HVAC Systems: Other Dodge Caravan IV

HEATER AND AIR CONDITIONER

A manually controlled single zone type heating-air conditioning system, manually controlled dual zone type heating-air conditioning system, manually controlled three zone type heating-air conditioning system or an automatic controlled three zone type heating-air conditioning system 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 74) The system combines air conditioning, heating, and ventilating capabilities in a single unit housing mounted within the passenger compartment under the instrument panel. The HVAC housing includes

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

Scheme 74

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 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 unit housing, it is further directed through molded plastic ducts to the various outlets in the vehicle interior. These outlets and their locations are as follows

1. Defroster Outlet - A single large defroster outlet is located in the center of the instrument panel top cover, near the base of the windshield.
2. Side Window Demister Outlets - There are two side window demister outlets, one is located at each outboard end of the instrument panel, near the A-pillars.
3. Panel Outlets - There are five panel outlets in the instrument panel, one located near each outboard end of the instrument panel facing the rear of the vehicle and three 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 center of the floor panel near the dash panel.

MANUAL SINGLE ZONE

The manual single zone heating and A/C system allows one temperature setting for the entire vehicle. The full range of temperatures that the system can produce are available by rotating the temperature control located on the A/C-heater control.

The A/C-heater control and integral computer is located in the instrument panel and contains

1. a rear window defogger on/off switch. Contains an LED that illuminates to show when the function is operational.
2. an air recirculation on/off switch. The Recirculate button contains an LED that illuminates to show when the function is in operation.
3. an air conditioning on/off switch. The Snowflake button contains an LED that illuminates to shown when the function is in operation.
4. a rotary knob for fan speed selection and turning the heater-A/C system off.
5. a rotary knob for temperature control of the discharged air.
6. a rotary knob for mode control.

MANUAL DUAL ZONE

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

The A/C-heater control and integral computer is located in the instrument panel and contains

1. a rear window defogger on/off switch. Contains an LED that illuminates to show when the function is operational.
2. slide 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 positioning the slide controls on the instrument panel.
3. an air recirculation on/off switch. The Recirculate button contains an LED that illuminates to show when the function is in operation.
4. an air conditioning on/off switch. The Snowflake button contains an LED that illuminates to shown when the function is in operation.
5. a rotary knob for fan speed selection and turning the heater-A/C system off.
6. a rotary knob for mode control.

MANUAL THREE ZONE

The fully adjustable manual three zone front and rear heating and A/C system allows intermediate seat passengers the ability to regulate air temperature as well as fan speed and provides floor outlets to the rear of the right sliding door and overhead outlets at each rear outboard seating position. Primary control for the rear blower is on the front A/C-heater control. All controls are identified by ISO graphic symbols.

FRONT CONTROL PANEL

The front A/C-heater control and integral computer mounted in the instrument panel contains

1. a rear window defogger on/off switch.
2. slide controls for completely independent side-to-side temperature control of the discharge air. The full range of temperature that the system can produce in any mode is available on either side of the vehicle by independently positioning the slide controls on the instrument panel.
3. an air recirculation button. The Recirculate button contains an LED that illuminates to show when the function is in operation.
4. an air conditioning button that allows the compressor to be turned on/off. The Snowflake button contains an LED that illuminates to shown when the function is in operation.
5. a rotary knob for front fan speed selection and turning the heater-A/C system off.
6. a rotary knob for rear fan speed selection.
7. a rotary knob for mode control.

REAR CONTROL PANEL

The rear A/C-heater control centrally mounted in the headliner allows intermediate seat passengers to adjust rear air distribution, temperature and blower motor speed when the center knob on the front A/C-heater control is set to the Rear position. The rear A/C-heater control contains

1. a rotary adjustment knob for temperature.
2. a rotary adjustment for fan speed control.

AUTOMATIC TEMPERATURE CONTROL (ATC)

Two different automatic temperature control (ATC) heating-A/C systems are available for this model depending on the market.

The Dual-Zone ATC system allows the driver and front occupants to each select individual comfort temperatures.

The Three-Zone ATC system allows both the driver and front occupants and the rear intermediate occupants to select individual comfort temperatures.

Note. Individual comfort temperatures are the perceived temperature level at the individual seating areas, NOT the actual passenger compartment air temperature.

The ATC system includes a particulate air filter. The 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 filter element.

The ATC computer utilizes integrated circuitry and information carried on the programmable communications interface (PCI) data bus network to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the ATC computer allow it to control electronic functions and features of the ATC system. The inputs to the ATC computer are

1. Vehicle Speed/Engine RPM - The ATC computer monitors engine rpm, vehicle speed and manifold absolute pressure information from the powertrain control module (PCM).
2. Coolant Temperature - ATC computer monitors coolant temperature received from the PCM and converts it to degrees Fahrenheit.
3. Ambient Temperature - ATC computer monitors ambient temperature from the compass mini trip computer (CMTC) and converts it to degrees Fahrenheit.
4. Engine Miscellaneous Sensor Status - ATC computer monitors A/C disable information from the PCM.
5. Refrigerant Pressure - ATC computer monitors barometric pressure, intake air temperature, high side pressure and methanol content as broadcast by the PCM.
6. Door Ajar Status - The ATC computer monitors driver front door, passenger front door, left rear door, right rear door and liftgate ajar information, as identified by the body control module (BCM), to determine if all in-car temperatures should be maintained.
7. Dimming - The ATC computer monitors dimming status from the BCM to determine the required level of brightness and will dim accordingly.
8. Vehicle Odometer - The ATC computer monitors the vehicle odometer information from the BCM to prevent flashing the vacuum-flourescent (VF) digital display icons if the manual motor calibration or manual cool down tests have failed. Flashing of the display icons will cease when the vehicle odometer is greater than 3 miles.
9. English/Metric - The ATC computer monitors the English/Metric information broadcast by the CMTC. The set temp displays for both the front and rear control heads will be set accordingly.
10. Vehicle Identification Number - The ATC computer monitors the last eight characters of the VIN broadcast by the PCM and compares it to the information stored in EEPROM. If it is different, the new number will be stored over the old one and a motor calibration shall be initiated.
11. A/C System Information - The ATC computer will send a message for evaporator temperature too low, fan blower relay status, evaporator sensor failure, rear window defogger relay and A/C select.

The front A/C-heater control and integral computer is mounted in the instrument panel and contains

1. a power button which allows the system to be completely turned off. The display is blank when the system is off.
2. a rocker switch that selects a cool-down rate. LO-AUTO or HI-AUTO are displayed when the system is in automatic operation.
3. three rocker switches that select comfort temperatures from 15° to 30° C (59° to 85° F), which are shown in the VF digital display. If the set temp is 15° C (59° F) and the down button is pressed, the set temp value will become 13° C (55° F) but the display will show LO. If the set temp is 29° C (85° F) and the up button is pressed, the set temp value will become 32° C (90° F) but the display will show HIGH. Temperatures can be displayed in either metric or Fahrenheit, which is controlled from the overhead console.
4. an air conditioning button that allows the compressor to be turned off. A Snowflake symbol is illuminated when air conditioning is on, whether under manual or automatic control.
5. an air recirculation button. A Recirculation symbol appears in the display when the button is pressed, or when the system exceeds 80 percent recirculated air under automatic control due to high air conditioning demand.
6. a rear window defogger on/off switch. A graphic symbol shows when the defroster is on.
7. a rotary knob for front fan speed selection can override the automatic controls. LEDs surrounding the knob show the current setting.
8. a rotary knob for control of the rear system (Three-Zone ATC system only).
9. a rotary knob for mode control can override the automatic controls. LEDs surrounding the knob show the current setting.
10. computer logic which remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the system is off when the ignition is turned off it will be off when the engine is restarted, etc.
11. computer logic which provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally accompanied by increased fan noise, the proportion of recirculated to outside air gradually approaches full recirculation over a broad temperature range.
12. computer logic which enables additional heat for diesel equipped vehicles by using a supplemental engine coolant heater.

