Heating & Air Conditioning - Service Information: Removal & Installation RAM Pickup 2500

REMOVAL

Note. The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

Scheme 11

1. Disconnect and isolate the negative battery cable.
2. Remove the glove box. Refer to «GLOVE BOX, Instrument Panel , Removal»(ref-457777-S40043193292012030200000) .
3. Disconnect the HVAC wire harness connector (1) from the blend door actuator (2) located at the rear of the HVAC housing (3).
4. Remove the two screws (4) that secure the blend door actuator to the HVAC housing and remove the actuator.

Scheme 12

1. Disconnect and isolate the negative battery cable.
2. Remove the HVAC housing (1) from the vehicle and place it on a workbench. Refer to «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
3. Disconnect the HVAC wire harness connector (2) from the blend door actuator (3) located at the front of the HVAC housing.
4. Remove the two screws (4) that secure the blend door actuator to the HVAC housing and remove the actuator.

INSTALLATION

Note. The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

Scheme 13

1. Position the blend door actuator (1) to the back of the HVAC housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (2) with those on the actuator coupler (3).
2. Install the two screws (4) that secure the blend door actuator (2) to the HVAC housing (3). Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (1) to the blend door actuator.
4. Install the glove box. Refer to «GLOVE BOX, Instrument Panel , Installation»(ref-457777-S18098025302012030200000) .
5. Reconnect the negative battery cable.
6. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 14

1. Position the blend door actuator (1) to the front of the HVAC housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (2) with those on the actuator coupler (3).
2. Install the two screws (4) that secure the blend door actuator (3) to the HVAC housing (1). Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (2) to the blend door actuator.
4. Install the HVAC housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .
5. Reconnect the negative battery cable.
6. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 15

The mode door actuators are reversible, 12-volt direct current (DC) servo motors. The heating-A/C systems on this vehicle use two mode door actuators. One for the defrost-air door and one for the panel/floor-air door.

Both the defrost door actuator (1) and the panel/floor door actuator (3) are located on the driver side end of the HVAC housing (2), close to the instrument panel.

All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The mode door actuators do not require mechanical indexing to the mode-air doors, as they are electronically calibrated by the A/C-heater control.

Note. The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door.

Note. Illustrations shown with instrument panel removed for clarity.

Scheme 16

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Removal»(ref-457777-S34461692702012030200000) .
3. When equipped with center floor console, remove radio. Refer to «RADIO , Removal»(ref-457804-S24605405702012030200000) .
4. When not equipped with center floor console, remove cupholder. Refer to «CUPHOLDER, Instrument Panel , Removal»(ref-457777-S26800679572012030200000) .
5. Disconnect the HVAC wire harness (2) from the panel/floor door actuator (3).
6. Remove the two screws (4) that secure the panel/floor door actuator to the back of the HVAC housing (1) and remove the actuator.

Scheme 17

1. Disconnect and isolate the negative battery cable.
2. Remove the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Removal»(ref-457777-S34461692702012030200000) .
3. When equipped with center floor console, remove radio. Refer to «RADIO , Removal»(ref-457804-S24605405702012030200000) .
4. When not equipped with center floor console, remove cupholder. Refer to «CUPHOLDER, Instrument Panel , Removal»(ref-457777-S26800679572012030200000) .
5. Disconnect the HVAC wire harness (1) from the defrost door actuator (2).
6. Remove the two screws (3) that secure the defrost door actuator to the back of the HVAC housing (4) and remove the actuator.

Note. The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door.

Note. Illustrations shown with instrument panel removed for clarity.

