Heating & Air Conditioning - Service Information: Other RAM Pickup 2500

A/C PERFORMANCE

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

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

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

HEATER PERFORMANCE

Before performing the following tests, see ENGINE COOLING SYSTEM for the procedures to check the engine coolant level and flow, engine coolant reserve/recovery system operation, accessory drive belt condition and tension, radiator air flow and the fan drive operation. Using a scan tool, check for any Diagnostic Trouble Codes (DTCs) in the A/C-heater control, Totally Integrated Power Module (TIPM), Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on engine application. Repair as necessary. Refer to DIAGNOSIS AND TESTING for ATC or DIAGNOSIS AND TESTING for MTC .

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow are as follows

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

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

MECHANICAL PROBLEMS

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

1. Obstructed cowl air intake.
2. Obstructed heater system outlets.
3. Blend-air door(s) or actuator(s) not functioning properly.
4. Faulty blower motor system
5. Inoperative A/C-heater control

TEMPERATURE CONTROL

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

1. Inoperative A/C-heater control.
2. Inoperative blend door actuator(s).
3. Inoperative, obstructed or improperly installed blend-air door.
4. Inoperative related wiring harness or connectors.
5. Improper engine coolant temperature.

STANDARD PROCEDURE - A/C EVAPORATOR CLEANING

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

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

1. Remove the cowl panel cover (refer to «COVER, COWL PANEL»(ref-457777-S34870038862012030200000) for more information).
2. Clean any dirt and debris that may be present at the HVAC fresh air inlet screen and at the top of the cowl panel.
3. Install the cowl panel cover.
4. Raise and support the vehicle.
5. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may be blocking the drain and repair as necessary.
6. Once drain operation has been verified; when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an appropriate pair of heater hose pliers. when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or plug and temporarily cap or plug the drain tube.
7. Lower the vehicle.
8. Place a protective cover over the front passenger side floor and seat area.
9. Remove the blower motor. Refer to «MOTOR, Blower , Removal»(ref-457787-S32701221202012030200000) .
10. Remove the blower motor resistor or power module, depending on application or Refer to «RESISTOR, Blower Motor , Removal»(ref-457787-S09262524832012030200000) and «MODULE, Power, Blower Motor , Removal»(ref-457787-S36968329172012030200000) .
11. Clean any dirt and debris that may be present inside the HVAC blower motor housing and all readily accessible areas inside the HVAC housing. If necessary, use a vacuum with a small flexible hose, and take caution not to damage the evaporator core fins.
12. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C evaporator with three bottles of Mopar® Cooling Coil Cleaner through the blower motor and power module or resistor openings. Be sure to use all of the coil cleaner in each container.
13. Allow the vehicle to sit for 30 minutes.
14. Raise and support the vehicle. WARNING: Excess cooling coil cleaner will drain from the evaporator housing when the clamp, cap or plug is removed from the evaporator drain hose or tube. Always use eye protection, rubber gloves and protective clothing. Avoid continuous breathing of vapors from evaporator coil cleaning fluid. Avoid contact with skin and eyes. Failure to follow these instruction may result in possible serious or fatal injury.
15. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow excess coil cleaner to drain from the HVAC housing.
16. Lower the vehicle.
17. Refill the three empty coil cleaner bottles with clean tap water.
18. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely rinse the entire surface of A/C evaporator with the three bottles of clean tap water through the blower motor and power module or resistor openings. Be sure to use all of the water in each container.
19. Install the blower motor. Refer to «MOTOR, Blower , Installation»(ref-457787-S18857238002012030200000) .
20. Install the blower motor resistor or power module, depending on application, refer to «RESISTOR, Blower Motor , Installation»(ref-457787-S21073769042012030200000) or «MODULE, Power, Blower Motor , Installation»(ref-457787-S40813075092012030200000) .
21. Disconnect the wire harness connector from the A/C compressor to disable compressor operation. Refer to «COMPRESSOR, A/C , Removal»(ref-457787-S14624345472012030200000) .
22. Start the engine
23. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
24. Set the A/C-heater controls to the following: air distribution to Panel and Recirculation mode temperature to full heat
25. Allow the vehicle to run for 20 minutes.
26. Turn the engine off.
27. Raise and support the vehicle.
28. Inspect the evaporator drain hose or tube (depending on application) for foreign material that may have blocked the drain during evaporator coil cleaning and repair as necessary.
29. Once drain operation has been verified; when equipped with a rubber drain hose, temporarily pinch the drain hose closed using an appropriate pair of heater hose pliers. when equipped with a solid plastic drain tube, obtain an appropriate size rubber or plastic cap or plug and temporarily cap or plug the drain tube.
30. Lower the vehicle.
31. Remove the blower motor. Refer to «MOTOR, Blower , Removal»(ref-457787-S32701221202012030200000) .
32. Remove the blower motor resistor or power module, depending on application or refer to «RESISTOR, Blower Motor , Removal»(ref-457787-S09262524832012030200000) or «MODULE, Power, Blower Motor , Removal»(ref-457787-S36968329172012030200000) .
33. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire surface of A/C evaporator with one bottle of Mopar® Cooling Coil Coating through the blower motor and power module or resistor openings. Be sure to use all of the coil coating in the container. NOTE: Be sure to thoroughly clean out the spray delivery tool with warm water once coil coating is complete to prevent damage to the tool.
34. Refill the empty bottles with clean warm tap water and completely rinse out the PSE Flex Spray Delivery Tool 534-62637, or equivalent.
35. Allow the vehicle to sit for 30 minutes.
36. Install the blower motor. Refer to «MOTOR, Blower , Installation»(ref-457787-S18857238002012030200000) .
37. Install the blower motor resistor or power module, depending on application. Refer to «RESISTOR, Blower Motor , Installation»(ref-457787-S21073769042012030200000) or «MODULE, Power, Blower Motor , Installation»(ref-457787-S40813075092012030200000) .
38. Raise and support the vehicle. WARNING: Excess cooling coil coating will drain from the evaporator housing when the clamp, cap or plug is removed from the evaporator drain hose or tube. Always use eye protection, rubber gloves and protective clothing. Avoid continuous breathing of vapors from evaporator coil sealing fluid. Avoid contact with skin and eyes. Failure to follow these instruction may result in possible serious or fatal injury.
39. Remove the previously installed clamp, cap or plug from the evaporator drain hose or tube and allow excess coil coating to drain from the HVAC housing.
40. Lower the vehicle.
41. Start the engine
42. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
43. Set the A/C-heater controls to the following: air distribution to Panel and Recirculation mode temperature to full heat
44. Allow the vehicle to run for 20 minutes.
45. Turn vehicle off.
46. Remove protective cover from front passenger side floor and seat area.
47. Connect the wire harness connector to the A/C compressor. Refer to «COMPRESSOR, A/C , Installation»(ref-457787-S06271131602012030200000) .
48. Verify proper A/C-heater system operation.