The Three-Zone ATC system utilizes a rear control panel centrally mounted on the headliner which includes a VF digital display, a rocker control for temperature and rotary controls for adjustment of mode and fan speed of the rear heating-A/C system by intermediate seat passengers.

The heating and air conditioning systems pulls outside (ambient) air through the cowl opening at the base of the windshield and into the plenum chamber above the heating, ventilation and air conditioning (HVAC) housing, then through the evaporator coil. Air flow can be directed either through or around the heater core by adjusting the blend door with the temperature control knob on the A/C-heater control located on instrument panel. The air flow can then be directed out from the panel, floor and defrost outlets in various combinations using the mode control knob located on the A/C-heater control. Air flow velocity can be adjusted with the blower speed selector located on the A/C-heater control.

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 heater and air conditioning system is a blend-air type system. In a blend-air system, a blend door controls the amount of conditioned air that is allowed to flow through, or around, the heater core. The temperature control knob determines the discharge air temperature by actuating an electric motor, which operates the blend door. This allows an almost immediate control of the output air temperature of the system.

On all models, the outside air intake can be shut off by pressing the Recirculation button on the A/C-heater control. This will operate a electric actuated recirculation air door that closes off the outside fresh air intake and recirculates the air that is already inside the vehicle.

The air conditioning 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 knob on the A/C-heater control is used to also direct the conditioned air to the selected system outlets. The mode control switch uses an electric motor to control the mode doors.

1. The temperature control knob enables 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.

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.

1. Primary control of the rear heater-A/C system is on the instrument panel. This control allows the driver to set the rear compartment fan speed, to turn the rear heater-A/C system off, or to give control to the intermediate seat occupants by switching to the Rear position. When the rear heater-A/C system is controlled from the instrument panel, rear air temperature is based on the driver-side temperature control position, and the mode (floor or overhead air) is based on the front control's mode position.
2. The mode control knob enables continuously variable proportioning of air flow between modes but has detents adjacent to each icon.
3. The blower control provides four separate speeds and an Off position. When the heater-A/C system is off, the HVAC computer closes the recirculation door to prevent outside air from entering the passenger compartment.
4. 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 control panel.
5. 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.
6. Air conditioning is available in any mode by pressing the snowflake, A/C on/off, button.

With the rear control active, temperature selection dictates the air distribution mode (floor or overhead air) of the rear unit: a cool temperature setting directs flow to the overhead outlets and a warm temperature setting to the floor.

Comfort temperature or perceived temperature is affected by air flow, sun levels on exposed skin, etc. The air temperature may be higher or lower than the comfort temperature. The automatic temperature control (ATC) system uses two infrared sensors in the instrument panel center stack to measure the temperature of the front occupants in order determine their comfort level relative to their selected comfort temperature. The integral HVAC computer adjusts temperature and air flow rates to maintain the customer-perceived comfort temperatures. The air temperature in the passenger compartment may be slightly higher or lower than the comfort temperature at any time. For instance, on sunny summer days the air flow will probably be cooler than the comfort temperature; on cold or cloudy days and at night it will probably be slightly warmer.

The Three-Zone ATC system uses the infrared sensors located in the instrument panel center stack along with an offset calibration strategy to meet the comfort requirements of the rear seat occupants.

1. AUTO HI/LO - This system features two sets of automatic control logic that allow either a rapid cool-down rate or a somewhat slower cool-down rate with less fan noise. HI-AUTO controls the system to reach its assigned temperature quickly with a higher fan speed. LO-AUTO controls the system to reach its assigned temperature somewhat slower with less fan noise. Both modes will automatically engage auto recirculation.
2. DEFROST - The defrost function must be manually selected to direct air flow to the windshield to remove fog or ice. The ATC system cannot automatically sense the presence of fog or ice on the windshield.
3. RECIRC - The RECIRC button will close the air inlet door. If the system is in auto recirc (indicator being displayed automatically), pressing the manual recirc button will disable the auto recirc function until one of the auto keys are pressed or the ignition is cycled. If Auto HI/LO is pressed while manual recirc is active, manual recirc will be deactivated.
4. REAR WINDOW DEFOGGER - Pushing the button sends a PCI bus message to the intelligent power module which controls the rear window defogger and side view mirror (if equipped) circuitry. The defogger function will be active for 10 minutes and can be turned off by a switch press. The defogger will function while the control is in the ON mode.
5. FAN/MODE - The Fan and Mode knobs have 17 manual selectable positions. Manually changing either of the rotary knobs for mode or fan speed settings makes control of that blower motor manual. If only one is changed manually, the other remains under automatic control. Pressing the HI-AUTO/LO-AUTO rocker switch restores full automatic control.
6. BLOWER DELAY TIMER - The word DELAY is displayed at start-up to signify that the system is waiting so that cold air will not be blowing. This tells the operator that it is unnecessary to turn the system off, raise the temperature setting or turn the fan speed setting down to prevent cold air from blowing. A countdown in minutes and seconds until the engine is warm enough to begin delivering heat to the passengers alternates with the DELAY message at 25 second intervals. This countdown is based on actual measurement of the rate of engine coolant temperature change. During the delay time, mix mode is selected and the fan operates at a low speed to keep the windshield fog free.
7. REAR CONTROL (Three-Zone only) - When the Rear System control knob is moved to the OFF position, there will be a delay of approximately 1 second before the system actually turns off. This delay is to prevent an undesired blower dropout if the knob is moved through OFF to the other selections.

REAR CONTROL PANEL - THREE ZONE ATC SYSTEM

Primary control of the rear compartment heating-A/C system for the Three-Zone ATC system is in the instrument panel center stack. This control allows the driver to turn the rear heating-A/C system off, or allows the intermediate seat occupants control of the rear system by switching to the REAR position, or provides fully automatic control based on the temperature setting shown on the front control display.

1. REAR CONTROL - Selecting automatic control of the rear unit at the instrument panel, illuminates a Locked Padlock in the rear control panel display. Selecting REAR activates the rear control panel and the Padlock then appears unlocked.
2. FAN KNOB - The rear fan control has Off and AUTO positions and a range of manual speed settings that override the AUTO setting.
3. MODE KNOB - The mode control allows intermediate seat occupants to manually override the automatic mode and select any balance of air flow between overhead and floor outlets from full overhead to full floor.
4. SET TEMP - The rear set temp control will operate identical to the front controls. If the front control rear set temp button is pressed simultaneously with the rear control head, then the front control head press events shall have priority, i.e. if the front user presses Rear Set Temp down and the rear user presses Set Temp up, then the rear set temp will decrease.

MANUAL TEMPERATURE CONTROL

The front blower speed and rear blower speed (if equipped with rear HVAC) 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 Rear Wipe/Wash buttons simultaneously and holding them depressed for no less than five seconds. The Rear Wipe/Wash and A/C 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 ATC 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 -6° 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 13 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 knob 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 75

Snap Ring Pliers C-4574 are required to service the A/C clutch and field coil. (Scheme 75)

A/C COMPRESSOR CLUTCH COIL

The air conditioning compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) through the A/C compressor clutch relay, which is located in the integrated power module (IPM) in the engine compartment. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.

PRELIMINARY CHECKS

1. If the compressor clutch will not engage, verify the refrigerant charge level (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ). 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 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 step «TESTS»(ref-248916-S42761652562007022700000) . If not OK, refer to «BODY DIAGNOSTIC PROCEDURES»(ref-247598) to perform further diagnosis.