Scheme 18

1. Position the panel/floor door actuator (1) to the back of the HVAC housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the panel/floor door actuator coupler (2).
2. Install the two screws (4) that secure the panel/floor door actuator (3) to the HVAC housing (1). Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (2) to the panel/floor door actuator.
4. When equipped with center floor console, install the radio. Refer to «RADIO , Installation»(ref-457804-S29646043912012030200000) .
5. When not equipped with center floor console, install the cupholder. Refer to «CUPHOLDER, Instrument Panel , Installation»(ref-457777-S20312346812012030200000) .
6. Install the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Installation»(ref-457777-S05696116832012030200000) .
7. Reconnect the negative battery cable.
8. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 19

1. Position the defrost door actuator (1) to the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the defrost door actuator coupler (4).
2. Install the two screws (3) that secure the defrost door actuator (2) to the HVAC housing (4). Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (1) to the defrost door actuator.
4. When equipped with center floor console, install the radio. Refer to «RADIO , Installation»(ref-457804-S29646043912012030200000) .
5. When not equipped with center floor console, install the cupholder. Refer to «CUPHOLDER, Instrument Panel , Installation»(ref-457777-S20312346812012030200000) .
6. Install the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Installation»(ref-457777-S05696116832012030200000) .
7. Reconnect the negative battery cable.
8. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 20

The recirculation door actuator (1) is a reversible 12-volt direct current (DC) servo motor. The single recirculation door actuator is located on the inboard side of the air inlet housing (2).

All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control.

Scheme 21

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.

Scheme 22

1. 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).
2. 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.).
3. Install the air inlet housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .
4. Install the HVAC housing assembly. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .
5. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 23

The A/C-heater control (1) for the automatic temperature control (ATC) dual zone heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. All controls are identified by ISO graphic symbols.

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

1. a rotary control for manual and automatic fan speed selection and turning the heating-A/C system off (2).
2. push button controls for driver and front seat passenger temperature control of the discharged air (3 and 5).
3. a vacuum-flourescent (VF) digital display (4).
4. a rotary control for manual and automatic mode control of the discharged air (6).
5. a push button rear window defogger/heated mirror on/off control (7). The push button contains an LED that illuminates when the rear window defogger/heated mirror system is in operation.
6. a push button A/C on/off control (8). A Snowflake icon appears in the VF display when the A/C system is in operation.
7. a push button synchronize control (9) that synchronizes the temperature of the driver and passenger comfort zones. SYNC appears in the VF display when the system is synchronized, whether under manual or automatic mode.
8. a push button air recirculation control (10). The push button contains an LED that illuminates when the recirculation function is manually activated.

The A/C-heater control utilizes integrated circuitry and information carried on the controller area network (CAN) bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control the electronic functions and features of the ATC heating-A/C system.

Some of the inputs received by the A/C-heater control of the ATC heating-A/C system on the CAN bus are as follows

1. Dimming
2. Refrigerant Pressure
3. A/C Clutch Engage
4. Vehicle Identification Number
5. Vehicle Odometer
6. Engine Coolant Temperature
7. Ambient Air Temperature
8. System Voltage
9. Vehicle Speed
10. Engine Speed

Some of the messages broadcasted by the A/C-heater control of the ATC heating-A/C system on the CAN bus are as follows

1. A/C Request
2. A/C Select
3. EBL Status
4. Auto Headlamp Signal

The A/C-heater control for the ATC system is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING for ATC or DIAGNOSIS AND TESTING for MTC .

The A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Scheme 24

The A/C-heater control (1) for the manual temperature control (MTC) single zone heating-A/C system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols.

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

1. a rotary control for fan speed selection and turning the heating-A/C system off (2).
2. a rotary control for temperature control of the discharged air (3).
3. a rotary control for recirculation and mode control of the discharged air (4).
4. a push button A/C on/off control (5). An LED in the button illuminates when the A/C system is in operation.
5. a push button rear window/side mirror defogger on/off control (6) when equipped with optional rear heated window and/or heated mirrors. An LED in the button illuminates when the rear window/mirror defogger (EBL) system is in operation.

The A/C-heater control for the MTC system is diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING for ATC or DIAGNOSIS AND TESTING for MTC .

The A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Scheme 25

Note. Typical A/C-heater control shown in illustration.

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel (1) from the instrument panel and disconnect the wire harness connectors (4 and 5) from the back of the A/C-heater control (2). Refer to «BEZEL, Instrument Panel, Center , Removal»(ref-457777-S34461692702012030200000) and «BEZEL, Instrument Panel, Driver Side , Removal»(ref-457777-S05792662012012030200000) . NOTE: Take the proper precautions to protect the front face of the center bezel from cosmetic damage.
3. Place the center bezel on a workbench and remove the four screws (3) that secure the A/C-heater control to the center bezel and remove the control.

