Heating & Air Conditioning - Service Information: Removal & Installation Dodge Nitro I

REMOVAL

Scheme 12

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. If equipped, remove the silencer from below the driver side of the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
3. Disconnect the wire harness connector (3) from the blend door actuator (2) located on the driver side of the air distribution housing (4).
4. Remove the two screws (5) that secure the blend door actuator to the actuator mounting bracket (1) and remove the actuator.

INSTALLATION

Note. LHD model shown. RHD model similar.

1. Position the blend door actuator (4) to the actuator mounting bracket (1) located on the driver side of the air distribution housing (4). Make sure the actuator output shaft is properly aligned to the door linkage. If necessary, rotate the actuator slightly to align the splines on the output shaft with those in the door linkage.
2. Install the two screws (5) that secure the blend door actuator to the actuator mounting bracket. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Connect the wire harness connector (3) to the blend door actuator.
4. If equipped, install the silencer below the driver side of the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
5. Reconnect the negative battery cable.
6. Initiate the Actuator Calibration function using a scan tool. See «DIAGNOSIS AND TESTING»(ref-306135-S27707253392008120900000) .

Scheme 13

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. If equipped, remove the silencer from below the driver side of the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
3. Disconnect the wire harness connector (3) from the mode door actuator (2) located on the driver side of the air distribution housing (5).
4. Remove the two screws (1) that secure the mode door actuator to the actuator mounting bracket (4) and remove the actuator.

Note. LHD model shown. RHD model similar.

1. Position the mode door actuator (2) to the actuator mounting bracket (4) located on the driver side of the air distribution housing (5). Make sure the actuator output shaft is properly aligned to the door linkage. If necessary, rotate the actuator slightly to align the splines on the output shaft with those in the mode door linkage
2. Install the two screws (1) that secure the mode door actuator to the actuator mounting bracket. Tighten the screws to 1.2 N.m (10 in lbs.).
3. Connect the wire harness connector (3) to the mode door actuator.
4. If equipped, install the silencer below the driver side of the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
5. Reconnect the negative battery cable.
6. Initiate the Actuator Calibration function using a scan tool. See «DIAGNOSIS AND TESTING»(ref-306135-S27707253392008120900000) .

Scheme 14

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. On LHD models, remove the glove box bin. Refer to «REMOVAL»(ref-306147-S34322015752008120900000) .
3. On RHD models, remove the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
4. Remove the two screws (2) that secure the recirculation door actuator (1) to the air inlet housing (3).
5. Disconnect the wire harness connector from the recirculation door actuator and remove the actuator from the vehicle.

Note. LHD model shown. RHD model similar.

1. Connect the wire harness connector to the recirculation door actuator (1).
2. Position the recirculation door actuator to the side of the air inlet housing (3). Make sure the actuator output shaft is properly aligned to the recirculation door pivot shaft. If necessary, rotate the actuator slightly to engage the splines on the output shaft with those in the pivot shaft.
3. Install the two screws (2) that secure the recirculation door actuator to the air inlet housing. Tighten the screws to 1.2 N.m (10 in lbs.).
4. On RHD models, install the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
5. On LHD models, install the glove box bin. Refer to «INSTALLATION»(ref-306147-S35230032082008120900000) .
6. Reconnect the negative battery cable.
7. Initiate the Actuator Calibration function using a scan tool. See «DIAGNOSIS AND TESTING»(ref-306135-S27707253392008120900000) .

Scheme 15

The A/C system on models equipped with the 3.7L engine use the Visteon HS-18 A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and retained with a snap ring (6). The A/C clutch bearing and pulley assembly is also retained to the front of this compressor by a snap ring (5). Both the A/C clutch bearing and pulley assembly and the field coil can be serviced separately.

Scheme 16

The A/C system on models equipped with the 2.8L and 4.0L engine use a Zexel DKS-17DS A/C compressor. The clutch assembly for this A/C compressor consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (6), and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt.

The A/C clutch field coil is pressed onto the front of this A/C compressor and cannot be serviced separately from the compressor. The A/C clutch bearing and pulley assembly is retained to the front of the compressor by a snap ring (5) and can be serviced separately.

Scheme 17

Note. MTC A/C-heater control shown. ATC control similar.

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 «REMOVAL»(ref-306147-S26297984622008120900000) .
3. Remove the four screws (1) that secure the A/C-heater control (2) to the instrument panel center bezel (3) and remove the control.

Note. MTC A/C-heater control shown. ATC control similar.

1. Install the A/C-heater control (2) onto the back of the instrument panel center bezel (3).
2. Install the four screws (1) that secure the A/C-heater control to the center bezel. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Position the center bezel to the instrument panel and connect the wire harness connectors to the back of the A/C-heater control.
4. Connect the wire harness connectors to the accessory switches and install the center bezel. Refer to «INSTALLATION»(ref-306147-S29293688322008120900000) .
5. Reconnect the negative battery cable. NOTE: The A/C-heater control will automatically perform the Actuator Calibration function when the ignition is initially turned on when installing a new control or when reinstalling the original control. However, the Actuator Calibration function must be manually initiated using a scan tool if the A/C-heater control has been previously installed in another vehicle. Refer to «HEATING & AIR CONDITIONING - ELECTRICAL DIAGNOSTICS»(ref-306156) for more information.
6. If required, initiate the Actuator Calibration function using a scan tool. See «DIAGNOSIS AND TESTING»(ref-306135-S27707253392008120900000) .

Scheme 18

A blower motor power module is used on this model when equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. See DESCRIPTION .

The blower motor power module is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate (1) with an integral connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry and a finned aluminum heat sink (3). The blower motor power module is accessed for service from under the instrument panel.

The blower motor power module is accessed for service through the glove box opening.

Scheme 19

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. Lower the glove box door.
3. Disconnect the two wire harness connectors (4) from the blower motor power module (3).
4. Remove the two screws (2) that secure the blower motor power module to the HVAC housing (1) and remove the power module.

Note. LHD model shown. RHD model similar.

1. Position the blower motor power module (3) into the HVAC housing (1).
2. Install the two screws (2) that secure the blower motor power module to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Connect the wire harness connectors (4) to the blower motor power module.
4. Close the glove box door.
5. Reconnect the negative battery cable.

Scheme 20

A blower motor resistor is used on vehicles equipped with the manual temperature control (MTC) heating-A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a blower motor power module, instead of the blower motor resistor. See DESCRIPTION .

The blower motor resistor is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate is the resistor circuit board located within a metal housing (3).

The blower motor resistor is accessed for service through the glove box opening.

Scheme 21

Note. Typical resistor shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. Lower the glove box door.
3. Disconnect the wire harness connector (2) from the blower motor resistor (1).
4. Remove the two screws (3) that secure the blower motor resistor to the HVAC housing (4) and remove the resistor.

Note. Typical resistor shown. RHD model similar.

1. Position the blower motor resistor (1) into the HVAC housing (4).
2. Install the two screws (3) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Connect the wire harness connector (2) to the blower motor resistor.
4. Close the glove box door.
5. Reconnect the negative battery cable.

Scheme 22

Note. Typical evaporator temperature sensor shown.

The evaporator temperature sensor (1) measures the temperature of the conditioned air downstream of the A/C evaporator (2). The evaporator temperature sensor is an electrical thermistor within a molded plastic case that is inserted into rear the HVAC housing (3) near the coldest point of the A/C evaporator. Two terminals within the connector receptacle (4) connect the sensor to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness.

The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system.

Note. Illustration shown with instrument panel removed for clarity.

Scheme 23

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. Partially remove the instrument panel to gain access to the evaporator temperature sensor (1) located in the rear of the HVAC housing (2), near the bottom of the instrument panel on the passenger side. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
3. Disconnect the instrument panel wire harness connector from the evaporator temperature sensor and remove the sensor from the HVAC housing.

Note. Illustration shown with instrument panel removed for clarity.

Note. LHD model shown. RHD model similar.

1. Install the evaporator temperature sensor (1) into rear of the HVAC housing (2) and connect the instrument panel wire harness connector.
2. Install the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
3. Reconnect the negative battery cable.

Scheme 24

The infrared temperature sensor (1) consists of an infrared transducer concealed behind a clear lens (4) located in a molded plastic housing with an integral wire connector receptacle (2) and mounting and alignment tabs (3 and 5).

The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heating-A/C system.

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

Scheme 25

Note. Typical overhead console shown.

1. Disconnect and isolate the negative battery cable.
2. Remove the overhead console (1) from the headliner and place it on a workbench. Refer to «OVERHEAD CONSOLE»(ref-306186-S24831735802008120900000) .
3. Remove the screw (2) that secures the infrared sensor (3) to the back of the overhead console and remove the sensor.

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

Note. Typical overhead console shown.

1. Position the infrared sensor (3) onto the back of the overhead console (1). Align the tab (4) on the sensor with the slot in the console.
2. Install the screw (2) that secures the infrared sensor(s) to the overhead console. Tighten the screw to 1.2 N.m (10 in. lbs).
3. Install the overhead console. Refer to «OVERHEAD CONSOLE»(ref-306186-S22893655522008120900000) .
4. Reconnect the negative battery cable.

Scheme 26

The A/C pressure transducer (1) sends a signal to the powertrain control module (PCM) which controls both A/C compressor clutch engagement/disengagement and electric cooling fan operation. The A/C pressure transducer is mounted on a fitting located on the A/C liquid line near the dash panel. The PCM will disengage the A/C compressor clutch when high side pressure rises above 2971 kPa (431 psi) or fall below 206 kPa (30 psi).

The fitting for the A/C pressure transducer on the A/C liquid line is equipped with an O-ring seal and contains a Schrader-type valve to allow the transducer to be serviced without discharging the refrigerant system.

Note. It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer.

Scheme 27

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C liquid line (3) near the dash panel (4) in the engine compartment.
3. Remove the A/C pressure transducer from the A/C liquid line and remove and discard the O-ring seal.

Note. Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor.

Note. LHD model shown. RHD model similar.

1. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the A/C pressure transducer fitting.
2. Install the A/C pressure transducer (2) onto the A/C liquid line (3) near the dash panel (4). Hand-tightened the transducer securely.
3. Connect the wire harness connector (1) to the A/C pressure transducer.
4. Reconnect the negative battery cable.

Scheme 28

1. Disconnect and isolate the negative battery cable.
2. Remove the radio from the instrument panel. Refer to «REMOVAL»(ref-306160-S20860169522008120900000) .
3. Reach through the opening in the instrument panel (2) and remove the three screws (3) that secure the center instrument panel duct (1) to the instrument panel.
4. Rotate the center instrument panel duct as necessary and remove the duct.

1. Rotate the center instrument panel duct as necessary to position the duct into the instrument panel.
2. Install the three screws (3) that secure the center instrument panel duct (1) to the instrument panel. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Install the radio. Refer to «INSTALLATION»(ref-306160-S19679953692008120900000) .
4. Reconnect the negative battery cable.

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

Scheme 29

1. Remove the instrument panel and place it on a workbench. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
2. Remove the three screws (3) that secure the defroster duct (2) to the instrument panel (1) and remove the duct.

1. Position the defroster duct (2) into the instrument panel (1).
2. Install the three screws (3) that secure the defroster duct to the instrument panel. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Install the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .

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

Scheme 30

1. If equipped, remove the silencer from below the driver side of the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
2. Remove the two screws (1) that secure the driver side front floor duct (3) to the driver side of the air distribution housing (2) and remove the duct.

Scheme 31

Scheme 32

1. Remove the HVAC Housing assembly and place it on a workbench. See «REMOVAL»(ref-306135-S07622186542008120900000) .
2. Remove the two screws (2) that secure the lower front passenger side floor duct (3) to the bottom of the HVAC housing (1).
3. Disconnect the lower front passenger side floor duct from the upper front passenger side floor duct (4) and remove the lower duct. NOTE: Illustration shown with air distribution housing removed from HVAC housing for clarity.
4. Remove the two screws (1) that secure the upper front passenger side floor duct to the passenger side of the air distribution housing (3) and remove the upper duct.

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

Note. Typical rear floor heat duct shown.

1. Position the rear floor heat duct (1) into the vehicle.
2. Connect the rear floor heat duct to the floor distribution duct (5) located in front of the gear shift lever assembly (4).
3. Install the push-pin retainer (2) that secures the rear floor heat duct to the floor console bracket (3).
4. Install the floor console. Refer to «INSTALLATION»(ref-306147-S30866878842008120900000) .

Note. The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing.

Scheme 33

Note. LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.
2. If equipped, remove the silencer from below the passenger side of the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
3. From underneath the instrument panel, disconnect the instrument panel wire harness connector (3) from the blower motor (4).
4. Remove the three screws (2) that secure the blower motor to the bottom of the HVAC housing (1) and remove the blower motor.

Note. LHD model shown. RHD model similar.

1. Position the blower motor (4) into the bottom of the HVAC housing (1).
2. Install the three screws (2) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Connect the instrument panel wire harness connector (3) to the blower motor.
4. If equipped, install the silencer below the passenger side of the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
5. Reconnect the negative battery cable.

Scheme 34

Note. LHD model shown. RHD model similar.

There are two defroster air outlets (1) located in the instrument panel top cover (2). The airflow from the defroster outlets is directed by fixed vanes and cannot be adjusted. The defroster air outlets are not serviceable from the instrument panel top cover. Refer to REMOVAL .

There are two side window demister air outlets (3). One located at each end of the instrument panel (4) near the A-pillars. The airflow from the side window demister air outlets is directed by fixed vanes and cannot be adjusted. The side window demister air outlets are integral to the left and right side instrument panel air outlets and cannot be serviced separately. See REMOVAL .

There are four instrument panel air outlets (5). One air outlet is located near each outboard end of the instrument panel facing the rear of the vehicle and the other two outlets are located near the top of the instrument panel center bezel. The left and right side instrument panel air outlets are serviced separately. See REMOVAL . The instrument panel air outlets located at the center of the instrument panel are integral to the instrument panel center bezel and cannot be serviced separately . Refer to REMOVAL . Each of the instrument panel air outlets contain an air outlet grille (6) that is used to direct or shut off the flow of the conditioned air leaving the instrument panel and cannot be serviced separately from the outlets.

Scheme 35

1. Disconnect and isolate the negative battery cable.
2. Remove the defroster grille. Refer to «REMOVAL»(ref-306147-S13406240552008120900000) .
3. Depending on the air outlet being serviced, remove the instrument cluster bezel or passenger side air bag. Refer to «REMOVAL»(ref-306147-S05437224162008120900000) or «REMOVAL»(ref-306149-S22655518822008120900000) .
4. Remove the A-pillar trim molding from the side of the vehicle being serviced. Refer to «REMOVAL»(ref-306147-S17742260522008120900000) .
5. Remove the screw (1) that secures the top of the air outlet (2) to the instrument panel (4).
6. Using a trim stick C-4755 or equivalent (3), gently pry the lower portion of the air outlet rearward to disengage the two metal retaining clips from the instrument panel and remove the outlet.
7. If required, carefully disengage the plastic retaining tabs that secure the air outlet grille to the back of air outlet and remove the grille from the outlet.

1. If removed, carefully install the air outlet grille onto the back of air outlet and engage the plastic retaining tabs that secure grille to the outlet. Make sure the retaining tabs are fully engaged.
2. Position the instrument panel air outlet(s) to the instrument panel and engage the two metal retaining clips to the instrument panel. Make sure the retainers are fully engaged.
3. Install the screw (1) that secures the top of the air outlet (2) to the instrument panel (4). Tighten the screw to 1.2 N.m (10 in. lbs.).
4. Install the A-pillar trim molding(s). Refer to «INSTALLATION»(ref-306147-S37731926412008120900000) .
5. Depending on the air outlet being serviced, install the instrument cluster bezel or passenger side air bag. Refer to «INSTALLATION»(ref-306147-S13789978012008120900000) or «INSTALLATION»(ref-306149-S09006765372008120900000) .
6. Install the defroster grille. Refer to «INSTALLATION»(ref-306147-S05098774272008120900000) .
7. Reconnect the negative battery cable.

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

Scheme 36

Scheme 37

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .
3. Remove the engine air cleaner housing.
4. Remove the secondary retaining clip and using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent), disconnect the A/C liquid line (1) from the condenser tube (2). See «REMOVAL»(ref-306135-S19252644082008120900000) . NOTE: Upper condenser retaining bracket and bolt shown. Lower retaining bracket and bolt similar.
5. Remove the grille. Refer to «REMOVAL»(ref-306147-S37207605592008120900000) .
6. If equipped with an automatic transmission, disconnect the transmission cooler lines from the transmission cooler portion of the A/C condenser. Refer to «REMOVAL»(ref-306154-S00207114292008120900000) .
7. Position the right side condenser air seal out of the way to gain access to the discharge line fitting and the lower condenser retaining bolt. NOTE: Rotate and tilt the A/C discharge line as necessary to disconnect it from the A/C condenser.
8. Remove the nut (4) that secures the A/C discharge line (5) to the A/C condenser (3) and disconnect the discharge line.
9. Remove the two bolts (2) that secure the A/C condenser to the right side of the radiator (1).
10. Carefully lift the A/C condenser straight up to disengage the condenser mounting brackets from the radiator and remove the condenser from the vehicle.
11. If required, remove the A/C receiver/drier from the A/C condenser. See «REMOVAL»(ref-306135-S20248556132008120900000) .
12. Remove and discard the O-ring seals and gasket and install plugs in, or tape over the opened refrigerant line fittings and the condenser and receiver/drier ports.

Note. When replacing multiple A/C system components, refer to REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system.

Note. If only the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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

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

Note. Upper condenser retaining bracket and bolt shown. Lower retaining bracket and bolt similar.

1. Remove the tape or plugs from the opened refrigerant line fittings and the receiver/drier and condenser ports.
2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. If removed, install the A/C receiver/drier onto the A/C condenser (3). See «INSTALLATION»(ref-306135-S19240741382008120900000) .
4. Position the A/C condenser into the engine compartment and install it onto the condenser mounting brackets.
5. Install the two bolts (2) that secure the A/C condenser to the right side of the radiator (1). Tighten the bolts to 5 N.m (44 in. lbs.). NOTE: Rotate and tilt the A/C discharge line as necessary to connect it to the A/C condenser.
6. Connect the A/C discharge line (5) to the A/C condenser and install the retaining nut (4). Tighten the nut to 22.5 N.m (200 in. lbs.).
7. Reposition the right side condenser air seal.
8. If equipped with an automatic transmission, connect the transmission cooler lines to the transmission cooler portion of the A/C condenser. Refer to «INSTALLATION»(ref-306154-S11154781672008120900000) .
9. Install the grille. Refer to «INSTALLATION»(ref-306147-S25858635422008120900000) .
10. Connect the A/C liquid line (1) to the condenser tube (2) and install the secondary retaining clip. See «INSTALLATION»(ref-306135-S35873542262008120900000) .
11. Install the engine air cleaner housing.
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .
14. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to «REFRIGERANT OIL CAPACITIES»(ref-306135-S01984728362008120900000) to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
15. Charge the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .

Scheme 38

The heater core (1) is mounted into the HVAC air distribution housing, located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes and fins. The heater core is secured to the air distribution housing by four plastic retaining tabs. The heater core tubes (3) are attached to the heater core by use of metal retaining clamps (2) and rubber O-ring seals.

The heater core tubes are not serviced separately from the heater core. The air distribution housing must be removed from the vehicle to service the heater core.

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

1. Remove the HVAC housing assembly and place it on a workbench. See «REMOVAL»(ref-306135-S07622186542008120900000) .
2. Remove the air distribution housing from the HVAC housing. See «REMOVAL»(ref-306135-S07622186542008120900000) .
3. Remove the two screws (1) that secure the upper front passenger side floor duct (7) to the passenger side of the air distribution housing (8) and remove the duct. NOTE: If the foam seal for the heater core tube flange is deformed or damaged, it must be replaced.
4. Carefully remove the foam seal (4) from the heater core tube flange (5). If the seal is deformed or damaged, it must be replaced.
5. Remove the screw (2) that secures the heater core tube flange to the air distribution housing.
6. Disengage the plastic retainer (5) from around the heater core tubes (6) and remove the flange. NOTE: If the foam insulator around the heater core is deformed or damaged, the insulator must be replaced.
7. Disengage the four plastic retaining tabs (1) that secure the heater core (2) to the passenger side of the air distribution housing (3) and carefully remove the heater core from the housing.

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

Note. If the foam insulator around the heater core is deformed or damaged, the insulator must be replaced.

1. Carefully install the heater core (2) into the passenger side of the air distribution housing (3) and engage the four plastic retainer tabs (1) that secure the heater core to the housing. Make sure the retaining tabs are fully engaged.
2. Position the heater core tube flange (4) over the heater core tubes (6) and onto the to the passenger side of the air distribution housing (8).
3. Engage the plastic retainer (5) around the heater core tubes. Make sure the retainer is fully engaged around the tubes.
4. Install the screw (2) that secure the heater core tube flange to the air distribution housing. Tighten the screws to 1.2 N.m (10 in lbs.).
5. Install the upper front passenger side floor duct (7) onto the air distribution housing and install the two retaining screws (1). Tighten the screws to 1.2 N.m (10 in lbs.). NOTE: If the foam seal for the heater core tube flange is deformed or damaged, it must be replaced.
6. Install the foam seal (3) onto the heater core tube flange.
7. Install the air distribution housing onto the HVAC housing. See «INSTALLATION»(ref-306135-S29230517562008120900000) . NOTE: If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(ref-306154-S25259837052008120900000) .
8. Install the HVAC housing assembly. See «INSTALLATION»(ref-306135-S29230517562008120900000) .

Scheme 39

Note. 3.7L LHD model shown. 2.8L , 4.0L and RHD models similar.

Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service equipment used for R-12 refrigerant.

The low-side service port (1) is located on the A/C suction line (2) at either the rear of the engine compartment or near the A/C compressor, depending on engine and market. The high-side service port (3) is located on the A/C liquid line (4) near the front of the engine compartment. Both the high-side and low-side A/C service port valve cores are serviceable.

Note. The protective cap aids in sealing the service port and helps to protect the refrigerant system from contamination. Remember to always reinstall the protective caps onto the service ports when refrigerant system service is complete.

Each of the service ports has a threaded plastic protective cap installed over it from the factory. The service port caps are serviceable items.

Scheme 40

Note. Typical A/C service port shown.

1. Remove the protective cap (1) from the service port (2).
2. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .
3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port.
4. Install a plug in, or tape over the opened service port(s).

Note. Typical A/C service port shown.

1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters.
3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s).
4. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .
5. Charge the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) . NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete.
6. Install the protective cap (1) onto the service port.

Scheme 41

The A/C liquid line (1) is attached to the A/C condenser outlet tube (2) by use of a spring-lock type refrigerant line coupler (3). A secondary retaining clip is installed over the connected coupler for added protection.

The spring-lock refrigerant line coupler requires a special disconnect tool for disengaging the two coupler halves.

Scheme 42

The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected.

O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material.

A secondary retaining clip (3) is installed over the connected coupler (5) for added protection.

Scheme 43

1. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .
2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler.
3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1).
4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening.
5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting.
6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4).

1. Clean any dirt or foreign material from the spring-lock type refrigerant line coupler.
2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak.
3. Install new O-rings (8) on the male half of the refrigerant line coupler.
4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Position the female half of the coupler over the male half of the coupler.
6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler.
7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler.
8. Install the secondary retaining clip (3) over connected coupler cage (5).
9. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .
10. Charge the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .

Scheme 44

Note. LHD model shown. RHD model similar.

The A/C evaporator (1) and its insulator (2) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator is positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heater core and heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator.

The A/C evaporator tubes (3) are connected and sealed to the A/C expansion valve by use of rubber O-rings (4) and a tapping block (5).

The A/C evaporator can only be serviced by removing and disassembling the HVAC housing.

Note. LHD model shown. RHD model similar.

1. Remove the HVAC housing assembly and place it on a workbench. See «REMOVAL»(ref-306135-S07622186542008120900000) .
2. Disassemble the HVAC housing. See «DISASSEMBLY»(ref-306135-S24626070132008120900000) . NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the rubber seal around the evaporator tubes and tapping block is deformed or damaged, the seal must be replaced.
4. If required, remove the rubber seal (4) from around the evaporator tubes and tapping block (5).

Note. When replacing multiple A/C system components, refer to REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system.

Note. If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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

Note. LHD model shown. RHD model similar.

Note. Make sure the rubber seal for the evaporator tubes and tapping block is properly positioned in the HVAC housing opening.

1. If removed, install the rubber seal (4) over the evaporator tubes and tapping block (5). NOTE: Make sure that the foam insulator around the A/C evaporator is properly positioned within the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3).
3. Assemble the HVAC housing. See «ASSEMBLY»(ref-306135-S13563954732008120900000) .
4. Install the HVAC housing assembly. See «INSTALLATION»(ref-306135-S29230517562008120900000) .
5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to «REFRIGERANT OIL CAPACITIES»(ref-306135-S01984728362008120900000) chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

Scheme 45

Note. 4.0L LHD model shown. Other models similar.

The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser.

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

The A/C discharge line has no serviceable parts except for the metal gaskets (2) and rubber O-ring seals (3). The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is removed and installed.

The A/C discharge line cannot be repaired and must be replaced if leaking or damaged.

Note. Illustration shown with A/C condenser removed from vehicle for clarity.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .
3. Remove the grille. Refer to «REMOVAL»(ref-306147-S37207605592008120900000) .
4. Remove the air seal from the left side of the cooling module assembly.
5. Reach through the opening at the bottom of the front fascia and remove the bolt (3) that secures the A/C receiver/drier (1) to the left side A/C condenser (3).
6. Disconnect the A/C receiver/drier from the A/C condenser and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened receiver/drier fittings and the condenser ports.

Note. When replacing multiple A/C system components, refer to REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system.

Note. If only the receiver/drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only the refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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

Note. Illustration shown with A/C condenser removed from vehicle for clarity.

1. Remove the tape or plugs from the receiver/drier fittings and the condenser ports.
2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the receiver/drier fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Connect the A/C receiver/drier (1) to the left end of the A/C condenser (2).
4. Install the bolt (3) that secures the A/C receiver/drier to the A/C condenser. Tighten the bolt to 22 N.m (16 ft. lbs.).
5. Install the air seal onto the left side of the cooling module assembly.
6. Install the grille. Refer to «INSTALLATION»(ref-306147-S25858635422008120900000) .
7. Reconnect the negative battery cable.
8. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .
9. If the A/C receiver/drier is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to «REFRIGERANT OIL CAPACITIES»(ref-306135-S01984728362008120900000) to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
10. Charge the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S22714907002008120900000) .

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

Scheme 46

1. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the nut (2) that secures the A/C suction line (1) and the A/C liquid line (4) to the A/C expansion valve (3).
4. Disconnect the A/C suction and liquid lines from the A/C expansion valve, remove and discard the O-ring seals and position the refrigerant lines out of the way.
5. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block (3).
6. Remove the A/C expansion valve from the evaporator tube tapping block and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened refrigerant line and evaporator tube fittings and all expansion valve ports.

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

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

1. Remove the tape or plugs from the opened refrigerant line and evaporator tube fittings and all of the expansion valve ports.
2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line and evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3).
4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.).
5. Connect the A/C suction line (1) and the A/C liquid line (4) to the A/C expansion valve (3).
6. Install the nut (2) that secures the A/C suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
7. Reconnect the negative battery cable.
8. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .
9. Recharge the refrigerant system. See «STANDARD PROCEDURE»(ref-306135-S14322548632008120900000) .

Scheme 47

Note. LHD model shown. RHD model similar.

An electric positive temperature coefficient (PTC) heater unit (1) is used on vehicles when equipped with the 2.8L diesel engine. The PTC heater unit aids in passenger compartment heating by compensating for the lower engine coolant temperatures produced by the diesel engine. The PTC heater unit is mounted in the HVAC air distribution housing, downstream of the heater core and is controlled by the diesel engine control module (ECM) and the totally integrated power module (TIPM) through two relays in diesel accessory fuse/relay block located below the left front fender.

The PTC heater consists of a molded plastic mounting plate (2) with an integral wire connector receptacle (3). Concealed behind the mounting plate are four heating elements with fins (4) that transfer the heat produced by the PTC heater to the conditioned air flowing within the air distribution housing. A positioning tab (5) is molded onto the end of the heater unit to help support the heater unit inside the air distribution housing. The PTC heater unit is connected to the vehicle electrical system through the instrument panel wire harness.

The PTC heater unit is accessed for service from underneath the instrument panel.

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

Scheme 48

Scheme 49

1. Disconnect and isolate the negative battery cable.
2. If equipped, remove the silencer from below the driver side of the instrument panel. Refer to «REMOVAL»(ref-306147-S01884369462008120900000) .
3. Disconnect the wire harness connector from the mode door actuator (2) and the blend door actuator (6) located on the driver side of the air distribution housing. See «REMOVAL»(ref-306135-S34021923702008120900000) .
4. Carefully disengage the retaining tabs (3) that secure the mode door actuator and the blend door actuator to the actuator mounting bracket (5) and remove the actuators.
5. Remove the three screws (1) that secure the actuator mounting bracket to the air distribution housing and remove the bracket.
6. Remove the screw (8) that secures the driver side front floor duct (7) to the air distribution housing and remove the duct NOTE: PTC heater shown removed from distribution housing for clarity. NOTE: To disconnect the wire harness connector from the PTC heater, disengage the connector lock while pulling the connector away from the heater unit.
7. Disengage the wire connector lock (2) that secures the wire harness connector (1) to the positive temperature coefficient (PTC) heater unit (3) and disconnect the connector from the heater.
8. Remove the two screws (1) that secure the PTC heater unit (2) to the air distribution housing (3).
9. Carefully pull the PTC heater unit straight out of the air distribution housing.

Note. LHD model shown. RHD model similar.

Scheme 50

1. Carefully install the positive temperature coefficient (PTC) heater unit (2) into the driver side of the air distribution housing (3). Make sure to position the two locator tabs on the end of the heater unit into the molded locator indentations on the right side of the air distribution housing.
2. Install the two screws (1) that secure the PTC heater unit to the air distribution housing. Tighten the screws to 1.2 N.m (10 in. lbs.). NOTE: PTC heater shown removed from distribution housing for clarity.
3. Connect the wire harness connector (1) to the PTC heater unit (3) while pushing inward on the connector lock (2). Make sure the wire harness connector and lock are fully engaged.
4. Install the driver side front floor duct (7) onto the driver side of the air distribution housing (4) and install the retaining screw (8). Tighten the screw to 1.2 N.m (10 in lbs.).
5. Position the actuator mounting bracket (5) onto the air distribution housing and install the three retaining screws (1). Tighten the screws to 1.2 N.m (10 in lbs.).
6. Position the mode door actuator (2) and the blend door actuator (6) onto the actuator mounting bracket. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the door linkage. NOTE: If the retaining tabs on the actuator mounting bracket become broken during service, the alignment pins on the bracket bosses can be removed and screws can be used to retain the actuator to the bracket. Once the alignment pins are removed, pre-made holes can be found the center of the bosses, exactly where the pins were. This assures correct actuator alignment to the bracket. Use care not to overtighten the screws and damage the bosses.
7. Engage the retaining tabs (3) that secure the mode and blend door actuators to the actuator mounting bracket. Make sure the retaining tabs are fully engaged.
8. Connect the wire harness connector to the mode and blend door actuators.
9. If equipped, install the silencer below the driver side of the instrument panel. Refer to «INSTALLATION»(ref-306147-S37560280272008120900000) .
10. Reconnect the negative battery cable.

Scheme 51

Two relays (1) are used for the electric positive temperature coefficient (PTC) heater system when equipped with the 2.8L diesel engine. The relays are International Standards Organization (ISO)-type relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The PTC relays are electromechanical devices that switch fused battery current directly to the heating elements of the PTC heater unit. The PTC relays are energized by control circuits of the totally integrated power module (TIPM).

The two PTC relays are located in the diesel accessory fuse/relay block at the right front corner of the engine compartment.

1. Position the positive temperature coefficient (PTC) relays as necessary into the proper receptacle of the diesel accessory fuse/relay block (2) located at the right front of the engine compartment.
2. Align the PTC relay terminals with the terminal cavities in the fuse/relay block and push down firmly on each relay until the terminals are fully seated.
3. Close the cover (1) of the diesel accessory fuse/relay block.
4. Reconnect the negative battery cable.