TESTS

1. Verify the battery state of charge «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - DIAGNOSIS AND TESTING)»(ref-248889-S13166259612007022700000) .
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-247598) to perform further diagnosis.
5. For the acceptable A/C clutch coil current draw specifications (Refer to «SPECIFICATIONS»(ref-248916-S15061380952007022700000) ). 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 the appropriate diagnostic 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 appropriate SYSTEM WIRING DIAGRAMS article. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.

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-248916-S03250295052007022700000) .
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.

RG MODELS

1. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner housing from the right side of the engine compartment.
3. Remove the windshield wiper assembly from the vehicle «(Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - REMOVAL)»(ref-248907-S09353424492007022700000).
4. If equipped with rear A/C, disconnect the liquid and suction lines from the A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/LIQUID LINE - REMOVAL)»(ref-248916-S16876865162007022700000).
5. Remove the retainer that secures the evaporator temperature sensor to the A/C expansion valve. (Scheme 76) NOTE: To disconnect the wire harness connector from the evaporator temperature sensor, first push the red retaining ring toward the connector to release the lock, then disconnect the connector from the sensor.
6. Remove the evaporator temperature sensor from the A/C expansion valve and disconnect the wire harness connector.

Scheme 76

RS MODELS

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel from the vehicle «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(ref-248887-S33941485712007022700000).
3. Disconnect the wire harness connector from the evaporator temperature sensor located on the top of the HVAC housing. (Scheme 77)
4. Remove the evaporator temperature sensor from the HVAC housing.

Scheme 77

Note. Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance.

1. Position the evaporator temperature sensor into the right rear corner of the engine compartment. NOTE: To connect the wire harness connector to the evaporator temperature sensor, first connect the connector to the sensor, then pull the red retaining ring toward the sensor.
2. Connect the wire harness connector to the evaporator temperature sensor.
3. Install the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve.
4. Install the temperature sensor retainer.
5. If equipped with rear A/C, connect the liquid and suction lines to the A/C expansion valve and recharge the A/C system «(Refer to HEATING & AIR CONDITIONING/PLUMBING/LIQUID LINE - INSTALLATION)»(ref-248916-S23442668262007022700000) .
6. Install the window wiper module «(Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE - INSTALLATION)»(ref-248907-S04338959212007022700000) .
7. Install the air cleaner housing into the right side of the engine compartment.
8. Reconnect the negative battery cable.
9. Run the HVAC Cool Down test to verify system is operating properly «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C COOLDOWN TEST)»(ref-248916-S17371574102007022700000) .

1. Install the evaporator temperature sensor into the top of the HVAC housing.
2. Connect the wire harness connector to the evaporator temperature sensor.
3. Install the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION)»(ref-248887-S06036673222007022700000) .
4. Reconnect the negative battery cable.

REAR BLOWER MOTOR RESISTOR

Note. For circuit descriptions and diagrams, refer to appropriate SYSTEM WIRING DIAGRAMS article. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds.

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-REAR/BLOWER MOTOR RESISTOR - REMOVAL)»(ref-248916-S03250295052007022700000) .
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.

DEMISTER OUTLETS

1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the outer perimeter of the demister outlet to the instrument panel top pad and remove the outlet. (Scheme 78)

Scheme 78

CENTER BEZEL OUTLETS

Note. Take the proper precautions to protect the front face of the instrument panel center bezel from cosmetic damage during this service procedure.

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel from the instrument panel and place it on a workbench «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL)»(ref-248887-S29709799012007022700000).
3. If the vehicle is equipped with the automatic temperature control (ATC) heating-A/C system, disconnect the infrared temperature sensor jumper harness from the infrared temperature sensor located at the bottom of the middle outlet. (Scheme 79)
4. Remove the three screws that secure the bottom of the center bezel outlet housing to the center bezel and disengage the retaining tabs at the top of the housing.
5. Remove the center bezel outlets and housing from the center bezel as an assembly.

Scheme 79

INSTRUMENT PANEL OUTLETS

1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the outer perimeter of the instrument panel outlet to the instrument panel top pad and remove the outlet. (Scheme 80)

Scheme 80

1. Position the demister outlet to the instrument panel top pad.
2. Using hand pressure, install the demister outlet firmly and evenly into the instrument panel top pad until the retaining tabs fully engage.

1. Position the center bezel outlets and housing assembly onto the back of the instrument panel center bezel and engage the retaining tabs to the top of the bezel.
2. Install the bottom of the outlet housing to the center bezel and install the three retaining screws. Tighten the screws to 2 N.m (17 in. lbs.).
3. If the vehicle is equipped with the ATC heating-A/C system, connect the infrared temperature sensor jumper harness to the infrared temperature sensor located at the bottom of the center outlet.
4. Install the center bezel onto the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION)»(ref-248887-S18476627072007022700000) .
5. Reconnect the battery negative cable.

1. Position the instrument panel outlet to the instrument panel top pad.
2. Using hand pressure, install the instrument panel outlet firmly and evenly into the instrument panel top pad until the retaining tabs fully engage.

BLOWER MOTOR

For circuit descriptions and diagrams, refer to appropriate SYSTEM WIRING DIAGRAMS article. 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.

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

Scheme 81

1. Remove the HVAC housing from the vehicle and place it on a workbench «HVAC HOUSING»(ref-248916-S30634273192007022700000).
2. Disconnect the HVAC wire harness connectors from the mode door actuator and the blend door actuator(s) located on the driver side of the air distribution housing and position the HVAC wire harness out of the way. see scheme 57 1 - WIRE HARNESS CONNECTOR 2 - MODE DOOR ACTUATOR 3 - SCREW (2) 4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE) 5 - HEATER CORE 6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER BLEND DOOR ACTUATOR (DUAL-ZONE)
3. Remove the foam seal from the heater core tubes and the flange located at the front of the HVAC housing. (Scheme 81) 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 82)
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-248916-S10555908352007022700000).

Scheme 82

AIR INLET HOUSING

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

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

1. Remove the HVAC housing assembly «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
2. Remove the recirculation door actuator. see scheme 60«(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/RECIRCULATION DOOR ACTUATOR - REMOVAL)»(ref-248916-S36364959232007022700000).
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 53
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 83) 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 83

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.

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

Scheme 84

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
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 - FRONT/LIQUID LINE - REMOVAL)»(ref-248916-S16876865162007022700000).
5. Disconnect the heater hoses from the heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER INLET HOSE - REMOVAL)»(ref-248916-S20761806192007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER RETURN HOSE - REMOVAL)»(ref-248916-S25534350792007022700000).
6. Remove the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. (Scheme 84) 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-248887-S33941485712007022700000).
8. Remove the nut and bolt that secure the HVAC housing to the passenger compartment side of the dash panel. (Scheme 85)
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-248916-S10555908352007022700000).

Scheme 85

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

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

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

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-248916-S05946612392007022700000).
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 86)
3. Remove the screws that secure the mode door actuator and the blend door actuator(s) 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 (if equipped) and the passenger side blend door stop from the driver side of the air distribution housing. (Scheme 87) 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 88) 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 89)
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. If equipped with dual zone heating -A/C system, push down on the retaining tab of the driver side blend door gear and carefully pull the gear out of the blend door pivot shaft. (Scheme 90) 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 91) 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 92) 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 92

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.

1. Remove the HVAC housing from the vehicle and place it on a workbench «HVAC HOUSING»(ref-248916-S30634273192007022700000).
2. Remove the air distribution housing from the HVAC housing. see scheme 72«(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
3. Remove the air inlet housing from the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR INLET HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000). 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 - FRONT/A/C EXPANSION VALVE - REMOVAL)»(ref-248916-S36365874302007022700000).
5. Disconnect the HVAC wiring harness from the blower motor resistor or power module (depending on application). (Scheme 93)
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 93

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. If equipped with dual zone heating-A/C system, 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 (if equipped), 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-248916-S39888388142007022700000) .

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. 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 - FRONT/A/C EXPANSION VALVE - INSTALLATION)»(ref-248916-S18738607262007022700000) .
11. Install the air inlet housing onto the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR INLET HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .
12. Install the air distribution housing onto the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - AIR DISTRIBUTION HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .
13. Install the HVAC housing into the vehicle «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

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 blend door actuator(s) 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-248916-S39888388142007022700000) .

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-248916-S33536297962007022700000) .
12. Install the HVAC housing assembly «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - FRONT/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

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-248887-S06036673222007022700000) .
6. Connect the heater hoses to the heater core «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER INLET HOSE - INSTALLATION)»(ref-248916-S28977550362007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER RETURN HOSE - INSTALLATION)»(ref-248916-S28041916792007022700000) .
7. Connect the suction and liquid lines to the A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/LIQUID LINE - INSTALLATION)»(ref-248916-S23442668262007022700000) .
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-248908-S09724997062007022700000) .
10. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .
11. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
12. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).
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-248916-S29538611692007022700000) .

WARNINGS

CAUTIONS

REFRIGERANT SYSTEM LEAKS

If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a (Refer to REFRIGERANT SYSTEM CHARGE ). If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location.

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

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.) (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure.
2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the system.
3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).
4. Proceed to «SYSTEM LOW»(ref-248916-S34054539542007022700000) 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 for five minutes with the system set to the following: Transaxle in Park Engine idling Rear A/C Off (if equipped) A/C controls set to 100 percent outside air Blower switch in the highest speed position A/C in the On position Front windows open CAUTION: A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134a refrigerant system.
3. Shut off the vehicle and wait 2 to 7 minutes. Then use an electronic leak detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct. A R-134a dye is available to aid in leak detection, use only DaimlerChrysler approved refrigerant dye.

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 94) 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 94

MANIFOLD GAUGE SET

A manifold gauge set may be needed with some recovery/recycling/charging equipment. 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 95)

Scheme 95

MANIFOLD GAUGE SET CONNECTIONS

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

REFRIGERANT SYSTEM RECOVERY

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 A/C compressor.

If a 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 refrigerant system.

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the air conditioner and damage the 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 - FRONT - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY)»(ref-248916-S22929154532007022700000) .
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 in 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 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 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 - FRONT - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE)»(ref-248916-S22929154532007022700000) .

REFRIGERANT SYSTEM CHARGE

Note. Always refer to the underhood HVAC 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, refer to the underhood HVAC Specification Label. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. 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-248916-S20782921882007022700000) ).
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 refrigerant system.
3. Measure the proper amount of 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 heater-air conditioner controls so that the 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 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 system performance. (Refer to «A/C PERFORMANCE TEST»(ref-248916-S04360343472007022700000) ).
9. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
10. Reinstall the caps onto the refrigerant system service ports.
11. Run the HVAC Control Cooldown test to verify proper operation «(Refer to HEATING & AIR CONDITIONING - DIAGNOSIS AND TESTING - A/C COOLDOWN TEST)»(ref-248916-S17371574102007022700000) .

A/C COMPRESSOR

Vehicles equipped with the 2.4L gasoline, 2.5L diesel, 2.8L diesel and 3.3L gasoline engines with the front heating-A/C system only, use the Denso 10S17 A/C compressor. Vehicles equipped with the 3.3L and the 3.8L gasoline engines with the optional rear heating-A/C system use the Denso 10S20 A/C compressor. Both A/C compressors include an integral high pressure relief valve. The A/C compressor is secured to a mounting bracket on the 2.4L, 2.5L and 2.8L engines and, directly to the cylinder block on the 3.3L and 3.8L engines. (Scheme 96)

Scheme 96

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.

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.

Scheme 97

Scheme 98

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Disconnect and isolate the negative battery cable.
3. Raise and support the vehicle.
4. On models equipped with the 2.5L and 2.8L diesel engines, remove the belly pan from underneath the engine compartment.
5. Remove the accessory drive belt(s) (Refer to «ACCESSORY DRIVE»(ref-248908-S07585227412007030500000) ).
6. Remove the nuts that secure the A/C suction line and the A/C discharge line to the A/C compressor.
7. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-rings seal and gaskets.
8. Install plugs in, or tape over the opened suction and discharge line fittings and the compressor ports.
9. Disconnect the engine wire harness connector from the A/C clutch coil connector. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector from the bracket located the top of the A/C compressor. (Scheme 97)
10. On models with the 2.4L, 2.5L and 2.8L engine, remove the four bolts that secure the A/C compressor to the A/C compressor mounting bracket. 1 - A/C CLUTCH COIL CONNECTOR 2 - DISCHARGE PORT 3 - A/C COMPRESSOR 4 - SUCTION PORT 5 - BOLT (4) 6 - A/C COMPRESSOR MOUNTING BRACKET
11. On models with the 3.3L and 3.8L engine, remove the two bolts and two nuts that secure the A/C compressor to the engine. (Scheme 98)1 - A/C COMPRESSOR 2 - BOLT (2) 3 - NUT (2) NOTE: If a replacement A/C compressor is being installed, be certain to drain and measure the refrigerant oil contained in the old compressor. This will determine how much refrigerant oil the replacement A/C compressor must contain before it is installed «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL)»(ref-248916-S37111703592007022700000). NOTE: The receiver/drier should always be replaced when the A/C compressor is replaced. This will help remove any contaminants including moisture from the system.
12. Remove the A/C compressor from the engine compartment.

A/C COMPRESSOR MOUNTING BRACKET-2.4L/2.5L/2.8L ENGINES

1. Remove the A/C compressor from the mounting bracket «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C COMPRESSOR - REMOVAL)»(ref-248916-S03528684072007022700000).
2. Remove the bolts that secure the A/C compressor mounting bracket to the engine and remove the bracket. (Scheme 99)

Scheme 99

Note. If a replacement A/C compressor is being installed, be certain to check the refrigerant oil level (Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. Position the A/C compressor into the engine compartment.
2. On models with the 2.4L, 2.5L and 2.8L engine, loosely install the four bolts that secure the A/C compressor to the A/C compressor mounting bracket. Tighten the bolts to 28 N.m (21 ft. lbs.).
3. On models with the 3.3L and 3.8L engines, loosely install the two bolts and the two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) using the following sequence: upper nut at the front of the compressor. lower nut at the front of the compressor. upper bolt at the rear of the compressor. lower bolt at the rear of the compressor.
4. Connect the engine wire harness connector to the A/C clutch coil connector. On models equipped with the 3.3L and 3.8L engines, engage the engine wire harness connector to the bracket located at the top of the A/C compressor.
5. Remove the tape or plugs from the suction and discharge line fittings and the compressor ports.
6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the A/C suction and discharge line.
7. Connect the A/C suction and discharge lines to the A/C compressor.
8. Install the nut that secures the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
9. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-248908-S07585227412007030500000) ).
10. Lower the vehicle.
11. Reconnect the negative battery cable.
12. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
13. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

1. Position the A/C compressor mounting bracket onto the engine.
2. Install the bolts that secure the A/C compressor mounting bracket to the engine. Tighten the bolts to 54 N.m (40 ft. lbs.).
3. Install the A/C compressor onto the mounting bracket «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C COMPRESSOR - INSTALLATION)»(ref-248916-S03009629852007022700000) .

2.4L/3.3L/3.8L ENGINES

Note. Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Remove the front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-248897-S42718852262007022700000). NOTE: It is not necessary to remove the quick-connect fittings from the transmission oil cooler tapping block when disconnecting the transmission oil cooler lines from the cooler.
3. Disconnect the transmission oil cooler lines from the quick-connect fittings located on the transmission oil cooler tapping block on the left side of the A/C condenser (combination cooler) «(Refer to COOLING/TRANSMISSION - STANDARD PROCEDURE - TRANSMISSION COOLING)»(ref-248908-S36373889412007022700000). see scheme 91 1 - A/C CONDENSER (COMBINATION COOLER) 2 - AUTO TRANS COOLER TAPPING BLOCK 3 - UPPER CONDENSER MOUNTING BRACKET (2) 4 - RADIATOR 5 - LOWER CONDENSER MOUNTING BRACKET (2)
4. Disconnect the A/C discharge line and the A/C liquid line from the right side of the A/C condenser «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C DISCHARGE LINE - REMOVAL)»(ref-248916-S17588610472007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C LIQUID LINE - REMOVAL)»(ref-248916-S16876865162007022700000). (Scheme 100)
5. Install plugs in, or tape over the opened A/C discharge and liquid line fittings and the condenser ports.
6. Disengage the retaining clips that secure the upper A/C condenser mounting brackets to the radiator.
7. Lift the A/C condenser (combination cooler) straight up to disengage the lower mounting brackets from the radiator and carefully remove the condenser from the engine compartment.

Scheme 100

2.5L/2.8L ENGINES

Note. Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Remove the front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL)»(ref-248897-S42718852262007022700000).
3. Disconnect the A/C discharge line and the A/C liquid line from the A/C condenser. (Scheme 101)«(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C DISCHARGE LINE - REMOVAL)»(ref-248916-S17588610472007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C LIQUID LINE - REMOVAL)»(ref-248916-S16876865162007022700000).
4. Install plugs in, or tape over the opened A/C discharge and liquid line fittings and the condenser ports.
5. Remove the three screws that secure the automatic transmission fluid cooler to the A/C condenser and position the cooler out of the way.
6. Remove the three bolts that secure the A/C condenser to the cooling module.
7. Lift the A/C condenser far enough to disengage the condenser from the lower right mounting bracket and remove the condenser from the engine compartment.

Scheme 101

Note. If the A/C condenser is being replaced, add 50 milliliters (1.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

Note. Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required for proper A/C and engine cooling system operation.

1. Position the A/C condenser (combination cooler) into the engine compartment.
2. Carefully lower the A/C condenser straight down to engage the lower mounting brackets to the radiator.
3. Engage the upper A/C condenser mounting brackets to the radiator. Be sure that the upper retaining clips are fully engaged to the upper mounting brackets.
4. Remove the tape or plugs from the opened refrigerant line fittings and the condenser ports.
5. Connect the A/C discharge line and the A/C liquid line to the A/C condenser «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C DISCHARGE LINE - INSTALLATION)»(ref-248916-S01241436232007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C LIQUID LINE - INSTALLATION)»(ref-248916-S23442668262007022700000) .
6. Connect the transmission oil cooler lines to the quick-connect fittings located on the transmission cooler tapping block. Be sure that the quick-connect fittings are fully engaged to the lines «(Refer to COOLING/TRANSMISSION - STANDARD PROCEDURE - TRANSMISSION COOLING)»(ref-248908-S36373889412007022700000) .
7. Install the front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-248897-S22452715182007022700000) .
8. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
9. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

2.5L/2.8L DIESEL ENGINES

Note. If the A/C condenser is being replaced, add 50 milliliters (1.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

Note. Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required for proper A/C and engine cooling system operation.

1. Position the A/C condenser onto the engine compartment.
2. Carefully lower the A/C condenser straight down into the lower right mounting bracket.
3. Install the three bolts that secure the A/C condenser to the cooling module. Tighten the bolts to 5 N.m (45 in. lbs.).
4. Position the automatic transmission fluid cooler onto the A/C condenser and install the three screws. Tighten the screws securely.
5. Remove the tape or plugs from the opened A/C discharge and liquid line fittings and the condenser ports.
6. Connect the A/C discharge line and the A/C liquid line to the A/C condenser «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C DISCHARGE LINE - INSTALLATION)»(ref-248916-S01241436232007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/A/C LIQUID LINE - INSTALLATION)»(ref-248916-S23442668262007022700000) .
7. Install the front fascia «(Refer to FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION)»(ref-248897-S22452715182007022700000) .
8. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
9. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

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-248916-S17371574102007022700000) .

FRONT HEATER CORE TUBES

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
2. Disconnect and isolate the negative battery cable.
3. Disconnect the heater hoses from the heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER INLET HOSE - REMOVAL)»(ref-248916-S20761806192007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER RETURN HOSE - REMOVAL)»(ref-248916-S25534350792007022700000).
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 screw that secures the heater core tube sealing plate to the heater core. (Scheme 102)
6. Push both heater core tubes simultaneously toward the dash panel and disengage the tubes from the heater core.
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 102

FRONT 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 «REMOVAL»(ref-248898-S16916630902007022700000) ).
3. Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm (Refer to «BRAKES - ABS»(ref-248888) ).
4. If equipped with power adjustable pedals, remove the adjustable pedal assembly. See «PEDALS - ADJUSTABLE»(ref-248913-S27818009492007022700000).
5. Remove the heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER CORE - HEATER CORE TUBES - REMOVAL)»(ref-248916-S15745100902007022700000).
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. (Scheme 103)and (Scheme 104) for clearance, remove the heater core from the air distribution housing.

Scheme 103

Scheme 104

1. Remove the plugs or tape from both heater core tube fittings and both heater core ports.
2. Position the heater core tubes and sealing plate to the dash panel, below the instrument panel.
3. Install both heater core tubes simultaneously through the dash panel seal.
4. 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.
5. Index both heater core tubes to the heater core ports.
6. 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.).
7. Install the silencer under the driver side end of the instrument panel.
8. Connect the heater hoses to the heater hose tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER INLET HOSE - INSTALLATION)»(ref-248916-S28977550362007022700000) and «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER RETURN HOSE - INSTALLATION)»(ref-248916-S28041916792007022700000) .
9. Reconnect the negative battery cable.
10. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

1. While pushing the brake pedal downward and pulling the accelerator pedal upward for clearance, install the heater core into the HVAC air distribution housing.
2. Install the two screws that secure the heater core to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Install the heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING - FRONT/HEATER CORE - INSTALLATION)»(ref-248916-S36363649542007022700000) .
4. Connect the power brake booster input rod (push rod) to the pin on the brake pedal arm «(Refer to BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - INSTALLATION)»(ref-248913-S01591498382007022700000) .
5. Install the brake lamp switch into its mounting bracket «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP SWITCH - INSTALLATION)»(ref-248898-S41729199962007022700000) .
6. If equipped with power adjustable pedals, install the adjustable pedal assembly. See «PEDALS - ADJUSTABLE»(ref-248913-S27818009492007022700000) .
7. Install the silencer boot around the base of the lower steering shaft on the dash panel.
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-248908-S09724997062007022700000) .
10. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

FRONT SECTION

1. Recover the refrigerant from the refrigerant system. (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Disconnect and isolate the negative battery cable.
3. Remove the right headlamp unit «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - REMOVAL)»(ref-248898-S19697015862007022700000).
4. Remove the nut that secures the A/C liquid line to the right end of the A/C condenser. see scheme 110
5. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket.
6. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. 1 - A/C CONDENSER 2 - A/C DISCHARGE LINE 3 - A/C LIQUID LINE 4 - NUT (2)
7. Remove the air cleaner housing and the air inlet tube «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248909-S02114513502007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248910-S06389018822007022700000).
8. Disengage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. (Scheme 105)
9. Remove the bolt that secures the front section of the A/C liquid line to the receiver/drier.
10. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal.
11. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier inlet port.
12. Remove the front section of the A/C liquid line from the engine compartment.

Scheme 105

Scheme 106

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Disconnect and isolate the negative battery cable.
3. Remove the air cleaner housing and the air inlet tube «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248909-S02114513502007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(ref-248910-S06389018822007022700000).
4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment.
5. Remove the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER - REMOVAL)»(ref-248916-S09772137262007022700000).
6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. (Scheme 105)
7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud.
8. Remove the bolt that secures the rear section of the A/C liquid line to the receiver/drier.
9. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal.
10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier outlet port.
11. Remove the nut that secures the A/C suction line and the A/C liquid line to the A/C expansion valve.
12. Disconnect the A/C suction line and the A/C liquid line from the A/C expansion valve and remove and discard the O-ring seals.
13. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports.
14. On RHD models, remove the rear section of the A/C liquid line from the retaining bracket located at the top of the dash panel
15. If the vehicle is equipped with the optional rear heating-A/C system, go to step 16. If the vehicle is not equipped with the optional rear heating-A/C system, go to step 22.
16. Raise and support the vehicle.
17. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. (Scheme 106) 1 - SUCTION LINE EXTENSION TUBE 2 - LIQUID LINE EXTENSION TUBE 3 - RETAINING STRAP 4 - REAR HEATER EXTENSION TUBES 5 - UNDERBODY REFRIGERANT LINES
18. Disconnect the A/C liquid line extension fitting from the underbody liquid line fitting for the rear A/C system.
19. Remove the O-ring seal from the underbody liquid line fitting and discard.
20. Install plugs in, or tape over the opened liquid line fittings.
21. Lower the vehicle.
22. Remove the rear section of the A/C liquid line from the engine compartment.

1. Position the front section of the A/C liquid line into the engine compartment.
2. Remove the tape or plugs from the liquid line fitting and the receiver/drier inlet port.
3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting.
4. Connect 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 (97 in. lbs.).
6. Engage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment.
7. Install the air cleaner housing and air inlet tube «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248909-S11333827532007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248910-S12179079592007022700000) .
8. Remove the tape or plugs from the condenser outlet port and the liquid line fitting.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting.
10. Connect the A/C liquid line to the A/C condenser.
11. 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.).
12. Install the right headlamp unit «(Refer to ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT - INSTALLATION)»(ref-248898-S35521518202007022700000) .
13. Reconnect the negative battery cable.
14. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
15. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

REAR SECTION

1. Position the rear section of the A/C liquid line into the engine compartment.
2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the suction line and liquid line fittings.
4. Reconnect the A/C liquid line and the A/C suction line to the A/C expansion valve.
5. Install the nut that secures the rear section of the A/C liquid line and the A/C suction line to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Remove the tape or plugs from the liquid line fitting and the receiver/drier outlet port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
8. Reconnect the A/C liquid line to the receiver/drier.
9. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.).
10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped).
11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.).
12. Install the A/C pressure transducer «(Refer to HEATING & AIR CONDITIONING/CONTROLS - FRONT/A/C PRESSURE TRANSDUCER - INSTALLATION)»(ref-248916-S09330225442007022700000) .
13. Connect the drain tube to the wiper module drain on the right side of the engine compartment.
14. Install the air cleaner housing and air inlet tube «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248909-S11333827532007022700000) «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(ref-248910-S12179079592007022700000) .
15. On RHD models, install the liquid line into the retaining bracket located at the top of the dash panel.
16. If the vehicle is equipped with the optional rear heating-A/C system, go to step 17 . If the vehicle does not have the optional rear heating-A/C system, go to step 23 .
17. Raise and support the vehicle.
18. Remove the tape or plugs from the A/C liquid line extension fitting and the underbody liquid line fitting.
19. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line fitting.
20. Connect the A/C liquid line extension fitting to the underbody liquid line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.).
21. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system.
22. Lower the vehicle.
23. Reconnect the negative battery cable.
24. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
25. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

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 REFRIGERANT OIL CAPACITIES . 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

REAR A/C EVAPORATOR

1. Remove the rear HVAC housing from the vehicle «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
2. Remove the rear evaporator line extension from the rear A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EVAPORATOR - EVAPORATOR LINE EXTENSION - REMOVAL)»(ref-248916-S00244088092007022700000).
3. Remove the rear A/C expansion valve from the rear A/C evaporator «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EXPANSION VALVE - REMOVAL)»(ref-248916-S36365874302007022700000).
4. Remove the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the rear A/C expansion valve.
5. Remove the three screws that secure the upper half of the rear HVAC housing to the lower half. (Scheme 107)
6. Remove the three metal spring clips that secure the upper half of the rear HVAC housing to the lower half.
7. Carefully separate and remove the upper half of the rear HVAC housing from the lower half.
8. Remove the rear A/C evaporator from the lower half of the rear HVAC housing.

Scheme 107

REAR EVAPORATOR LINE EXTENSION

Scheme 108

Scheme 109

1. Remove the rear HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - REMOVAL)»(ref-248916-S05946612392007022700000).
2. Remove the screw that secures the flange to the rear HVAC housing and remove the flange. (Scheme 108) 1 - LOWER REAR HVAC HOUSING 2 - FLANGE 3 - EVAPORATOR LINE EXTENSION
3. Carefully remove the foam insulating from the bottom of the rear A/C expansion valve to gain access to the evaporator line extension sealing plate. (Scheme 109) 1 - UPPER REAR HVAC HOUSING 2 - LOWER REAR HVAC HOUSING 3 - EXPANSION VALVE BRACKET 4 - EVAPORATOR LINE EXTENSION 5 - EXPANSION VALVE STUD 6 - FOAM INSULATING
4. Remove the two screws that secure the expansion valve bracket to the lower rear HVAC housing.
5. Remove the nut that secures the expansion valve bracket to the expansion valve stud and remove the bracket
6. Remove the nut that secures the evaporator line extension seal plate to the expansion valve stud and remove the seal plate.
7. Remove the evaporator line extension from the rear A/C expansion valve and the lower rear HVAC housing.
8. Remove the seals from the evaporator line extension fittings and discard.
9. Install plugs in, or tape over the opened evaporator line extension fittings and both expansion valve ports.

Note. If the rear A/C evaporator is being replaced, add 50 milliliters (1.7 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

1. Carefully lower the rear A/C evaporator and its foam wrap into the lower half of the rear HVAC housing.
2. Position the upper half of the rear HVAC housing onto the lower half.
3. Install the three metal spring clips that secure the upper half of the rear HVAC housing to the lower half.
4. Install the three screws that secure the upper half of the rear HVAC housing to the lower half. Tighten the screws to 2 N.m (17 in. lbs.).
5. Install the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the rear A/C expansion valve.
6. Install the rear A/C expansion valve onto the rear A/C evaporator «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EXPANSION VALVE - INSTALLATION)»(ref-248916-S18738607262007022700000) .
7. Install the rear evaporator extension line onto the rear A/C expansion valve «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/A/C EVAPORATOR - EVAPORATOR EXTENSION LINE - INSTALLATION)»(ref-248916-S10343353542007022700000) .
8. Install the rear HVAC housing (Refer to «INSTALLATION»(ref-248916-S38415368852007022700000) ).

1. Remove the tape or plugs from the evaporator line extension fittings and both expansion valve ports.
2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator line extension fittings.
3. Position the evaporator line extension to the rear A/C expansion valve and the lower rear HVAC housing.
4. Position the evaporator line extension seal plate over the expansion valve stud.
5. Install the nut that secures the evaporator line extension seal plate to the expansion valve stud. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Position the expansion valve bracket over the expansion valve stud.
7. Install the two screws that secure the expansion valve bracket to the lower rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the nut that secures the expansion valve bracket to the expansion valve stud. Tighten the nut to 23 N.m (17 ft. lbs.).
9. Install the foam insulating over the rear A/C expansion valve.
10. Position the flange over the rear evaporator line extension and into the lower rear HVAC housing.
11. Install the screw that secures the flange to the rear lower HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
12. Install the rear HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION - REAR/HVAC HOUSING - INSTALLATION)»(ref-248916-S39888388142007022700000) .

REAR HEATER CORE FILLING

The rear heater core is positioned in the rear HVAC housing at a higher level than the radiator fill opening. Therefore, when the cooling system is drained and refilled, gravity will not totally refill the rear heater core. This may result in two problems

1. Insufficient coolant level in the engine cooling system, which may result in engine overheating.
2. Air entrapped within the rear heater core, which may result in insufficient rear heater performance.

There are two methods that may be employed to prevent these problems

1. Pre-filling of the rear heater core.
2. Thermal cycling of the engine cooling system.

Following are descriptions of both prevention methods, as well as a method to verify rear heater performance.

PRE-FILLING

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.

If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings.

1. The heater core should be installed in the rear HVAC housing, and the rear HVAC housing should be installed in the vehicle.
2. Insert the small end of an appropriate funnel into the upper hose fitting of the heater core. (Scheme 110)
3. Carefully pour the proper pre-mixed engine coolant solution into the rear heater core through a funnel until coolant begins to appear at the lower hose fitting of the rear heater core.
4. Connect the heater hoses to the rear heater core tubes «(Refer to HEATING & AIR CONDITIONING/PLUMBING - REAR/HEATER HOSE - INSTALLATION)»(ref-248916-S28977550362007022700000).
5. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000).

Scheme 110

THERMAL CYCLING

If the rear heater core was emptied and was not pre-filled, it will be necessary to thermal cycle the vehicle at least two times to ensure that the rear heater core is properly filled.

1. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .
2. Start the engine and allow it to operate until the thermostat opens.
3. Turn the engine off and allow it to cool.
4. With the engine cold and not running, check and top off the engine coolant level as necessary «(Refer to COOLING - STANDARD PROCEDURE - COOLANT LEVEL CHECK)»(ref-248908-S09724997062007022700000) and «(Refer to COOLING - STANDARD PROCEDURE - COOLANT - ADDING)»(ref-248908-S09724997062007022700000) .
5. Start the engine and allow it to operate until the thermostat opens again.
6. Turn the engine off and allow it to cool down again.
7. With the engine cold and not running, check and top off the engine coolant level as necessary «(Refer to COOLING - STANDARD PROCEDURE - COOLANT LEVEL CHECK)»(ref-248908-S09724997062007022700000) and «(Refer to COOLING - STANDARD PROCEDURE - COOLANT - ADDING)»(ref-248908-S09724997062007022700000) .
8. Check the performance of the rear heater. Refer to «REAR HEATER PERFORMANCE CHECK»(ref-248916-S37862001412007022700000) .

REAR HEATER PERFORMANCE CHECK

Successful completion of the rear heater performance check will confirm that the rear heater core is properly filled with engine coolant. If the check is not successful, either there is still air trapped in the rear heater core or the rear heater plumbing is restricted. This check should be performed with the vehicle in a shop where the ambient temperature is about 21° C (70° F).

1. Start the engine and allow it to idle until it warms up to normal operating temperature.
2. Adjust the A/C-heater controls so that the front heater is turned Off and the rear heater is set for full Heat with the rear blower motor at its highest speed setting.
3. Use an accurate test thermometer to measure the temperature of the air being discharged from the rear heater outlet located at the base of the right C-pillar.
4. Proper discharge air temperature readings should be from 57° to 63° C (135° to 145° F).

UNDERBODY HEATER TUBES

Scheme 111

1. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN)»(ref-248908-S09724997062007022700000).
2. Raise and support vehicle.
3. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and carefully pulling downward on the heater tube fittings. (Scheme 111)
4. Lower the underbody heater tubes and drain any residual coolant from the tubes into a suitable container. 1 - INSERT 2 - QUICK CONNECT FITTING 3 - COMPRESS INSERT FOR REMOVAL
5. Using spring tension clamp pliers, compress and slide the clamps off of the rubber hoses at the front of the underbody heater tubes. see scheme 134 CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak.
6. Disconnect the heater hoses by carefully twisting the hoses back and forth on the rear heater extension tubes, while gently pulling them away from the end of the tubes.
7. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal.
8. Remove the screws that secure the underbody line retaining straps to the vehicle underbody.
9. Remove the underbody heater tubes from the retaining straps.
10. Remove the underbody heater tubes from the vehicle.

UNDERBODY REFRIGERANT LINES

1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-248916-S34383804102007022700000) ).
2. Raise and support vehicle.
3. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way «(Refer to EXHAUST SYSTEM - DESCRIPTION)»(ref-248895-S19488205222007022700000).
4. Disconnect the underbody refrigerant lines from the front liquid and suction line extension tubes and remove and discard the O-ring seals. see scheme 135
5. Install plugs in, or tape over the opened refrigerant line fittings. 1 - SUCTION LINE EXTENSION TUBE 2 - LIQUID LINE EXTENSION TUBE 3 - RETAINING STRAP 4 - REAR HEATER EXTENSION TUBES 5 - UNDERBODY REFRIGERANT LINES
6. Remove the screws that secure the underbody line retaining straps to the vehicle underbody.
7. Remove the underbody refrigerant lines from the retaining straps.
8. Remove the bolt or nut (depending on application) that secures the underbody refrigerant lines to the rear evaporator extension line tapping plate, located behind the right rear wheel housing. see scheme 136and see scheme 137.
9. Disconnect the underbody refrigerant lines from the rear evaporator extension line tapping plate and remove and discard the O-ring seals.
10. Install plugs in, or tape over the opened underbody refrigerant line fittings and the rear evaporator extension line ports.
11. Remove the underbody refrigerant lines from the vehicle. 1 - UNDERBODY LIQUID LINE 2 - NUT 3 - SEALING PLATE 4 - UNDERBODY SUCTION LINE 5 - EXTENSION LINE TAPPING PLATE 1 - UNDERBODY LIQUID LINE 2 - BOLT 3 - EXTENSION LINE TAPPING PLATE 4 - UNDERBODY SUCTION LINE 5 - SEALING PLATE
12. If required, place the underbody refrigerant lines on a workbench, remove the nylon wedges that secure the underbody refrigerant lines to the underbody refrigerant line sealing plate and remove the lines from the sealing plate. (Scheme 112)

Scheme 112

1. Position the underbody heater tubes onto the vehicle underbody.
2. Install the underbody heater tubes into the underbody line retaining straps.
3. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely.
4. Connect the rubber hoses at the front of the underbody heater tubes to the rear heater extension tubes.
5. Using spring tension clamp pliers, compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube.
6. Connect the rear underbody heater tube quick connections to the rear heater core extension tubes.
7. Lower the vehicle.
8. Refill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL)»(ref-248908-S09724997062007022700000) .

1. If removed, install the underbody refigerant lines into the underbody refrigerant line sealing plate and install the nylon wedges that secure the refrigerant lines to the sealing plate.
2. Position the underbody refrigerant lines onto the vehicle underbody.
3. Install the underbody refrigerant lines into the underbody line retaining straps.
4. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely.
5. Remove the tape or plugs from the rear underbody refrigerant line fittings and the rear evaporator extension line ports.
6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings.
7. Connect the underbody refrigerant lines to the rear evaporator extension line tapping plate.
8. Install the bolt or nut (depending on application) that secures the underbody refrigerant line sealing plate to the rear evaporator extension line tapping plate. Tighten the bolt or nut to 23 N.m (17 ft. lbs.).
9. Remove the tape or plugs from the front liquid and suction line extension tubes and the underbody refrigerant line fittings.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings.
11. Connect the underbody refrigerant line fittings to the front liquid and suction line extension tubes. Tighten the fittings to 23 N.m (17 ft. lbs.).
12. Position the exhaust system and install it to the exhaust hanger rubber isolators «(Refer to EXHAUST SYSTEM - DESCRIPTION)»(ref-248895-S19488205222007022700000) .
13. Lower the vehicle.
14. Evacuate the refrigerant system (Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-248916-S20782921882007022700000) ).
15. Charge the refrigerant system (Refer to «REFRIGERANT SYSTEM CHARGE»(ref-248916-S19305970212007022700000) ).

MANUAL TEMPERATURE CONTROL SYSTEM

The supplemental cabin heater is activated via the temperature slide control or knob on the A/C-heater control when equipped with the manual temperature control (MTC) system. If the slide control or knob is moved to or above the upper set point the cabin heater is activated. The cabin heater can operate in a full or partial load range as well as an idle mode all dependent on the engine coolant temperature. The cabin heater will also turn off if the A/C-heater temperature control is lowered to less than the lower set point. The cabin heater can take up to three minutes to completely shut down when either the heater temperature is set below the lower set point or the vehicle ignition is shut down.

Note. Do not apply a strong vacuum source such as a garage ventilation system directly on the supplemental cabin heater exhaust line. Too strong of a vacuum can prevent the supplemental cabin heater from starting. If required, place the vacuum source at least 75 mm (3 in.) away from the exhaust line.

The supplemental cabin heater only operates when the engine is running, the mileage exceeds 8 kilometer (5 mph) and the fuel tank volume exceeds 1/8 of a tank. The supplemental heater control module monitors blower speed and combustion during its start-up. The cabin heater should operate if the coolant temperature is below 40° C (104° F).

AUTOMATIC TEMPERATURE CONTROL SYSTEM

The automatic temperature control (ATC) system will activate the supplemental cabin heater based on engine coolant temperature and interior component settings. The cabin heater can operate in a full or partial load range as well as an idle mode all dependent on the engine coolant temperature. The cabin heater will also turn off if the A/C-heater temperature control is lowered to less than the lower set point. The cabin heater can take up to three minutes to completely shut down when either the heater temperature is set below the lower set point or the vehicle ignition is shut down.

Note. Do not apply a strong vacuum source such as a garage ventilation system directly on the supplemental cabin heater exhaust line. Too strong of a vacuum can prevent the supplemental cabin heater from starting. If required, place the vacuum source at least 75 mm (3 in.) away from the exhaust line.

The supplemental cabin heater only operates when the engine is running, the mileage exceeds 8 kilometer (5 mph) and the fuel tank volume exceeds 1/8 of a tank. The supplemental heater control module monitors blower speed and combustion during its start-up. The cabin heater should operate if the coolant temperature is below 40° C (104° F).

WARNING

SUPPLEMENTAL CABIN HEATER

Refer to SYMPTOMS DIAGNOSIS for basic checks of the diesel fueled supplemental cabin heater.

SYMPTOMS DIAGNOSIS

CLEANING

1. Remove the cabin heater fuel line «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - REMOVAL)»(ref-248916-S35687606452007022700000) .
2. With the cabin heater fuel line removed from the vehicle, place a shop cloth on the fuel tank end of the fuel line to catch any residue, then apply a small amount of air pressure to the other end of the fuel line.
3. Check to see if air pressure is coming from the tank end of the line. If pressure is flowing unrestricted the line is clean.
4. If the fuel line shows any signs of being restricted after air pressure is applied, the fuel line should be replaced.
5. Install the cabin heater fuel line «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/FUEL LINE - INSTALLATION)»(ref-248916-S10194605182007022700000) .
6. Verify function of the cabin heater.

HEATER UNIT

1. Raise and support the vehicle. Take note of the location of the flexible section of the cabin heater exhaust tube.
2. Drain the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - DRAINING COOLING SYSTEM)»(ref-248908-S09724997062007022700000) .
3. Carefully open one hose to the underbody tube assembly and drain the remaining coolant. A salvage hose is a good idea to control the residual coolant, as flow will occur from both the cabin heater and the hose and tube assemblies.
4. Remove the second hose from the underbody hose and tube assembly.
5. Loosen the hose and tube assembly from the toe-board crossmember at two locations.
6. Disconnect the electrical connector from the body harness near the toe-board crossmember and rail.
7. Remove the wiring harness from the toe-board crossmember «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - REMOVAL - WIRE HARNESS)»(ref-248916-S26360850102007022700000) .
8. Open the fuel filler cap. Disconnect the rubber fuel hose between the body tube assembly and the fuel pump nipple at the body tube joint. A minimal amount of fuel may flow from the open port. NOTE: Utilize an approved fuel storage container to catch any residual fuel.
9. Loosen the two fasteners at the rail. Take care to notice that the exhaust tube bracket tab is on top of the heater bracket and that there are two spacer washers installed between the rubber grommets.
10. Remove the flexible section of the cabin heater exhaust tube from the exhaust tube by loosening the clamp. Remove the hose from the exhaust tube. Removal of the rail tube assembly may aid in this service operation «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/EXHAUST TUBE - REMOVAL)»(ref-248916-S32068978632007022700000) .
11. Remove seat hex nut at the heater mounting flange to crossmember.
12. Loosen the remaining fasteners which mount the exhaust tube assembly to the vehicle. Install a suitable support device under the cabin heater and secure the cabin heater to the support.
13. Loosen the remaining three fasteners to the crossmembers.
14. Remove the loosened fasteners that support the cabin heater while supporting the weight of the heater.
15. Swing the cabin heater mounting bracket from between the exhaust bracket and rail mounting location. Drain any residual coolant from the cabin heater.
16. Remove the cabin heater from the vehicle.

1. Install the cabin heater mounting bracket between the exhaust bracket and the rail mounting location.
2. Support the cabin heater and install the fasteners that secure the cabin heater to the mounting bracket.
3. Install the three fasteners to the crossmembers. Tighten the M6 fasteners to 7 N.m (62 in. lbs.).
4. Position the two spacer washers between the body and the rubber grommets for the two mounting points on the rail.
5. Tighten the remaining M6 fasteners to 7 N.m (62 in. lbs.) and the M8 fasteners to 23 N.m (17 ft. lbs.) which mount the exhaust tube assembly to the vehicle.
6. Install the seat hex nut at the heater mounting flange to the crossmembers. Tighten the nut to 60 N.m (44 ft. lbs.)
7. Install the flexible section of the cabin heater exhaust tube to the exhaust tube. Tighten the M6 bolt of the clamp securely. Install the hose to the exhaust tube.
8. Tighten the two M8 fasteners at the rail to 23 N.m (17 ft. lbs.). Taking care so that the exhaust tube bracket tab is on the top of the heater bracket.
9. Install the wiring harness «(Refer to HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - INSTALLATION - WIRE HARNESS)»(ref-248916-S14290335232007022700000) .
10. Tighten the hose and tube assembly to the toe-board crossmember at two locations.
11. Install the second hose to the underbody hose and tube assembly.
12. Connect the rubber fuel hose between the body tube assembly and the fuel pump nipple at the body tube joint. Close the fuel fill cap.
13. Remove the cabin heater support device from under the vehicle.
14. Lower the vehicle.
15. Fill the engine cooling system «(Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM FILL)»(ref-248908-S09724997062007022700000) .
16. Verify function of the heater unit.