A/C SYSTEM

AIR INLET HOUSING

Scheme 63

Scheme 64

1. Remove the HVAC housing assembly. 1 «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
2. Disconnect the HVAC wire harness (1) from the recirculation door actuator (2).
3. Carefully disengage the two retaining tabs (4) that secure the rear of the air inlet housing (3) to the top of the HVAC housing (5).
4. Carefully disengage the two retaining tabs (3) that secure the front of the air inlet housing (1) to the top of the HVAC housing (2) and remove the inlet housing. NOTE: If the foam seal on the air inlet housing is deformed or damaged, it must be replaced.
5. If required, disassemble the air inlet housing. Refer to «HOUSING, HVAC , Disassembly»(ref-457787-S17490439592012030200000) .

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Remove the HVAC housing assembly. Refer to «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
2. Remove the air inlet housing (1) and place it on a workbench. Refer to «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
3. Remove the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing and remove the actuator. NOTE: If the seal on the air inlet is deformed or damaged, the seal must be replaced.
4. Carefully disengage the four retaining tabs (1 and 2) that secure the air inlet (3) to the top of the air inlet housing (4) and remove the air inlet.
5. To remove the recirculation-air door (2) from the air inlet housing (3), first carefully release the actuator coupler retaining tab (1) located on the inside of the air inlet housing.
6. With the actuator coupler retaining tabs released, pull the actuator coupler (1) out of the recirculation-air door (2). NOTE: If the seals on the air door or air inlet housing are deformed or damaged, the air door or housing seal must be replaced.
7. Disengage the door pivot shaft (3) from the air inlet housing (2) and carefully remove the recirculation-air door (1) from the housing.

HVAC HOUSING

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

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Remove the HVAC housing and place it on a workbench. Refer to «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
2. Disconnect the HVAC wiring harness (1) from the recirculation door actuator (2), power module or blower resister (3) (depending on application) and the blower motor (4).
3. Disengage the HVAC wiring harness from the two retaining clips (5) and position the harness out of the way. NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
4. Remove the foam seal (1) from the front of the HVAC housing (2).
5. If required, remove the two bolts (4) that secure the A/C expansion valve (5) to the evaporator tube tapping block (3) and remove the valve.
6. Remove the three screws (2 and 5) that secure the blower motor and evaporator housing (6) to the HVAC housing (3).
7. Carefully disengage the nine retaining tabs (1 and 4) that secure the blower motor and evaporator housing the HVAC housing.
8. Carefully separate the blower motor and evaporator housing from the HVAC housing NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
9. If required, remove the A/C evaporator (1) from the blower motor and evaporator housing (2).
10. If the A/C evaporator is going to be reused, remove and discard the O-ring seals from the evaporator fittings and install plugs into, or tape over the evaporator ports.
11. If equipped with dual zone system, disconnect the HVAC wire harness connector (2) and remove the two screws (4) that secure the blend door actuator (3) to the front of the HVAC housing (1) and remove the actuator. NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
12. Remove the seal (1) from the flange (2) at the front of the HVAC housing.
13. Remove the two screws (3) that secure the flange (1) to the front of the HVAC housing (2).
14. Carefully disengage the retaining tab that secures the flange to the HVAC housing and remove the flange. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
15. Carefully pull the heater core (4) out of the HVAC housing.
16. Inspect all foam seals and replace as required.
17. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2), blend door actuator (3) and mode door actuators (4 and 6).
18. Remove the HVAC wire harness from the HVAC housing (5).
19. Remove the evaporator temperature sensor from the HVAC housing.
20. Remove the screws that secure the blend and mode door actuators to the HVAC housing and remove the actuators. NOTE: If the foam seals on top of the HVAC housing are deformed or damaged, they must be replaced.
21. Carefully cut the foam seals (1) along the parting line (5) of the two halves of the HVAC housing (2 and 4).
22. Release the fourteen retaining tabs (3) that secure the two halves of the HVAC housing together and carefully separate the housing.
23. Carefully disengage the mode air doors (1 and 2) from the actuator couplers (5) by pulling the doors straight upward. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
24. Remove the mode air doors and the center partition (3), if equipped, from the rear half of the HVAC housing (4). NOTE: Dual zone system with two blend doors shown in illustration. Single zone system with one blend door similar.
25. Carefully disengage the blend air door(s) (2), as equipped, from the actuator coupler(s) (3) by pulling the door(s) straight upward. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
26. Remove the blend air door(s) from the HVAC housing (1). NOTE: Typical actuator coupler shown in illustration.
27. Remove the actuator coupler(s) (1) from the HVAC housing (2), as required. Carefully release the three retaining tabs (3) on each actuator coupler from the inside surface of the HVAC housing and push the coupler(s) out of the housing.

Note. If the seals on the air door or air inlet housing are deformed or damaged, the air door or housing seal must be replaced.