Note. Typical A/C-heater control shown in illustration.

1. Position the A/C-heater control (2) onto the back of the instrument panel center bezel (1).
2. Install the four screws (3) that secure the A/C-heater control to the center bezel. Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Connect the wire harness connectors (4 and 5) to the back of the A/C-heater control and install the instrument panel center bezel. Refer to «BEZEL, Instrument Panel, Center , Installation»(ref-457777-S05696116832012030200000) and «BEZEL, Instrument Panel, Driver Side , Installation»(ref-457777-S10723021932012030200000) .
4. Reconnect the negative battery cable.
5. Initiate the Actuator Calibration function using a scan tool. Refer to «STANDARD PROCEDURE»(ref-457876-S41951374432012030200000) and «STANDARD PROCEDURE»(ref-457874-S02669228202012030200000) .

Scheme 26

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

The blower motor power module is mounted to the bottom of the HVAC housing, on the passenger side of the vehicle. The blower motor power module consists of a molded plastic mounting plate (1) with an integral connector receptacle (2). Concealed behind the mounting plate is the power module electronic circuitry (3) and a finned aluminum heat sink (4). The blower motor power module is accessed for service from under the instrument panel.

Scheme 27

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector (1) from the blower motor power module (2) located at the bottom of the HVAC housing (3) on the passenger side of the vehicle.
3. Remove the two screws (4) that secure the blower motor power module to the HVAC housing and remove the power module.

1. Position the blower motor power module (2) onto the bottom of the HVAC housing (3).
2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the wire harness connector (1) to the blower motor power module.
4. Reconnect the negative battery cable.

Scheme 28

The blower motor resistor is mounted to the bottom of the HVAC housing, below the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Behind the mounting plate are resistors contained within a metal heat sink (3).

Scheme 29

1. Disconnect and isolate the negative battery cable.
2. Reach under the passenger side of the instrument panel and disconnect the HVAC wire harness connector (4) from the blower motor resistor (3).
3. Remove the two screws (1) that secure the blower motor resistor to the HVAC housing (2) and remove the resistor.

1. Position the blower motor resistor (3) into the HVAC housing (2).
2. Install the two screws (1) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
3. Connect the HVAC wire harness connector (4) to the blower motor resistor.
4. Reconnect the negative battery cable.

Scheme 30

The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ATC system uses the sensor data to maintain optimum cabin temperature levels. The ambient air temperature sensor is mounted inside the front fascia.

Note. Illustration shown in illustration with instrument panel removed for clarity.

1. Install the evaporator temperature sensor (1) into the top of the HVAC housing (3). Make sure the sensor is fully engage to the housing.
2. Connect the HVAC wire harness (2) to the evaporator temperature sensor.
3. Install the storage bin. Refer to «BIN, Instrument Panel , Installation»(ref-457777-S31003808462012030200000) .
4. Install the glove box. Refer to «GLOVE BOX, Instrument Panel , Installation»(ref-457777-S18098025302012030200000) .
5. Reconnect the negative battery cable.

Scheme 31

Note. Typical infrared sensor shown in illustration.

The infrared temperature sensor is located in the overhead console and consists of an infrared transducer concealed behind a clear lens (2) in a molded plastic housing with an integral mounting tab (3) and wire connector receptacle (1).

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

1. Position the infrared sensor (2) onto the overhead console (1).
2. Install the screw (3) that secures the infrared sensor to the overhead console. Tighten the screw to 1.1 N.m (10 in. lbs.).
3. Install the overhead console. Refer to «CONSOLE, Overhead, Front , Installation»(ref-457777-S18800645112012030200000) .
4. Reconnect the negative battery cable.

Scheme 32

Note. Typical sun sensor assembly shown in illustration.

The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through a trim panel located at the top of the instrument panel. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness.

Scheme 33

1. Disconnect and isolate the negative battery cable.
2. Remove the trim panel (2) that contains the sun sensor (1) from the top of the instrument panel using Trim Stick (special tool #C-4755, Trim Stick) or equivalent and disconnect the instrument panel wire harness connector from the sensor.
3. Using Trim Stick (special tool #C-4755, Trim Stick) or equivalent, gently pry on both sides of the sun sensor assembly and remove the sun sensor from the panel.

1. Align the tab on the sun sensor (1) with the opening in the panel (2).
2. Gently push the sun sensor into the panel until the sensor snap retainers are securely engaged.
3. Connect the instrument panel wire harness to the sun sensor and install the panel onto the instrument panel. Make sure the panel snap retainers are fully engaged.
4. Reconnect the negative battery cable.

Scheme 34

The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals.

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

Scheme 35

Note. Typical A/C pressure transducer and refrigerant line shown in illustration.

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3).
3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal.

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

Note. Typical A/C pressure transducer and refrigerant line shown in illustration.

1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3).
2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer to 5.1 N.m (45 in. lbs.).
3. Connect the wire harness connector (1) to the A/C pressure transducer.
4. Reconnect the negative battery cable.

Note. Take the proper precautions to protect the instrument panel from cosmetic damage.

Scheme 36

1. Remove the instrument panel and place it on a workbench. Refer to «PANEL, Instrument , Removal»(ref-457777-S33453955062012030200000) .
2. Remove the instrument panel cover. Refer to «COVER, Instrument Panel , Removal»(ref-457777-S23142639732012030200000) .
3. Remove the instrument panel ducts and place the center distribution duct on a workbench. Refer to «DUCT, Instrument Panel , Removal»(ref-457787-S15393211452012030200000) .
4. Remove the three retainers (3 and 4) that secure the defroster duct (1) to the center distribution duct (2) and remove the defroster duct.

1. Position the defroster duct (1) onto the center distribution duct (2).
2. Install the three retainers (3 and 4) that secure the defroster duct to the center distribution duct.
3. Install the instrument panel ducts onto the instrument panel support. Refer to «DUCT, Instrument Panel , Installation»(ref-457787-S28234008552012030200000) .
4. Install the instrument panel cover Refer to «COVER, Instrument Panel , Installation»(ref-457777-S14566843742012030200000) .
5. Install the instrument panel. Refer to «PANEL, Instrument , Installation»(ref-457777-S21962648422012030200000) .

Scheme 37

Note. Illustration shown in illustration with seat cushions removed for clarity.

Note. Automatic transmission model shown in illustration. Manual transmission model similar.

Scheme 38

1. Remove the floor console. Refer to «CONSOLE, Floor , Removal»(ref-457777-S37024560332012030200000) .
2. Disengage the floor console duct (1) from the rear duct adapter (3) and slide the adapter rearward into the rear duct (2).
3. Disengage the floor console duct from the stud (4) on the floor panel.
4. Disengage the floor console duct from the rear floor distribution duct (5) and remove the console duct. NOTE: Illustration shown in illustration with center front seat removed for clarity.
5. If required, remove the front seat. Refer to «SEAT, Front , Removal»(ref-457777-S40693473282012030200000) and «SEAT, Front Center , Removal»(ref-457777-S38332699542012030200000) .
6. Remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat support (3).
7. Disengage the rear duct from the rear outlet (4) and remove the rear duct.

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

1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the outlet.
2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the front seat. Refer to «SEAT, Front , Installation»(ref-457777-S41622774832012030200000) and «SEAT, Front Center , Installation»(ref-457777-S08268480482012030200000) . NOTE: Illustration shown with seat cushions removed for clarity. NOTE: Automatic transmission models shown in illustration. Manual transmission model similar.
3. Install the floor console duct (1) onto the rear floor distribution duct (5). Make sure the ducts are fully engaged to each other.
4. Engage the floor console duct onto the stud (4).
5. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure the ducts are fully engaged to each other.
6. Install the floor console. Refer to «CONSOLE, Floor , Installation»(ref-457777-S26995067582012030200000) .

Scheme 39

1. Remove the front seats. Refer to «SEAT, Front , Removal»(ref-457777-S40693473282012030200000) and «SEAT, Front Center , Removal»(ref-457777-S38332699542012030200000) .
2. Roll back the front carpet from under the instrument panel toward the rear of the vehicle. Refer to «CARPET, Floor , Removal»(ref-457777-S35576273262012030200000) .
3. Disengage the rear floor ducts (2 and 5) from the floor support bracket (3) and from the studs (4) located on the floor panel.
4. Disconnect the rear floor ducts from the HVAC housing (1) and remove the ducts.

1. Connect the rear floor ducts (2 and 5) to the HVAC housing (1).
2. Engage the rear floor ducts to the studs (4) and the floor support bracket (3).
3. Reposition the front carpet. Refer to «CARPET, Floor , Installation»(ref-457777-S29207556902012030200000) .
4. Install the front seats. Refer to «SEAT, Front , Installation»(ref-457777-S41622774832012030200000) «SEAT, Front Center , Installation»(ref-457777-S08268480482012030200000) .

Note. Take the proper precautions to protect the instrument panel from cosmetic damage.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Remove the instrument panel and place it on a workbench. Refer to «PANEL, Instrument , Removal»(ref-457777-S33453955062012030200000) .
2. Remove the instrument panel cover. Refer to «COVER, Instrument Panel , Removal»(ref-457777-S23142639732012030200000) .
3. Remove the retainer (1) that secures the driver side demister duct (2) to the end of the instrument panel support (4).
4. Disconnect the driver side demister duct from the center distribution duct (3) and remove the demister duct.
5. Remove the retainer (1) that secures the passenger side demister duct (5) to the end instrument panel support (6).
6. Remove the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel duct (3).
7. Disconnect the passenger side demister duct from the center distribution duct (4) and remove the demister duct.
8. Remove the retainer (3) that secures the passenger side instrument panel duct (2) to the end of the instrument panel support (1).
9. Remove the retainer (2) that secures the passenger side instrument panel duct (3) to the middle of the instrument panel support (3).
10. Remove the retainer (1) that secures the driver side instrument panel duct (3) to the middle of the instrument panel support (2).
11. Remove the retainer (4) that secures the passenger side instrument panel duct (6) to the middle of the center distribution duct (5).
12. Remove the retainer (3) that secures the driver side instrument panel duct (1) to the end of the instrument panel support (2).
13. Remove the two retainers (1) that secure the passenger side instrument panel duct (2) and the driver side instrument panel duct (4) to the middle of the instrument panel support (3).
14. Remove the passenger side instrument panel duct.
15. Remove the two retainers (1 and 3) that secure the center distribution duct (4) to the middle of the instrument panel support (5).
16. Remove the driver side instrument panel duct (2) and the center distribution duct.

1. Position the driver side instrument panel duct (2) and the center distribution duct (4) to the instrument panel support (5).
2. Install the two retainers (1 and 3) that secure the center distribution duct (4) to the middle of the instrument panel support.
3. Position the passenger side instrument panel duct (2) the instrument panel support (3) and connect it to the center distribution duct.
4. Install the two retainers (1) that secure the passenger side instrument panel duct and the driver side instrument panel duct (4) to the middle of the instrument panel support.
5. Install the retainer (3) that secures the driver side instrument panel duct (1) to the end of the instrument panel support (2).
6. Install the retainer (1) that secures the driver side instrument panel duct (3) to the middle of the instrument panel support (2).
7. Install the retainer (4) that secures the passenger side instrument panel duct (6) to the middle of the center distribution duct (5).
8. Install the retainer (2) that secures the passenger side instrument panel duct (3) to the middle of the instrument panel support (3).
9. Install the retainer (3) that secures the passenger side instrument panel duct (2) to the end of the instrument panel support (1).
10. Position the driver side demister duct (2) to the instrument panel support (4) and connect it to the distribution duct (3).
11. Install the retainer (1) that secures the driver side demister duct to the instrument panel support.
12. Position the passenger side demister duct (5) to the instrument panel support (6) and connect it to the distribution duct (4).
13. Install the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel duct (3).
14. Install the retainer (1) that secures the passenger side demister duct to the instrument panel support.
15. Install the instrument panel cover. Refer to «COVER, Instrument Panel , Installation»(ref-457777-S14566843742012030200000) .
16. Install the instrument panel. Refer to «PANEL, Instrument , Installation»(ref-457777-S21962648422012030200000) .

Note. Take the proper precautions to protect the instrument panel from cosmetic damage.

1. Remove the instrument panel and place it on a workbench. Refer to «PANEL, Instrument , Removal»(ref-457777-S33453955062012030200000) .
2. Remove the instrument panel cover. Refer to «COVER, Instrument Panel , Removal»(ref-457777-S23142639732012030200000) .
3. Remove the retainer (1) that secures the driver side demister duct (2) to the instrument panel support (4).
4. Disconnect the driver side demister duct from the center distribution duct (3) and remove the duct.
5. Remove the retainer (1) that secures the passenger side demister duct (5) to the instrument panel support (6).
6. Remove the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel duct (3).
7. Disconnect the passenger side demister duct from the center distribution duct (4) and remove the demister duct.

1. Position the driver side demister duct (2) to the instrument panel support (4) and connect it to the distribution duct (3).
2. Install the retainer (1) that secures the driver side demister duct to the instrument panel support.
3. Position the passenger side demister duct (5) to the instrument panel support (6) and connect it to the distribution duct (4).
4. Install the retainer (2) that secures the passenger side demister duct to the passenger side instrument panel duct (3).
5. Install the retainer (1) that secures the passenger side demister duct to the instrument panel support.
6. Install the instrument panel cover. Refer to «COVER, Instrument Panel , Installation»(ref-457777-S14566843742012030200000) .
7. Install the instrument panel. Refer to «PANEL, Instrument , Installation»(ref-457777-S21962648422012030200000) .

Scheme 48

All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted behind the instrument panel in the passenger compartment. The HVAC housing assembly consists of the following

1. HVAC housing - The HVAC housing (1) consists of three pieces that are attached together by molded plastic retaining clips and screws. The HVAC housing contains the heater core, A/C evaporator and blend-air and mode-air doors, and has mounting provisions for the air-door actuators, floor console duct (when equipped with center floor console), blower motor, blower motor resistor or power module (depending on the control application), foam seals and the HVAC wire harness.
2. Air inlet housing - The air inlet housing (2) is mounted to the right end of the HVAC housing and contains the recirculation-air door and has mounting provisions for the recirculation door actuator.

The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is allowed to flow through or around the heater core. The dual zone heating A/C system uses two blend door actuators while the single zone system uses only one blend door actuator.

The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an H-block type A/C expansion valve, evaporator and evaporator temperature sensor to cool and dehumidify the incoming air prior to blending it with the heated air. The temperature control(s) determines the discharge air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the output air temperature of the system. The mode door actuators operate the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor or power module (depending on application), which is located at the bottom of the HVAC housing. The electric door actuators, blower motor resistor or power module, blower motor and evaporator temperature sensor are connected to the vehicle electrical system by the HVAC wire harness.

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

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

Scheme 49

1. Disconnect and isolate the negative battery cable.
2. Disconnect the HVAC wire harness lead (3) from the blower motor (2).
3. Remove the three screws (1) that secure the blower motor to the bottom of the HVAC housing (4) and remove the blower motor.

1. Position the blower motor (2) into the bottom of the HVAC housing (4).
2. Install the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.7 N.m (15 in. lbs.).
3. Connect the HVAC wire harness lead (3) to the blower motor.
4. Reconnect the negative battery cable.

Note. Disassembly of the HVAC housing is not required to remove heater core.

Scheme 50

Scheme 51

1. Remove the HVAC housing (4) and place it on a workbench. Refer to «HOUSING, HVAC , Removal»(ref-457787-S23114339322012030200000) .
2. Remove the foam seal (1) from the flange (2).
3. Remove the two screws (3) that secure the flange to the front of the HVAC housing.
4. Carefully disengage the retaining tab that secures the flange to the HVAC housing and remove the flange.
5. Carefully pull the heater core (2) out of the front of the HVAC housing (1).
6. Inspect all foam seals and replace as required.

Note. If the foam seals on the heater core are deformed or damaged, they must be replaced.

1. Inspect the foam seals on the heater core (2) and replace as required.
2. Carefully install the heater core into the front of the HVAC housing (1).
3. Position the flange (2) onto the front of the HVAC housing (4). Make sure the retaining tab is fully engaged.
4. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 1.1 N.m (10 in. lbs.).
5. Install the foam seal (1) onto the flange. NOTE: If the heater core is being replaced, flush the cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
6. Install the HVAC housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .

Scheme 52

Note. Typical A/C service port shown in illustration.

1. Remove the protective cap (1) from the service port (2).
2. Recover the refrigerant from the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port.
4. Install a plug in, or tape over the opened service port(s).

Note. Typical A/C service port shown in illustration.

1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Remove the tape or plug from the service port (2). CAUTION: Damage may result to a service port valve core if the valve core is not fully seated in the A/C service port. Such damage can result in a loss of refrigerant.
3. Install and tighten the valve core into the service port(s) using a Schrader type valve core tool.
4. Evacuate and charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) . NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete.
5. Install the protective cap (1) onto the service port.

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. 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. 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.

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.

Note. If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

1. Carefully install the A/C evaporator (1) into the blower motor and evaporator housing (2).
2. Carefully install the blower motor and evaporator housing (6) onto the HVAC housing (3). Align the dowel pins to the holes in the housing.
3. Carefully engage the nine retaining tabs (1 and 4). Make sure the retaining tabs are fully engaged.
4. 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.).
5. Remove the tape or plugs from the evaporator tube fittings.
6. 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.
7. Install the A/C expansion valve (5) onto the evaporator tube tapping block (3).
8. 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.
9. Install the foam seal (1) onto the HVAC housing (2).
10. 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).
11. Engage the HVAC wiring harness to the two retaining clips (5). Make sure the wire harness is fully engaged to the retaining clips.
12. Install the HVAC housing. Refer to «HOUSING, HVAC , Installation»(ref-457787-S16509831732012030200000) .
13. 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.

Scheme 53

Scheme 54

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. If equipped with a gasoline engine, remove the air filter housing and mounting bracket from the right side of the engine compartment.
4. If equipped with the 6.7L diesel engine, remove the battery and battery tray from the right side of the engine compartment.
5. Remove the nut (2) that secures the A/C liquid line (4) from the condenser jumper line tapping block (1).
6. Disconnect the A/C liquid line from the condenser jumper line tapping block and remove and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened refrigerant line fitting and jumper line port.
8. 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).
9. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-ring seals.
10. 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.
11. Disengage the A/C liquid line (2) from the two retaining clips (1) and remove the liquid line.
12. If required, replace the two liquid line retaining clips.

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.

1. Position the A/C liquid line (2) into the engine compartment and engage the liquid line to the two retaining clips (1). Make sure the retaining clips are fully engaged.
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 (3) to 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.).
6. Remove the tape or plugs from the opened liquid line fitting and condenser jumper line port.
7. Lubricate a new O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring 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 liquid line (4) to the condenser jumper line tapping block (1).
9. Install the nut (2) that secures the A/C liquid line to the condenser jumper line tapping block. Tighten the nut to 23 N.m (17 ft. lbs.).
10. If equipped with the 6.7L diesel engine, install the battery tray and battery to the right side of the engine compartment.
11. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing to the right side of the engine compartment.
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) .

Scheme 55

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 (1) that secures the A/C liquid line (2) and A/C suction line (3) to the A/C expansion valve (4).
4. Disconnect the A/C liquid and suction lines and from the A/C expansion valve and position the refrigerant lines out of the way.
5. Remove the O-ring seals from the liquid and suction line fittings and discard.
6. Install plugs in, or tape over the opened liquid and suction line fittings.
7. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block (3).
8. Remove the A/C expansion valve from the evaporator tube tapping block and remove and discard the O-ring seals.
9. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports.

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.

1. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports.
2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the 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.
3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3).
4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 N.m (97 in. lbs.).
5. Remove the tape or plugs from the liquid and suction line fittings.
6. Lubricate new O-ring seals with clean refrigerant oil and install them onto the liquid and 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.
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. Reconnect the negative battery cable.
10. Evacuate the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
11. Adjust the refrigerant oil level. Refer to «OIL, Refrigerant , Standard Procedure»(ref-457787-S36984087812012030200000) .
12. Charge the refrigerant system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .