerant system following the operating instructions supplied by the recovery/recycling/charging station manufacturer.
4. Disconnect the refrigerant recovery/recycling/charging station from the refrigerant system service ports.
5. Reinstall the caps onto the refrigerant system service ports.

REFRIGERANT SYSTEM EVACUATE

If the A/C refrigerant system has been open to the atmosphere, it must be evacuated before the A/C system can be recharged with R-134a refrigerant.

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 A/C compressor.

Moisture and air in the A/C 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. Always use an R-134a refrigerant recovery/recycling/charging station with a vacuum pump (1) that meets SAE standard J2788, or an R-134a compatible manifold gauge set and a stand-alone vacuum pump.

If an A/C compressor is left open to the atmosphere for an extended period of time, it is recommended that the refrigerant oil in the compressor be drained and replaced with new refrigerant oil to reduce the possibility of contaminating the refrigerant system. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE .

EVACUATION PROCEDURE

1. Recover the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) . NOTE: When connecting service equipment couplers to refrigerant line service ports, verify that the valve of each coupler is fully closed prior to connecting. This will reduce the amount of effort required to make the connections.
2. Connect an R-134a refrigerant recovery/recycling/charging station with a vacuum pump that meets SAE standard J2788 to the refrigerant system, or an R-134a compatible manifold gauge set and a stand-alone vacuum pump (depending on available equipment).
3. Open the refrigerant recovery/recycling/charging station or manifold gauge set valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to recharge to eliminate all moisture in system. When the low-side gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the refrigerant system fails to reach 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 valves and allow the refrigerant system to evacuate an additional 10 minutes.
4. Close the refrigerant recovery/recycling/charging station or manifold gauge set valves. Turn off and disconnect the vacuum pump.
5. Disconnect the refrigerant recovery/recycling/charging station or manifold gauge set from the refrigerant system service ports.
6. Reinstall the caps onto the refrigerant system service ports.

REFRIGERANT SYSTEM CHARGE

After all A/C refrigerant system repairs have been completed and the refrigerant system has been evacuated, the A/C system can be recharged with R-134a refrigerant.

When charging the A/C system, use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2788. Per SAE standard J2788, refrigerant recovery stations must charge the system to an accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

CHARGING PROCEDURE

1. Recover and evacuate the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system.
3. When required, adjust the refrigerant oil level. Refer to «OIL, REFRIGERANT, STANDARD PROCEDURE»(ref-485480-S10373791782012071300000) . NOTE: A/C system refrigerant capacity can be found on the HVAC Specification Label, located in the engine compartment.
4. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. Refer to «REFRIGERANT, SPECIFICATIONS»(ref-485480-S25756786772012071300000) . See the operating instructions supplied by the equipment manufacturer for proper use of this equipment.
5. Open both the low and high side valves, then open the charge valve to allow the heated refrigerant to flow into the refrigerant system.
6. When the transfer of refrigerant has stopped, close the valves. WARNING: Take care not to open the high side (high pressure) valve while performing Step 7. Failure to follow these instructions may result in possible serious or fatal injury.
7. Perform the following if all of the refrigerant charge did not transfer from the dispensing device. Open all of the windows in the vehicle. Set the heating and A/C system so that the A/C compressor is operating 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 does not operate, test the compressor control circuits and repair as required. Open the low side valve and the charge valve to allow the remaining refrigerant to flow into the refrigerant system. When the transfer of refrigerant has stopped, close the valves.
8. Disconnect the refrigerant recovery/recycling/charging station from the refrigerant system service ports.
9. Reinstall the caps onto the refrigerant system service ports.

Scheme 86

To protect the A/C compressor from any liquid slugging, an A/C accumulator (1) is used in this A/C system to retain any refrigerant that may exit from the evaporator in a liquid state.

The A/C accumulator is mounted below the engine compartment behind the right side of the front fascia. A band and mounting bracket (2) secures the A/C accumulator to the right front frame rail and the connections are sealed by use of metal gaskets (3) and rubber O-rings (4).

Scheme 87

Note. Typical A/C accumulator shown in illustration.

Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5).

Note. Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

The A/C accumulator has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C accumulator is removed and installed.

The A/C accumulator cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred.

HIGH PRESSURE RELIEF VALVE

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

FIXED DISPLACEMENT A/C COMPRESSOR

The Denso 10SR18 fixed displacement A/C compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. This 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 the suction port, then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is pumped to the A/C condenser through the compressor discharge port.

The Denso 10SR18 fixed displacement A/C compressor cannot be repaired and must be replaced if inoperative or damaged. The A/C clutch, pulley and bearing assembly, and clutch coil are available for service if inoperative or damaged. If an internal failure of the A/C compressor has occurred, the A/C accumulator must also be replaced. Refer to ACCUMULATOR, REMOVAL .

Scheme 88

Note. Typical variable displacement A/C compressor shown in illustration.

The Denso 6SEU16 A/C compressor is a Variable Displacement Compressor (VDC) which is driven by the engine through a drive hub (1) and pulley (2). This A/C compressor does not require the use of an electromagnetic clutch, as the compressor uses an integral control solenoid (3) to reduce or increase the stroke of the five pistons (4) within the compressor by automatically adjusting the angle of the swashplate (5).

The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is then pumped to the A/C condenser through the compressor discharge port. The A/C compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE .

The A/C compressor is controlled by the Powertrain Control Module (PCM). The PCM calculates compressor displacement required by A/C system load and demand by monitoring vehicle speed, A/C high side pressure, engine speed, evaporator temperature, accelerator pedal position, ambient temperature and A/C-heater request signals. The PCM then sends a Pulse Width Modulated (PWM) signal to the A/C compressor control solenoid to increase or decrease refrigerant flow through an orifice located within the compressor housing. The amount of refrigerant allowed to pass through the orifice in the compressor determines the head pressure which controls the angle of the swashplate, which in turn, determines the amount of compressor displacement. When there is no demand for A/C, the swashplate is adjusted to nearly a zero degree angle, which removes compressor torque drag from the engine.

This A/C compressor will reduce the displacement of the compressor based on ambient air temperature. For example; as the outside temperature falls from 27° C (80° F) to 19° C (66° F), the amount of refrigerant flow required through the A/C orifice tube to keep the A/C evaporator cool becomes less, and the swashplate is adjusted to a lower angle, which reduces compressor displacement. However, due to the lower outside air temperature, panel air outlet temperature will not noticeably change.

The A/C compressor control system is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING .

Note. The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly.

The A/C compressor cannot be repaired or adjusted and must be replaced if inoperative or damaged. If an internal failure of the A/C compressor has occurred, the A/C accumulator must also be replaced. Refer to ACCUMULATOR, REMOVAL .

CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

The clutch components for the Denso 10SR18 fixed displacement A/C compressor provide the means to engage and disengage the compressor from the engine accessory drive belt. When the electromagnetic A/C clutch coil is energized, it magnetically draws the clutch plate into contact with the clutch 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 assembly.

A/C clutch engagement is controlled by the Powertrain Control Module (PCM).

The A/C clutch control system is diagnosed using a scan tool. Refer to the appropriate Electrical Diagnostic article. .

The A/C clutch components cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Scheme 89

Note. Typical clutchless compressor pulley drive hub shown in illustration.

The design of the Denso 6SEU16 variable displacement A/C compressor does not require the use of an electromagnetic clutch, as the compressor is controlled by an integral control valve that allows refrigerant to bypass within the compressor. Refer to COMPRESSOR, A/C, DESCRIPTION .

The three bridges (1) located on compressor drive hub (2) are designed to break away in the event of compressor seizure. This action prevents damage to the serpentine accessory drive belt. Refer to COMPRESSOR, A/C, INSPECTION .

Note. The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly.

The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. The A/C compressor must be replaced if the drive hub or pulley and bearing assembly is worn or damaged.

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 high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached.

The high pressure relief valve should not open when the A/C system is operating correctly. If the high pressure relief valve vents refrigerant, there is most likely a problem within the A/C refrigerant system. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. If the high pressure relief valve vents refrigerant, see the A/C System Diagnosis chart. Refer to DIAGNOSIS AND TESTING .

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

The A/C clutch coil electrical circuit for the Denso 10SR18 fixed displacement A/C compressor is controlled by the Powertrain Control Module (PCM). Refer to the appropriate wiring information for complete HVAC wiring diagrams. Begin testing of a suspected A/C clutch coil problem by performing the preliminary checks.

PRELIMINARY CHECKS

1. Using a scan tool, check for Diagnostic Trouble Codes (DTCs) in the A/C-heater control and PCM. If no DTCs are found, go to 2 . If any DTCs are found, repair as required.
2. If the A/C clutch still will not engage, verify the refrigerant charge level. Refer to «DIAGNOSIS AND TESTING»(ref-485480-S39433239362012071300000) . If the refrigerant charge level is OK, refer to «COIL RESISTANCE TEST»(ref-485480-S11233849202012071300000) and/or «COIL CURRENT DRAW TEST»(ref-485480-S16860783992012071300000) . If the refrigerant charge level is not OK, adjust the refrigerant charge as required.

A/C COMPRESSOR

Note. Variable displacement compressor shown in illustrations. Fixed displacement similar.

Scheme 90

Scheme 91

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
3. Raise and support the vehicle.
4. Remove the splash shield from the right side frame rail. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-485483-S05679842352012071300000) .
5. Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
6. Disconnect the engine wire harness (1) from the clutch coil or compressor control valve (2), depending on application.
7. Remove the nuts (4) that secure the A/C discharge line (5) and the A/C suction line (6) to the A/C compressor (3).
8. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
9. Support the A/C compressor (1) and remove the three bolts (2) that secure the compressor to the engine and remove the compressor.
10. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.

Note. The compressor clutch assembly can be serviced with the refrigerant system fully-charged and with the A/C compressor installed on the engine.

Note. Typical A/C compressor and clutch assembly shown in illustrations.

Scheme 92

Scheme 93

Scheme 94

Scheme 95

1. Disconnect and isolate the negative battery cable.
2. Raise and support the vehicle.
3. Remove the splash shield from the right side frame rail. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL»(ref-485483-S05679842352012071300000) .
4. Remove the accessory drive belt. Refer to «BELT, SERPENTINE, REMOVAL»(ref-485484-S39989615472012071300000) .
5. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). NOTE: Some models (depending on engine application) may require the A/C compressor to be removed from its installed location and repositioned to gain access to the compressor shaft bolt and/or pulley and field coil snap rings. However, the refrigerant system can still remain fully charged.
6. If necessary, remove the bolts that secure the A/C compressor to the engine and reposition the compressor to gain access to the shaft bolt and/or pulley and field coil snap rings. Refer to «COMPRESSOR, A/C, REMOVAL»(ref-485480-S16902540862012071300000) .
7. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2).
8. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.
9. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).
10. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) or equivalent (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly.
11. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) or equivalent (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil.

Note. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE .

Note. Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

Note. Variable displacement compressor shown in illustrations. Fixed displacement similar.

1. If the A/C compressor (1) is being replaced, refrigerant oil must first be drained from the new A/C compressor. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to «OIL, REFRIGERANT, STANDARD PROCEDURE»(ref-485480-S10373791782012071300000) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor into the engine compartment.
3. Install the three bolts (2) that secure the A/C compressor to the engine. Tighten the bolts to 25 N.m (18 ft. lbs.).
4. Remove the tape or plugs from the compressor ports and the refrigerant line fittings.
5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant 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 discharge line (5) and the A/C suction line (6) to the A/C compressor (3).
7. Install the nuts (4) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 20 N.m (15 ft. lbs.).
8. Connect the engine wire harness (1) to the clutch coil or compressor control valve (2), depending on application.
9. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
10. Install the splash shield onto the right side frame rail. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-485483-S00528336772012071300000) .
11. Lower the vehicle.
12. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system when equipped with the Denso 6SEU16 variable displacement compressor. Failure to follow this caution will result in serious A/C compressor damage.
13. Evacuate and charge the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .

Note. Typical A/C compressor and clutch assembly shown in illustrations.

Scheme 96

1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor.
2. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) or equivalent (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the A/C clutch will result.
3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
4. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) or equivalent (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.
6. Install the clutch plate (4) onto the front of the A/C compressor (5).
7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the compressor clutch coil wire lead is routed so that it is not pinched between the A/C compressor and the coil connector bracket.
9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
10. Install the compressor clutch field coil connector (1) onto the connector bracket.
11. Reinstall the A/C compressor onto the engine if removed for A/C clutch service. Refer to «COMPRESSOR, A/C, INSTALLATION»(ref-485480-S12532763762012071300000) .
12. Connect the engine wire harness to the compressor clutch field coil connector.
13. Install the accessory drive belt. Refer to «BELT, SERPENTINE, INSTALLATION»(ref-485484-S29366023502012071300000) .
14. Install the splash shield onto the right side frame rail. Refer to «SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION»(ref-485483-S00528336772012071300000) .
15. Lower the vehicle.
16. Reconnect the negative battery cable.

Scheme 97

The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state.

The A/C condenser is equipped with tapping blocks for the A/C discharge and liquid lines (2), and the integral automatic transmission cooler (3).

UPPER A/C SUCTION LINE

Note. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line.

Note. Illustration shown with front fascia removed for clarity.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
3. Raise and support the vehicle.
4. Remove the A/C accumulator. Refer to «ACCUMULATOR, REMOVAL»(ref-485480-S27511470072012071300000) .
5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2).
6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports.
8. Lower the vehicle.
9. Remove the top nut (2) that secures the heat shield (3) to the stud (1) located on the dash panel. NOTE: Two slots are provided at the bottom of the heat shield to aid in heat shield removal. Complete removal of the two bottom heat shield retaining nuts is not required.
10. Reach behind the engine and remove the two bottom nuts the that secure the heat shield to the studs located on the dash panel and remove the heat shield. Rotate and tilt the heat shield as required. NOTE: It is only necessary to position the power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the power steering fluid and engine coolant is not required.
11. Remove the power steering fluid reservoir and the engine coolant reservoir and position them out of the way.
12. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5).
13. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way.
14. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6).
15. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals.
16. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
17. Remove the A/C liquid and suction line assembly from the engine compartment.

Scheme 98

Scheme 99

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
3. Raise and support the vehicle.
4. Remove the right front wheel. Refer to «REMOVAL»(ref-485473-S40943611502012071300000) .
5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator.
6. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1).
7. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket.
8. Install plugs in, or tape over the opened suction line fitting and the accumulator port.
9. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3).
10. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket.
11. Install plugs in, or tape over the opened suction line fitting and the compressor port.
12. Remove the lower A/C suction line from the engine compartment.

1. Position the A/C liquid and suction line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 25 N.m (18 ft. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 20 N.m (15 ft. lbs.).
8. Install the power steering fluid reservoir and the engine coolant reservoir.
9. Position the heat shield (3) onto the three studs (1) located on the dash panel in the engine compartment.
10. Install the three nuts (2) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity.
11. Raise and support the vehicle.
12. Remove the tape or plugs from the liquid line fitting and the condenser port.
13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is 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.
14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 25 N.m (18 ft. lbs.).
15. Install the A/C accumulator. Refer to «ACCUMULATOR, INSTALLATION»(ref-485480-S12786991012012071300000) .
16. Lower the vehicle.
17. Reconnect the negative battery cable.
18. Evacuate the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Refer to «OIL, REFRIGERANT, STANDARD PROCEDURE»(ref-485480-S10373791782012071300000) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
20. Charge the A/C system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .

LOWER A/C SUCTION LINE

1. Position the lower A/C suction line (2) into the engine compartment.
2. Remove the tape or plugs from the suction line fitting and the compressor port.
3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is 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 lower A/C suction line to the A/C compressor (3).
5. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.).
6. Remove the tape or plugs from the suction line fitting and the accumulator port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is 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.
8. Connect the lower A/C suction line (3) to the A/C accumulator (1).
9. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 25 N.m (18 ft. lbs.).
10. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely.
11. Install the right front wheel. Refer to «INSTALLATION»(ref-485473-S08436569672012071300000) .
12. Lower the vehicle.
13. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
14. Evacuate the refrigerant system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .
15. Adjust the refrigerant oil level. Refer to «OIL, REFRIGERANT, STANDARD PROCEDURE»(ref-485480-S10373791782012071300000) .
16. Charge the A/C system. Refer to «PLUMBING, STANDARD PROCEDURE»(ref-485480-S27112582802012071300000) .

STANDARD PROCEDURE - 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 A/C 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 amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions.

It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended 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 an A/C accumulator, A/C evaporator or A/C condenser is replaced. Refer to REFRIGERANT OIL CAPACITIES .

The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. Refer to COMPRESSOR OIL DRAIN PROCEDURE - DENSO 6SEU16 VARIABLE DISPLACEMENT or COMPRESSOR OIL DRAIN PROCEDURE - DENSO 10SR18 FIXED DISPLACEMENT .

REFRIGERANT OIL CAPACITIES