1. Position the recirculation-air door (1) into the air inlet housing (2).
2. Engage the door pivot shaft (3) to the opening in the air inlet housing. CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing.
3. Align the actuator coupler (1) with the recirculation door pivot shaft (2) and install the coupler until the coupler retaining tab is fully engaged to the recirculation door. Be sure to install the coupler with the coupler arm located between the two stop tabs on the air inlet housing. NOTE: If the seal on the air inlet is deformed or damaged, the seal must be replaced.
4. Position the air inlet (3) to the top of the air inlet housing (4) and engage the four retaining tabs (1 and 2). Make sure the retaining tabs are fully engaged.
5. Install the recirculation door actuator (1) onto the side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (4) with those in the recirculation door actuator coupler (3).
6. Install the two screws (2) that secure the recirculation door actuator (3) to the air inlet housing (1). Tighten the screws to 1.1 N.m (10 in. lbs.).
7. Install the air inlet housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .
8. Install the HVAC housing assembly. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .

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

Note. If 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 O-ring seals is required anytime the A/C expansion valve is removed from the A/C evaporator. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.

Scheme 80

Note. Typical actuator coupler shown in illustration.

1. Install the actuator coupler(s) (1) into the HVAC housing (3), as required. Make sure the arm (2) on the coupler is positioned between the two stops (4) on the HVAC housing. Make sure the three retaining tabs on each actuator coupler are fully engaged to the inside surface of the HVAC housing. NOTE: Dual zone system with two blend doors shown in illustration. Single zone system with one blend door similar. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
2. Install the blend air door(s) (2), as equipped, onto the actuator coupler(s) (3). Align the keyway in the blend air door pivot shaft with the key on the actuator coupler. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
3. Install the mode air doors (1 and 2) and the center partition (3), if equipped, to the rear half of the HVAC housing (4). Align the keyways in the mode air door pivot shafts with the keys on the actuator couplers (5). Align the dowel pins on the center partition to the holes in the HVAC housing.
4. Align the pivot shafts of the air doors to the holes in the HVAC housing halves (2 and 4).
5. Align the dowel pins on the rear half of the HVAC housing to the holes in the front half of the HVAC housing and install the two halves of the housing together.
6. Carefully engage the fourteen retaining tabs (3). Make sure the retaining tabs are fully engaged. NOTE: If the foam seals on top of the HVAC housing are deformed or damaged, they must be replaced.
7. Inspect the foam seals (1), especially along the parting line (5) and replace as required.
8. Install the blend and mode door actuators (3, 4 and 6) onto the HVAC housing (5). If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those on the actuator coupler.
9. Install the screws that secure the blend and mode door actuators to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
10. Install the evaporator temperature sensor (2) onto the HVAC housing.
11. Connect the HVAC wire harness (1) to the evaporator temperature sensor and the blend and mode door actuators.
12. Install the HVAC wire harness onto the HVAC housing. Make sure the wiring harness is routed correctly and is fully engaged to the retaining clips. NOTE: If the foam seals on the heater core are deformed or damaged, they must be replaced.
13. Inspect the foam seals on the heater core (4) and replace as required.
14. Carefully install the heater core into the front of the HVAC housing (2).
15. Position the flange (1) onto the front of the HVAC housing. Make sure the retaining tab is fully engaged.
16. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.). NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
17. Install the foam seal (1) onto the flange (2) at the front of the HVAC housing.
18. If equipped with dual zone system, install the blend door actuator (3) onto the front of the HVAC housing (1). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the actuator coupler.
19. Install the screws (4) that secure the blend door actuator to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
20. Connect the HVAC wire harness connector (2) to the blend door actuator. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
21. Inspect the foam insulator on the A/C evaporator (1) and replace as required.
22. Carefully install the A/C evaporator into the blower motor and evaporator housing (2).
23. Carefully install the blower motor and evaporator housing (6) onto the HVAC housing (3). Align the dowel pins to the holes in the housing.
24. Carefully engage the nine retaining tabs (1 and 4). Make sure the retaining tabs are fully engaged.
25. Install the three screws (2 and 5) that secure the blower motor and evaporator housing to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
26. Remove the tape or plugs from the evaporator tube fittings.
27. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
28. Install the A/C expansion valve (5) onto the evaporator tube tapping block (3).
29. Install the two bolts (4) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.). NOTE: If the foam seal is deformed or damaged, the seal must be replaced.
30. Install the foam seal (1) onto the HVAC housing (2).
31. Connect the HVAC wiring harness (1) to the recirculation door actuator (2), power module or blower resister (3) (depending on application) and the blower motor (4).
32. Engage the HVAC wiring harness to the two retaining clips (5). Make sure the wire harness is fully engaged to the retaining clips.
33. Install the HVAC housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) . NOTE: If the heater core is being replaced, flush the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
34. 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 «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) 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.

Note. If the foam seal on the air inlet housing is deformed or damaged, it must be replaced.

1. Position the air inlet housing (1) onto the top of the HVAC housing (2).
2. Engage the two retaining tabs (3) that secure the front of the air inlet housing to the HVAC housing.
3. Engage the two retaining tabs (4) that secure the rear of the air inlet housing (3) to the HVAC housing (5).
4. Connect the HVAC wire harness (1) to the recirculation door actuator (2).
5. Install the HVAC housing assembly. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .

FRONT CENTER AIR OUTLETS

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

Scheme 81

Scheme 82

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel (1) from the instrument panel and place it on a workbench. Refer to «BEZEL, Instrument Panel, Center , Removal»(ref-457777-S34461692702012030200000) .
3. Using Trim Stick (special tool #C-4755, Trim Stick) (2) or equivalent, carefully disengage the eight plastic retaining clips (4) that secure each air outlet (3) to the center bezel.
4. Lift the top of each air outlet (1) rearward and upward to disengage the bottom of each outlet from the center bezel (2) and remove the outlet(s).

FRONT OUTER AIR OUTLETS

Note. The front outer instrument panel air outlets can be serviced separately. The center instrument panel air outlets are serviced with the instrument panel center bezel. Refer to BEZEL, Instrument Panel, Center , Removal .

Scheme 83

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

1. Using Trim Stick (special tool #C-4755, Trim Stick) (1) or equivalent, carefully disengage the retaining tabs that secure each outer instrument panel air outlet (2) to the instrument panel cover (3) and remove the outlet.
2. If servicing the driver side air outlet, disconnect the head lamp switch wiring harness from the head lamp switch (4) and if required, remove the switch from the outlet bezel. Refer to «SWITCH, Headlamp , Removal»(ref-457789-S10039097312012030200000) .

Scheme 84

Note. Illustration shown with front seat cushions removed for clarity.

Scheme 85

1. Remove the two screws (1) that secure the rear air outlet housing (2) to the rear of the front center seat support (3).
2. Remove the rear air outlet housing and place it on a workbench.
3. Using Tim Stick (special tool #C-4755, Trim Stick) or equivalent (1), disengage the retaining tabs that secure the rear air outlets (2) to the rear air outlet housing (3) and gently pry the outlets from the housing (3).

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

Scheme 86

Scheme 87

1. Position the center air outlets (1) to the back of the instrument panel center bezel (2) and engage the bottom of each outlet to the center bezel.
2. Carefully engage the eight plastic retaining clips (2) that secure each air outlet (1) to the center bezel (3). Make sure the retaining clips are fully engaged.
3. Install the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Installation»(ref-457777-S05696116832012030200000) .
4. Reconnect the negative battery cable.

Scheme 88

Note. Driver side air outlet 3. Passenger side outlet similar.

1. If required, install the head lamp switch (1) onto the air outlet (2). Refer to «SWITCH, Headlamp , Installation»(ref-457789-S06787496502012030200000) .
2. If servicing the driver side air outlet, connect the head lamp switch wiring harness to the head lamp switch. Refer to «SWITCH, Headlamp , Installation»(ref-457789-S06787496502012030200000) .
3. Position the air outlet to the opening in the instrument panel cover (3) and align the outlet to the instrument panel duct.
4. Engage the retaining tabs that secure each air outlet to the instrument panel cover. Make sure the retaining tabs are fully engaged.

REAR SEAT AIR OUTLETS

Note. The air outlets are retained into the air outlet housing by eight retaining tabs. The air outlets must be first installed onto the bottom set of retaining tabs, then the upper set of tabs can be engaged.

Scheme 89

1. Position the rear air outlets (1) to the back of the rear air outlet housing (2) and engage the lower set of retaining tabs (3).
2. Gently engage the upper set of retaining tabs (4). Make sure all of the retaining tabs are fully seated. NOTE: Illustration shown with front seat cushions removed for clarity.
3. Position the rear air outlet housing (2) to the rear of the front center seat support (3).
4. Install the two screws (1) that secure the rear air outlet housing to the center seat support. Tighten the screws to 2.2 N.m (20 in. lbs.).

WARNING

CAUTION

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -8 kPa (-26 in. Hg) or greater vacuum) for at least 30 minutes. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) . CAUTION: Use only Chrysler LLC approved R-134a leak detection dye. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using low-budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.
2. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye.
3. Prepare the vehicle specific amount of R-134a refrigerant. «REFRIGERANT , Specifications»(ref-457787-S08326230462012030200000) . NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.
4. Dispense the leak detection dye and the correct amount of R-134a refrigerant into the evacuated refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
5. Proceed to «LEAK TEST»(ref-457787-S23536972962012030200000) .

SYSTEM LOW

1. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye. NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.
2. Dispense the leak detection dye and 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Proceed to «LEAK TEST»(ref-457787-S23536972962012030200000) .

REFRIGERANT SYSTEM RECOVERY

Scheme 90

When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2788 must be used. Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

Note. A/C system should be tested prior to refrigerant recovery if the use of A/C system sealants are suspected. These sealants have the potential to clog refrigerant recovery equipment and cause vehicle A/C component damage. Various tool manufacturers make tool kits that detect A/C system sealants. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

If sealants are detected in an A/C system, the system should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners void the warranty for the A/C system.

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 an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time, it is recommended that the refrigerant oil be drained and replaced with new oil, or a new A/C 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 A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. Use the following procedure to evacuate the refrigerant system

Note. When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection.

1. Recover the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
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 to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the 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 «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

REFRIGERANT SYSTEM CHARGE

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

CHARGING PROCEDURE

1. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
2. Connect an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system.
3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. Refer to «REFRIGERANT , Specifications»(ref-457787-S08326230462012030200000) . 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 heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch circuits and repair as required. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow these instructions may result in possible serious or fatal injury.
7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system.
8. Disconnect the charging station from the refrigerant system service ports.
9. Reinstall the caps onto the refrigerant system service ports.

Scheme 91

Note. Typical A/C clutch assembly shown in illustration.

The A/C compressor clutch assembly 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 bearing and pulley assembly is retained to the front of the compressor with a snap ring (6). The A/C clutch field coil is also retained to the front of the compressor using a snap ring (5).

Scheme 92

Note. Typical Denso A/C compressor shown in illustration.

The A/C system on models equipped with the 3.7L and 4.7L engine use the Denso 10SRE15 A/C compressor (1). This A/C compressor has a fixed displacement of 150 cubic centimeters (9.2 cubic inches).

The A/C system on models equipped with the 5.7L engine use the Denso 10SRE18 A/C compressor. This A/C compressor has a fixed displacement of 180 cubic centimeters (11 cubic inches).

The A/C system on models equipped with the 6.7L diesel engine use the Denso 10S17 A/C compressor. This A/C compressor has a fixed displacement of 170 cubic centimeters (10.4 cubic inches).

All A/C compressors are ten cylinder, reciprocating swash plate type compressors with the suction and discharge ports (2) located on the compressor cylinder head (3) and have a label identifying the use of R-134a refrigerant.

HIGH PRESSURE RELIEF VALVE

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

A/C CLUTCH

The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the A/C clutch coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.

A/C clutch engagement is controlled by the Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-B bus to the Totally Integrated Power Module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the TIPM to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch coil.

The A/C clutch control system is diagnosed using a scan tool or (Refer to 28 - DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Diagnosis and Testing). Refer to DIAGNOSIS AND TESTING or DIAGNOSIS AND TESTING .

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

A/C COMPRESSOR

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

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

The A/C compressor cannot be repaired and must be replaced if inoperative or damaged. The compressor clutch, pulley and bearing assembly, and clutch field coil are available for service. If an internal failure of the A/C compressor has occurred, the A/C condenser must also be replaced. Refer to CONDENSER, A/C , Removal .

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

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

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

A/C CLUTCH COIL

The A/C clutch coil electrical circuit is controlled by the Powertrain Control Module (PCM) or Engine Control Module (ECM), depending on engine application, through the Totally Integrated Power Module (TIPM). See appropriate Wiring Information for complete HVAC wiring diagrams. Begin testing of a suspected A/C clutch coil problem by performing the preliminary checks.

PRELIMINARY CHECKS

1. Using a scan tool, check for Diagnostic Trouble Codes (DTCs) in the A/C-heater control, TIPM and PCM/ECM. If no DTCs are found, refer to 2 . If any DTCs are found, repair as required.
2. If the A/C clutch still will not engage, verify the refrigerant charge level by conducting the A/C Performance test. Refer to «Diagnosis and Testing»(ref-457787-S09173920312012030200000) . If the refrigerant charge level is OK, refer to «COIL RESISTANCE TEST»(ref-457787-S09993458052012030200000) and «COIL CURRENT DRAW TEST»(ref-457787-S42721036792012030200000) . If the refrigerant charge level is not OK, adjust the refrigerant charge as required.

Note. The compressor clutch assembly can be serviced with the refrigerant system fully-charged.

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

Scheme 93

Scheme 94

Scheme 95

1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5).
4. Remove the fasteners that secure the A/C compressor to the engine and support the A/C compressor. Refer to «COMPRESSOR, A/C , Removal»(ref-457787-S14624345472012030200000) .
5. Carefully remove the compressor clutch coil connector and wire lead from the connector bracket (2).
6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.
7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3).
8. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly.
9. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, remove the snap ring (4) that secures the compressor clutch coil (2) to the front of the A/C compressor (3) and remove the field coil.

3.7L/4.7L ENGINES

Note. The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil, engine, engine cylinder head or the generator.

Note. 4.7L engine shown in illustrations. 3.7L engine similar.

Scheme 96

Scheme 97

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the resonator. Refer to «BODY, Air Cleaner , Removal , 3.7L»(ref-457795-S05169193642012030200000) , «BODY, Air Cleaner , Removal , 4.7L»(ref-457796-S06661718552012030200000) , «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) and «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
4. Remove the accessory drive belt (3). Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
5. Remove the nuts (5) that secure the A/C discharge line (2) and the A/C suction line (4) to the A/C compressor (1).
6. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
7. Install plugs in, or tape over the opened refrigerant line fittings and the compressor ports.
8. Disconnect the engine wire harness connector (1) from the A/C compressor (7).
9. Loosen the bolt (3) that secures the support bracket (4) to the front of the engine.
10. Remove the three bolts (2, 5 and 6) that secure the A/C compressor to the engine and remove the compressor

5.7L ENGINE

Note. The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system.

Scheme 98

Scheme 99

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the accessory drive belt (5). Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
4. Disengage the plastic refrigerant line bracket from the upper front of the engine. Refer to «LINE, A/C Discharge , Removal»(ref-457787-S16362274132012030200000) .
5. Raise and support the vehicle.
6. Disconnect the engine wire harness connector from the A/C compressor (4).
7. Remove the nuts (2) that secure the A/C suction line (1) and the A/C discharge line (3) to the A/C compressor.
8. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
9. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
10. Remove the three bolt (1 and 2) that secure the A/C compressor (3) to the engine and remove the compressor.

6.7L DIESEL ENGINE

Note. The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch coil or engine.

Scheme 100

Note. Illustration shown in illustration with lower radiation hose removed for clarity.

Scheme 101

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the air filter housing.
4. Remove the turbocharger outlet tube.
5. Remove the nuts (1) that secure the A/C suction line (3) and the A/C discharge line (4) to the A/C compressor (2).
6. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
7. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
8. Remove the accessory drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
9. Disconnect the engine wire harness (1) from the A/C clutch coil connector (5).
10. Remove the three bolts (4) that secure the A/C compressor (3) to the mounting bracket (2) and remove the compressor.

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

Scheme 102

1. Align the dowel pin on the back of the compressor clutch coil (2) with the hole in the front of the A/C compressor (3) and position the coil onto the compressor. Be certain that the compressor clutch coil wire lead is properly routed so that it is not pinched between the A/C compressor and the coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor.
2. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, install the snap ring (4) that secures the compressor clutch coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the A/C clutch will result.
3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
4. Using A/C Snap Ring Pliers (special tool #9764, Pliers, A/C Snap Ring) (1) or equivalent, install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.
6. Install the clutch plate (4) onto the front of the A/C compressor (5).
7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the A/C clutch coil wire harness is properly routed so that it is not pinched between the A/C compressor and the coil connector bracket.
9. Carefully route the compressor clutch coil wire lead behind the connector bracket (2).
10. Install the compressor clutch coil connector (1) onto the connector bracket.
11. Position the A/C compressor to the engine and install the fasteners. Refer to «COMPRESSOR, A/C , Installation»(ref-457787-S06271131602012030200000) .
12. Connect the engine wire harness to the compressor clutch coil connector.
13. Install the accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
14. Reconnect the negative battery cable.

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

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

Note. 4.7L engine shown in illustrations. 3.7L engine similar.

1. If the A/C compressor (7) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) 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.
2. Position the A/C compressor onto the engine.
3. Install and tighten the bolts in the following sequence: Install bolt (2) and hand tighten. Install bolt (5) and hand tighten. Install bolt (6) and hand tighten. Tighten bolt (2) to 40 N.m (30 ft. lbs.). Tighten bolt (5) to 55 N.m (41 ft. lbs.). Tighten bolt (6) to 55 N.m (41 ft. lbs.). Tighten bolt (4) to 55 N.m (41 ft. lbs.).
4. Connect the engine wire harness connector (1) to the A/C compressor.
5. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
6. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
7. Install the A/C discharge line (2) and the A/C suction line (4) onto the A/C compressor (1).
8. Install the nuts (5) that secure the refrigerant lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
9. Install the accessory drive belt (3). Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
10. Install the resonator. Refer to «BODY, Air Cleaner , Installation , 3.7L»(ref-457795-S37004940822012030200000) , «BODY, Air Cleaner , Installation , 4.7L»(ref-457796-S16050623352012030200000) , «BODY, Air Cleaner , Installation , 5.7L»(ref-457797-S01216084882012030200000) and «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
11. Reconnect the negative battery cable.
12. Evacuate and charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

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

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

1. If the A/C compressor (3) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) 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.
2. Position the A/C compressor to the engine.
3. If removed, install and securely tighten the two studs (3) that secure the A/C compressor to the engine.
4. Loosely install the three bolts (1 and 2) that secure the A/C compressor to the engine.
5. Tighten each of the bolts to 28 N.m (21 ft. lbs.) using the following sequence: Upper bolt at front of compressor. Lower bolt at front of compressor. Bolt at rear of compressor.
6. Connect the engine wire harness connector to the A/C compressor.
7. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
8. Lubricate new O-rings with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Install the A/C discharge line (3) and the A/C suction line (1) onto the A/C compressor (4).
10. Install the nuts (2) that secure the A/C discharge and suction lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
11. Lower the vehicle.
12. Engage the plastic refrigerant line bracket to the upper front of the engine. Refer to «LINE, A/C Discharge , Installation»(ref-457787-S17944751752012030200000) .
13. Install the accessory drive belt (5). Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
14. Reconnect the negative battery cable.
15. Evacuate and charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Note. When replacing multiple A/C system components, see OIL, Refrigerant , Standard Procedure to determine how much oil should be removed from the new A/C compressor.

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

1. If the A/C compressor (2) is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor (3) to the mounting bracket (2) and loosely install the three bolts (4) that secure the compressor to the bracket.
3. Tighten each of the bolts to 28 N.m (21 ft. lbs.) using the following sequence: Upper bolt at front of compressor. Lower bolt at front of compressor. Bolt at rear of compressor.
4. Connect the engine wire harness (1) to the A/C clutch coil connector (5).
5. Install the accessory drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) . NOTE: Illustration shown in illustration with lower radiation hose removed for clarity.
6. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
7. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Connect the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (2).
9. Install the nuts (1) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
10. Install the turbocharger outlet hose.
11. Install the air filter housing.
12. Reconnect the negative battery cable.
13. Evacuate and charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

3.7L/4.7L/5.7L ENGINES

Scheme 103

Note. 4.7L model shown in illustration. 3.7L and 5.7L models similar.

Scheme 104

Scheme 105

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Drain the engine cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
4. If equipped, disconnect the automatic transmission cooler lines from the transmission cooler jumper lines located near the right side of the radiator. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
5. Remove the nuts (2) that secure the A/C discharge line (3) and the A/C liquid line (4) to the condenser jumper line tapping block (1).
6. Disconnect the A/C discharge and liquid lines from the condenser jumper line tapping block and remove and discard the O-ring seals and gaskets.
7. Install plugs in, or tape over the opened refrigerant line fittings and jumper line ports.
8. Remove the radiator (4) and A/C condenser (2) as an assembly from the vehicle and place them on a workbench. Refer to «RADIATOR, Engine Cooling , Removal»(ref-457792-S21225288992012030200000) .
9. If equipped, remove the bolt (1) that secures the automatic transmission cooler jumper lines (10) to the transmission cooler tapping block and disconnect the jumper lines. Remove and discard the O-ring seals and install plugs in the transmission cooler ports.
10. Remove the bolt (7) that secures the condenser jumper line tapping block (6) to the radiator.
11. Remove the bolts (3 and 8) that secure the discharge jumper line and liquid jumper line to the A/C condenser.
12. Disconnect the discharge and liquid jumper lines from the A/C condenser and remove and discard the O-ring seals and gaskets.
13. Install plugs in, or tape over the opened jumper line fittings and condenser ports.
14. Remove the two bolts (5 and 9) that secure the A/C condenser to the right side of the radiator.
15. Disengage the two condenser mounting brackets (2) from the left side of the radiator (1) and remove the A/C condenser (3).

Note. A/C condenser for manual transmission model shown in illustration. shown in illustration with front fascia removed for clarity. Automatic transmission model similar.

Scheme 106

1. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
2. Remove the grille.
3. If equipped, disconnect the automatic transmission cooler lines from the transmission fluid cooler fittings located at each end of the A/C condenser (1). Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
4. Remove the bolts (6 and 8) that secure the A/C liquid line (5) and the A/C discharge line (9) from the A/C condenser.
5. Disconnect the A/C liquid and discharge lines from the A/C condenser and remove and discard the O-ring seals and gaskets.
6. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports.
7. Remove the four bolts (2, 7 and 10) that secure the A/C condenser to the charge air cooler.
8. Remove the A/C condenser from the engine compartment.
9. If required, remove the four bolts (4) that secure the four retaining brackets (3) to the A/C condenser and remove the brackets. Replace the rubber isolators if necessary.

Note. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to OIL, Refrigerant , Standard Procedure .

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

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

Note. Be certain that each of the radiator and condenser air seals are installed in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed.

1. Position the A/C condenser (3) to the front of the radiator (1) and engage the two condenser mounting brackets (2) to the radiator.
2. Install the two bolts (5 and 9) that secure the A/C condenser (2) to the right side of the radiator (4). Tighten the bolts to 2.2 N.m (20 in. lbs.).
3. Remove the plugs or tape from the opened jumper line fittings and condenser ports.
4. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the jumper line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Connect the discharge and liquid jumper lines to the A/C condenser and install the bolts (3 and 8). Tighten the bolts to 23 N.m (17 ft. lbs.).
6. Install the bolt (7) that secures the condenser jumper line tapping block (6) to the radiator. Tighten the bolt securely.
7. If equipped, remove the plugs from the transmission cooler ports and using new O-ring seals, install the automatic transmission cooler jumper lines (10) to the transmission cooler tapping block and install the bolt (1). Tighten the bolt securely. NOTE: 4.7L model shown in illustration. 3.7L and 5.7L models similar.
8. Install the radiator and A/C condenser as an assembly. Refer to «RADIATOR, Engine Cooling , Installation»(ref-457792-S25692808462012030200000) .
9. If equipped, connect the automatic transmission cooler lines to the transmission cooler jumper lines. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
10. Remove the plugs or tape from the opened refrigerant line fittings and condenser jumper line ports.
11. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
12. Connect the A/C discharge line (3) and A/C liquid line (4) to the condenser jumper line tapping block (1) and install the nuts (2). Tighten the nuts to 23 N.m (17 ft. lbs.).
13. Reconnect the negative battery cable.
14. Refill the engine cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
15. If equipped, check and adjust the automatic transmission fluid level. Refer to «FLUID and FILTER , Standard Procedure»(ref-457852-S12484225282012030200000) and «FLUID and FILTER , Standard Procedure»(ref-457827-S35811224762012030200000) .
16. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
17. 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, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
18. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Note. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to OIL, Refrigerant , Standard Procedure .

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 disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

Note. A/C condenser for manual transmission model shown in illustration. shown in illustration with front fascia removed for clarity. Automatic transmission model similar.

1. If removed, install the four retaining brackets (3), isolators and bolts (4) onto the A/C condenser (1). Tighten the bolts to 10.5 N.m (95 in. lbs.).
2. Position the A/C condenser into the engine compartment and install the four bolts (2, 7 and 10) that secure the A/C condenser to the charge air cooler. Tighten the bolts to 10.5 N.m (95 in. lbs.).
3. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Connect the A/C liquid line (5) and A/C discharge line (9) to the A/C condenser and install the bolts (6 and 8). Tighten the bolts to 23 N.m (17 ft. lbs.).
6. If equipped, connect the automatic transmission cooler lines to the transmission fluid cooler fittings located at each end of the A/C condenser. Refer to «TUBES AND HOSES, Transmission Oil Cooler , Standard Procedure»(ref-457792-S39844769592012030200000) .
7. Install the grill.
8. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
9. 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, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) . Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
10. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Scheme 107

The heater core (1) is a heat exchanger made of rows of tubes and fins and is located at the front of the HVAC housing. The heater core tubes (2) are attached to the front of the heater core and are secured to the HVAC housing by a flange.

The heater core can be serviced by removing the HVAC housing assembly from the vehicle.

Scheme 108

Note. 4.7L engine shown in illustration. 3.7L engine similar.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Disconnect the wire harness connector from the A/C pressure transducer (2).
4. Remove the nut (1) that secures the A/C discharge line (4) to the condenser jumper line tapping block (3).
5. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket.
6. Remove the nut (6) that secures the A/C discharge line to the A/C compressor (5).
7. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket.
8. Install plugs in, or tape over the opened refrigerant line fittings and the compressor and condenser jumper line ports.
9. If necessary, remove the A/C pressure transducer from the A/C discharge line. Refer to «TRANSDUCER, A/C Pressure , Removal»(ref-457787-S25904005662012030200000) .

Scheme 109

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the nut (2) that secures the A/C discharge line (3) to the condenser jumper line tapping block (1).
4. Disconnect the A/C discharge line from the condenser jumper line tapping block.
5. Remove the nut (2) that secures the A/C discharge line (3) to the A/C compressor (4).
6. Disconnect the A/C discharge line from the A/C compressor. NOTE: Illustration shown with refrigerant lines removed for clarity.
7. Disconnect the wire harness connector from the A/C pressure transducer (4).
8. Remove the two plastic retaining brackets (2 and 3) that secure the A/C discharge line (5) to the A/C suction line (1) and to the upper front of the engine.
9. Remove the A/C discharge line from the engine compartment.
10. Remove and discard the O-ring seals and gaskets from the A/C discharge line and install plugs in, or tape over the opened discharge line fittings and the jumper line and compressor ports.
11. If necessary, remove the A/C pressure transducer from the A/C discharge line. Refer to «TRANSDUCER, A/C Pressure , Removal»(ref-457787-S25904005662012030200000) .

Scheme 110

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the air filter housing.
4. Disconnect the wire harness connector from the A/C pressure transducer (1).
5. Remove the nut (3) that secures the A/C discharge line (2) to the condenser jumper line tapping block (4).
6. Disconnect the A/C discharge line from the condenser jumper line tapping block and remove and discard the O-ring seal and gasket. NOTE: Illustration shown with lower radiation hose removed for clarity.
7. Remove the turbocharger outlet tube.
8. Remove the nut (1) that secures the A/C discharge line (4) to the A/C compressor (2).
9. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket.
10. Install plugs in, or tape over the opened discharge line fittings and the compressor and jumper line ports.
11. If necessary, remove the A/C pressure transducer from the A/C discharge line. Refer to «TRANSDUCER, A/C Pressure , Removal»(ref-457787-S25904005662012030200000) .

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

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

Note. 4.7L engine shown in illustration. 3.7L engine similar.

1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (4). Refer to «TRANSDUCER, A/C Pressure , Installation»(ref-457787-S22620389972012030200000) .
2. Remove the tape or plugs from the opened discharge line fitting and the compressor and condenser jumper line ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C discharge line to the condenser jumper line tapping block (3) and install the nut (1). Tighten the nut to 23 N.m (17 ft. lbs.).
5. Connect the A/C discharge line to the A/C compressor (5) and install the nut (6). Tighten the nut to 23 N.m (17 ft. lbs.).
6. Connect the wire harness connector to the A/C pressure transducer.
7. Reconnect the negative battery cable.
8. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
9. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
10. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

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

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

Note. Illustration shown with refrigerant lines removed for clarity.

1. If removed, install the A/C pressure transducer (4) onto the A/C discharge line (3). Refer to «TRANSDUCER, A/C Pressure , Installation»(ref-457787-S22620389972012030200000) .
2. Remove the plugs or tape from the opened discharge line fittings and compressor and jumper line ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Position the A/C discharge line (5) into the engine compartment.
5. Install the two retaining brackets (2 and 3) that secure the A/C discharge line to the A/C suction line (1) and to the upper front of the engine.
6. Connect the wire harness connector to the A/C pressure transducer.
7. Connect the A/C discharge line (3) to the A/C compressor (4).
8. Install the nut (2) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
9. Connect the A/C discharge line to the condenser jumper line tapping block (1) and install the nut (2). Tighten the nut to 23 N.m (17 ft. lbs.).
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
12. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
13. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Note. When replacing multiple A/C system components, see OIL, Refrigerant , Standard Procedure to determine how much oil should be added to the refrigerant system.

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

Note. Illustration shown with lower radiation hose removed for clarity.

1. If removed, install the A/C pressure transducer onto the A/C discharge line (4). Refer to «TRANSDUCER, A/C Pressure , Installation»(ref-457787-S22620389972012030200000) .
2. Remove the tape or plugs from the discharge line fittings and the compressor and jumper line ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C discharge line to the A/C compressor (2).
5. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
6. Install the turbocharger outlet hose.
7. Connect the A/C discharge line (2) to the condenser jumper line tapping block (4) and install the nut (3). Tighten the nut to 23 N.m (17 ft. lbs.).
8. Connect the wire harness connector to the A/C pressure transducer (1).
9. Reconnect the negative battery cable.
10. Install the air filter housing.
11. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
12. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
13. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Scheme 111

Note. 4.7L engine shown in illustration. 3.7L engine similar.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the air filter housing cover and resonator inlet tube. Refer to «BODY, Air Cleaner , Removal , 3.7L»(ref-457795-S05169193642012030200000) , «BODY, Air Cleaner , Removal , 4.7L»(ref-457796-S06661718552012030200000) , «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) , or «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
4. Remove the nuts (3) that secures the A/C liquid line (1) and the A/C suction line (5) to the A/C expansion valve (2) and to the A/C compressor (4).
5. Disconnect the A/C suction line and the A/C liquid line from the A/C expansion valve and the A/C compressor.
6. Separate the A/C liquid line from the A/C suction line and remove and discard the O-ring seals and gaskets.
7. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve and compressor ports.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the air filter housing cover and engine air inlet tube. Refer to «BODY, Air Cleaner , Removal , 3.7L»(ref-457795-S05169193642012030200000) , «BODY, Air Cleaner , Removal , 4.7L»(ref-457796-S06661718552012030200000) , «BODY, Air Cleaner , Removal , 5.7L»(ref-457797-S42752377112012030200000) , or «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
4. Remove the nut (1) that secures the A/C liquid line (2) and A/C suction line (3) to the A/C expansion valve (4).
5. Disconnect the A/C liquid and suction lines from the A/C expansion valve and separate the lines from each other.
6. Remove the nut (2) that secures the A/C suction line (1) to the A/C compressor (4).
7. Disconnect the A/C suction line from the A/C compressor. NOTE: Illustration shown with refrigerant lines removed for clarity.
8. Remove the two plastic retaining brackets (2 and 3) that secure the A/C suction line (1) to the A/C discharge line (5) and to the upper front of the engine.
9. Remove the A/C suction line from the engine compartment.
10. Remove and discard the O-ring seals and gaskets from the A/C suction line and install plugs in, or tape over the opened suction line fittings and the expansion valve and compressor ports.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Remove the air filter housing.
4. Remove the nut (1) that secures the A/C liquid line (2) and A/C suction line (3) to the A/C expansion valve (4).
5. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-ring seals.
6. Separate the A/C liquid line from the A/C suction line and install plugs in, or tape over the opened refrigerant line fittings and expansion valve ports. NOTE: Illustration shown with lower radiation hose removed for clarity.
7. Remove the turbocharger outlet tube.
8. Remove the nut (1) that secures the A/C suction line (3) to the A/C compressor (2).
9. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seals and gaskets.
10. Install plugs in, or tape over the opened suction line fittings and compressor port.

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

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

Note. 4.7L engine shown in illustration. 3.7L engine similar.

1. Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve and compressor ports.
2. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fitting. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Connect the A/C liquid line (1) and the A/C suction line (5) to the A/C expansion valve (2).
4. Install the nut (3) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
5. Connect the A/C suction line to the A/C compressor (4).
6. Install the nut that secures the A/C suction line to the compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
7. Install the air filter housing cover and resonator inlet tube. Refer to «BODY, Air Cleaner , Installation , 3.7L»(ref-457795-S37004940822012030200000) , «BODY, Air Cleaner , Installation , 4.7L»(ref-457796-S16050623352012030200000) , «BODY, Air Cleaner , Installation , 5.7L»(ref-457797-S01216084882012030200000) , or «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
8. Reconnect the negative battery cable.
9. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
10. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
11. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

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

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

Note. Illustration shown with refrigerant lines removed for clarity.

1. Remove the plugs or tape from the opened suction line fittings and the expansion valve and compressor ports.
2. Lubricate new O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Position the A/C suction line (1) into the engine compartment.
4. Install the two retaining brackets (2 and 3) that secure the A/C suction line (1) to the A/C discharge line (5) and to the upper front of the engine.
5. Connect the A/C suction line (1) to the A/C compressor (4).
6. Install the nut (2) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
7. Connect the A/C liquid line (2) and the A/C suction line (3) to the A/C expansion valve (4).
8. Install the nut (1) that secures the A/C liquid and suction lines the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
9. Install the air filter housing cover and engine air inlet tube. Refer to «BODY, Air Cleaner , Installation , 3.7L»(ref-457795-S37004940822012030200000) , «BODY, Air Cleaner , Installation , 4.7L»(ref-457796-S16050623352012030200000) , «BODY, Air Cleaner , Installation , 5.7L»(ref-457797-S01216084882012030200000) , or «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
12. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
13. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .

Note. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Refer to OIL, Refrigerant , Standard Procedure .

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

1. Position the A/C suction line (3) into the engine compartment.
2. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve ports.
3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C liquid line (2) and A/C suction line ot the A/C expansion valve (4).
5. Install the nut (1) that secures the A/C liquid and suction lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). NOTE: Illustration shown with lower radiation hose removed for clarity.
6. Remove the tape or plugs from the opened suction line fitting and compressor port.
7. Lubricate a new O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Connect the A/C suction line (3) to the A/C compressor (2).
9. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.).
10. Install the turbocharger outlet hose.
11. Install the air filter housing.
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
14. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
15. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .