04 - (2011) HVAC Manual (S16053) PDF

SERVICE MANUAL
SERVICE MANUAL SECTION
HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010
Model: TranStar®
Model: WorkStar®
S16053
January 2011
S16053
© January 2011 NC2 Global LLC All rights reserved
All other trademarks are the property of their respective owners.
TABLE OF CONTENTS
TABLE OF CONTENTS
1. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1. SYSTEM OPERATIONAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Distribution (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Distribution (Air Conditioning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Air Distribution (Heat and Ventilation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Air Distribution (Defrost). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A/C Refrigerant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.2. COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Freeze Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Recirculation Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HVAC Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3. INTERNAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Heater Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Evaporator Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.4. UNDER HOOD COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Compressor and Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
A/C Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.5. HVAC ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
General Operation Of The HVAC Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3. SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.1. CONTROL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.2. BLOWER FAN SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3. TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4. MODE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
MAX Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
NORM Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Bi-Level Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Vent Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Floor Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Mix Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.5. DEHUMIDIFYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4. SERVICE PROCEDURES FOR R-134A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.1. R-134A SERVICE PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.2. RECOMMENDED SERVICE TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3. SEALANT DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.4. REFRIGERANT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.5. LEAK DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
IRTI4608032100 Leak Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
S16053 I
TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

ITNOD400 Leak Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Ultrasonic Leak Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Refrigerant Leak Testing with Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.6. AUTOMATIC MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.7. DISCHARGING THE SYSTEM (RECYCLE MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.8. EVACUATING THE SYSTEM (VACUUM MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.9. CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.10. FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Flushing Using the IRTI4608032100 (Recommended Method). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Alternate Method for Flushing (and Purging) the A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.11. OIL FILL GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Oil Separation During Refrigerant Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Excessive Oil Loss Due to Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.12. CHECKING COMPRESSOR OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5. REMOVE AND INSTALL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.1. PRESSURE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Pressure Transducer – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Pressure Transducer – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.2. LOW PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Low Pressure Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Low Pressure Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
5.3. FREEZE PROBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Freeze Probe – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Freeze Probe – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
5.4. HVAC AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
HVAC Air Filter – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
HVAC Air Filter – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.5. REFRIGERANT LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Refrigerant Line – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Refrigerant Line – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
5.6. FILTER-DRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Filter-Drier – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Filter-Drier – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
5.7. THERMOSTATIC EXPANSION VALVE (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Thermostatic Expansion Valve (TXV) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Thermostatic Expansion Valve (TXV) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5.8. FRESH AIR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fresh Air Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fresh Air Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
5.9. INTERIOR MODULE TRIM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Interior Module Trim Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Interior Module Trim Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
5.10. FRESH/RECIRCULATE DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Fresh/Recirculate Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Fresh/Recirculate Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
5.11. BLEND DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Blend Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Blend Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
5.12. MODE DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Mode Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
ii S16053
TABLE OF CONTENTS

Mode Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.13. FRESH/RECIRCULATE DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fresh/Recirculate Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fresh/Recirculate Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
5.14. BLEND DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Blend Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Blend Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
5.15. MODE DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Mode Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Mode Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
5.16. RECIRCULATION FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Recirculation Filters – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Recirculation Filters – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
5.17. LINEAR POWER MODULE (LPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Linear Power Module (LPM) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Linear Power Module (LPM) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
5.18. BLOWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Blower Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Blower Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.19. HEATER CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Heater Core – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Heater Core – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.20. HVAC CONTROL PANEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
HVAC Control Panel Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
HVAC Control Panel Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.21. COMPRESSOR/CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Compressor/Clutch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Compressor/Clutch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.22. A/C CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5.23. HEATER HOSES/LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5.24. EVAPORATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Evaporator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Evaporator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
5.25. BLOWER SCROLL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Blower Scroll Housing – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Blower Scroll Housing – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
5.26. SPLITTING/SEPARATING BLOWER SCROLL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Splitting/Separating Blower Scroll Housing – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Splitting/Separating Blower Scroll Housing – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
5.27. INTERIOR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Interior Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Interior Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
5.28. SPLITTING/SEPARATING INTERIOR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Splitting/Separating Interior Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Splitting/Separating Interior Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
5.29. FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
6. DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

6.1. PRELIMINARY CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Check for Obvious Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Refrigerant Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
S16053 III
TABLE OF CONTENTS
Check for Noncondensable Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

6.2. PHYSICAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Physical Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Refrigerant Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Line Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
6.3. A/C SYSTEM TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
6.4. TROUBLESHOOTING TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
HVAC Control Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Mode Door Actuator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Blend Door Actuator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Fresh/Recirculate Door Actuator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Linear Power Module/Blower Motor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
A/C Compressor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Pressure Transducer Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Freeze Probe Thermistor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Low Pressure Switch Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
7. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
7.1. TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
7.2. AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
8. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

8.1. SERVICING SYSTEM (IRTI4608032100). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
8.2. IRTI4608032100 TEMPERATURE PROBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
8.3. REFRIGERANT IDENTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
8.4. ITNOD400 REFRIGERANT LEAK DETECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
8.5. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
8.6. FLUSH/PURGE FITTING ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
8.7. TOOLS OBTAINED LOCALLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
8.8. ELECTRONIC SERVICE TOOL (EST), EZ-TECH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
iv S16053
1. SAFETY PRECAUTIONS
Refrigerant R-134a is a nonflammable, nonexplosive, and noncorrosive hydrofluorocarbon refrigerant. R-134a
is heavier than air and has a slight ether-type odor. Although R-134a is classified as a safe refrigerant, the
following precautions must be observed to protect the A/C system components and the person working on
the system.
WARNING
Carbon monoxide is a colorless, odorless, and dangerous gas that is present in vehicle
exhaust. To prevent personal injury or death, when it is necessary to operate the engine
during vehicle service in a confined area, always use the proper equipment to vent the
exhaust gasses outside of the work area.
WARNING
To prevent personal injury or death, safety goggles or other adequate eye protection
must be worn when working with refrigerant. The temperature of liquid refrigerant is
-29 degrees C (-20 degrees F). Serious injury or blindness will result from refrigerant
contacting the eyes.
WARNING
To prevent personal injury or death, if the refrigerant should contact the eyes, DO NOT
rub them. Splash the eyes with cold water for at least 15 minutes to gradually get the
temperature above the freezing point. See a doctor immediately.
WARNING
To prevent personal injury or death, wear nonporous gloves. Should liquid refrigerant
come into contact with the skin, remove any contaminated clothing, including shoes;
then treat the injury as though the skin had been frostbitten or frozen. See a doctor
immediately.
WARNING
To prevent personal injury or death, be certain that pressurized refrigerant containers

are not exposed to open flame or temperatures above 51 degrees C (125 degrees F). Do
not discard empty refrigerant containers where they are likely to be subjected to the heat
of trash burners, etc.; they may explode, resulting in personal injury or possible death.
Containers must be stored, installed, and disposed of in accordance with all state and
local ordinances.
S16053 1
WARNING
To prevent personal injury or death, never weld, solder, steam clean or use excessive
heat on any of the air conditioning lines or equipment while the system is charged. Heat
applied to any part will cause the pressure within the system to become excessive, which
may result in an explosion and possible personal injury.
WARNING
To prevent personal injury or death, do not smoke or allow any type of fire or flame
in the immediate area while servicing the air conditioning system. Refrigerant is not
combustible; however, in the presence of heat it changes to a poisonous gas. Inhalation
can cause death or serious injury.
WARNING
To prevent personal injury or death, R-134a must not be mixed with air and then
pressurized. When mixed with large quantities of air and pressurized, R-134a becomes
combustible.
WARNING
To prevent personal injury or death, refrigerant must be recovered from the air
conditioning system before any components of the system are removed or replaced.
Removing components while pressure is in the system will cause personal injury or
death.
WARNING
To prevent personal injury or death, do not remove the compressor oil fill plug to
check the oil level in the refrigerant compressor while the A/C system is charged with
refrigerant. The crankcase side of the compressor is under pressure and personal
injury or death may result. It is not possible to check the oil level in the compressor on
an A/C system that is under system pressure.
WARNING
To prevent personal injury or death, do not install or remove A/C testing or charging
equipment while the engine is running. Serious injury or death may result from doing
so.
2 S16053
WARNING
To prevent personal injury or death, always use approved refrigerant recycling

equipment when working with R-134a to prevent accidental discharge. If released into
the atmosphere, the refrigerant evaporates very quickly and may displace the oxygen
surrounding the work area, especially in small or enclosed areas. This situation creates
the hazard of suffocation or brain damage for anyone in the work area. If a leak should
occur, avoid breathing the refrigerant and lubricant vapor. Thoroughly ventilate the
area before continuing with service. Federal and state laws require that refrigerant be
recovered and recycled to help protect the environment.
WARNING
To prevent personal injury or death, while the manifold gauge set is connected to both the
air conditioning system and refrigerant supply cylinder, never open the high side hand
valve of the manifold gauge set while the A/C system is operating. If hot, high pressure
refrigerant is forced through the gauge to the refrigerant supply cylinder, it could cause
the cylinder to rupture and cause personal injury or death.
WARNING
To prevent personal injury or death, always use correct replacement refrigerant hoses.
Do not use hoses other than those specified for the system being serviced. The use of
improper hoses may cause a hose rupture, which may result in personal injury or death.
WARNING
To prevent personal injury or death, during system diagnostic tests, DO NOT turn either
hand valve on the manifold gauge set for any reason; equipment can be damaged and
personal injury or death can result. When connected to the A/C system the gauges will
indicate the system pressures with the valves closed (fully CW). These valves are used
only while servicing the A/C refrigerant system.
WARNING
To prevent personal injury or death, when installing and removing any service hose or
fitting, a small amount of refrigerant may escape. Always follow all safety precautions to
avoid injury.
CAUTION
To prevent damage to HVAC components, use only new or recycled R-134a refrigerant;
not any of the so called “direct replacement” refrigerants. Use of a recovery machine
dedicated for R-134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns.
S16053 3
CAUTION
To prevent damage to HVAC components, use only the specified PAG lubricant in the
refrigerant system (see SPECIFICATIONS). PAG oils absorb atmospheric moisture very
quickly. Never leave PAG oil exposed to air for a prolonged time. Wear nonporous gloves
while handling PAG oil, and tightly reseal the oil container immediately after each use.
CAUTION
To prevent damage to HVAC components, use only MINERAL BASED refrigerant oil (see
SPECIFICATIONS) to lubricate O-rings and fittings.
CAUTION
Disconnect battery ground cable during service to prevent damage to the vehicle
electrical system. If the battery must remain connected for a specific test, use extreme
caution when taking measurements.
CAUTION
To prevent damage to engine and/or HVAC components, after replacing a compressor,

verify that the pulley alignment and belt tension are correct.
CAUTION
To prevent damage to HVAC components, when charging the A/C system, the refrigerant
tank must be kept upright. If the tank is not in the upright position, liquid refrigerant may
enter the system and cause compressor damage.
CAUTION
To prevent damage to the test equipment, make sure test equipment is clear of all moving
parts in the engine compartment.
CAUTION
To prevent damage and/or contamination to the IRTI4608032100 and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
IRTI4608032100. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the IRTI4608032100 charge cylinder.
CAUTION

sealants and leak stop chemicals in A/C systems may cause serious damage to the
IRTI4608032100 if they are present in the refrigerant recovered intended for recovery.
Detection devices are readily available to check for the presence of these chemicals and
are highly recommended to protect the IRTI4608032100.
NOTE – When servicing the A/C system, ensure that the inner gaskets are present in both service port
caps; and verify that the caps are installed when service is completed. The service port caps, with
functioning gaskets, are an important part of maintaining a leak free A/C system.
4 S16053
NOTE – Although your service equipment may appear physically different from the equipment shown
here, the function of the equipment used to perform each service procedure is basically the same. If
you are performing these service procedures using service equipment different from that shown, refer
to the manufacturer’s instructions supplied with that equipment.
S16053 5
GENERAL DESCRIPTION
2. GENERAL DESCRIPTION
1. INTERIOR MODULE 6. CONDENSER

2. FRESH AIR MODULE 7. CONDENSER TO EVAPORATOR
3. SUCTION LINE LINE
4. COMPRESSOR 8. FILTER-DRIER
5. COMPRESSOR TO 9. LOW PRESSURE SWITCH
CONDENSER LINE
Figure 1 The Heater/Ventilation/Air Conditioning (HVAC) System
The Blend-Air air conditioning and heating system is a system of components designed to provide conditioned
air to the occupants of the vehicle. The term "Blend-Air" refers to the mixing or blending of air from the
cooling and heating systems to produce a desired air temperature for the vehicle occupants. The two main
modules (the fresh air module and interior module) are mounted on opposite sides of the cowl panel on the
passenger side of the vehicle. The evaporator core, freeze probe, fresh/recirculate air door, air door actuator,
and recirculation air filter(s) are located on, or near, the cowl mounted interior module on the interior side of the
cowl panel. The expansion valve, filter-drier, and low pressure switch are part of the interior module, however,
these components are located on the under-hood side of the cowl assembly. The condenser, compressor,
heater hoses, and A/C lines are located under the hood. The fresh air module houses the HVAC filter only, and
has two drain tubes located on the bottom of the module. The HVAC filter can be accessed from the HVAC
filter access cover located on front of the fresh air module.
NOTE – A heater-only version of the system is also available. The heater components and operation are
identical to those described for the air conditioning and heating system.
6 S16053
GENERAL DESCRIPTION
1. FUSE PANEL COVER 3. HVAC CONTROL PANEL

2. CENTER IP TRIM PANEL 4. HVAC TRIM COVER
(BEZEL)
Figure 2 In-Cab HVAC Components
The HVAC control panel is located in the center section of the instrument panel. The heater core, blower
motor, linear power module, evaporator, blower air scroll housing, passenger floor duct, and air door actuators
are located in (or on) the interior module and may be serviced without removing the interior module. The
interior module is located behind the HVAC trim cover.
S16053 7
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION
2.1. SYSTEM OPERATIONAL DESCRIPTION

Air Distribution (General)
1. HVAC AIR INLET 9. TEMPERATURE BLEND DOOR

2. FLOOR DUCT OUTLET 10. INTERIOR MODULE
3. DEFROST OUTLET 11. BLOWER ASSEMBLY
4. DEFROST/FLOOR DOOR 12. RECIRCULATE AIR INLET
(MODE DOOR) (OPEN TO CAB INTERIOR)
5. VENT OUTLET FOR 13. EVAPORATOR
INSTRUMENT PANEL 14. FRESH/RECIRCULATION AIR
6. IP VENTS/FLOOR DOOR (MODE DOOR
DOOR) 15. FRESH AIR MODULE
7. HEATER SCRUB DOOR 16. HVAC FILTER ELEMENT
8. HEATER CORE
Figure 3 Cross-Section of Front HVAC Air Handling Components
The electrically actuated fresh/recirculate air door is located in the interior module, and is controlled by the
mode control on the HVAC control panel. When the door is in the recirculate position, outside air is blocked
by the door. Recirculation air, from the cab, enters the interior module through recirculation filters located on
each side of the interior module. With the fresh/recirculate air door in the fresh air position, fresh outside air
enters the top of the fresh air module via an air duct which is part of the cowl drain tray. (The recirculate air is
blocked by the fresh/recirculate air door.) The air entering from the fresh air module enters the evaporator,
flows through the dual inlet, dual scroll blower assembly and then, is pushed through the interior module.
8 S16053
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION
The temperature blend door is controlled by the temperature control on the HVAC control panel. The electrically
actuated temperature blend door diverts air from the blower assembly, either through the heater core or around
it, depending on the temperature selected for the outlet air. Engine coolant flows through the heater core at all
times. The air proceeds to the mode doors. In addition to the temperature blend door there is the heater scrub
door, which is controlled via a linkage driven from the temperature blend door. The purpose of the heater scrub
door is to close off the air pathway from picking up hot air while operating in A/C mode.
The two mode doors, defrost/floor and IP vent/floor, are controlled by the mode control on the HVAC control
panel. The doors are located at the top of the interior module and are controlled together via a gear assembly
and an electrical actuator. These mode doors direct air to the air outlets (floor ducts, instrument panel vents,
and/or defrost vents) based on the mode selected by the operator. The ductwork for the instrument panel
vents and the defrost vents is integrated into the instrument panel structure. The upper surfaces of the interior
module interface with ductwork through two large openings in the bottom of the Instrument Panel. Right-hand
drive (RHD) vehicles have a passenger floor duct attachedand a driver side floor duct attached to the right
side of the module.
The speed of the system blower motor, which controls the volume of air moved through the system, is selected
by the fan speed control on the HVAC control panel.
S16053 9
Air Distribution (Air Conditioning)
Figure 4 System Airflow by Mode
Figure 4A illustrates the system airflow when operating in the NORM A/C mode. In the NORM A/C mode, the
fresh/recirculate air door is in the fresh air position. Fresh outside air enters the top of the fresh air module
via an air duct, which is part of the cowl drain tray. The remainder of NORM A/C operation is identical
to MAX A/C operation.
10 S16053
Figure 4B illustrates the system airflow when operating in the MAX A/C mode. In the MAX A/C mode, the
fresh/recirculate air door is in the recirculate position; outside air is blocked by the door. Recirculation air
(REC), from the cab, enters the interior module through the recirculation filters, located on each side of
the interior module. The air is pulled by the blower assembly through the evaporator core and is pushed
through the interior module. The temperature blend air door diverts air either through the heater core or past
it depending on the temperature selected for the outlet air. Although the temperature control is operational
while in the A/C modes, the temperature control is generally set to divert all air around the heater core. The air
proceeds to the mode doors where all of the air is directed to the instrument panel vents.
Figure 4C illustrates the system airflow when operating in the Bi-Level A/C mode. The Bi-Level A/C mode
operation is identical to NORM A/C operation; except, the mode doors direct the output air to both the floor
ducts, and the instrument panel vents.
Air Distribution (Heat and Ventilation)
Figure 4A illustrates the system airflow when operating in the Heat and Ventilation Vent mode. In the Heat
and Ventilation Vent mode, the fresh/recirculate air door is in the fresh air position. Fresh outside air enters
the top of the fresh air module via an air duct, which is part of the cowl drain tray. The air is pulled into the
interior module, through the evaporator core, by the dual scroll blower assembly. The blower then pushes the
air through the remainder of the interior module. The temperature blend air door diverts air either through the
heater core or past it depending on the temperature selected for the outlet air. The temperature blended air
proceeds to the mode doors where all of the air is directed to the instrument panel vents. Figure 4A shows all
air bypassing the heater core (temperature control set to cool, full CCW).
Figure 4D illustrates the system airflow when operating in the Heat and Ventilation Floor mode. The Heat
and Ventilation Floor mode is identical to the Heat and Ventilation Vent mode; except, the mode doors direct
all of the output air to the floor ducts. Figure 4D shows all air diverted through heater core (temperature
control set to hot, full cw).
Air Distribution (Defrost)
Figure 4E illustrates the system airflow when operating in the Bi-Level Defrost/Heat mode. In the Bi-Level
Defrost/Heat mode the fresh/recirculate air door is in the fresh air position. Fresh outside air enters the top of
the fresh air module via an air duct, which is part of the cowl drain tray. The air is pulled into the interior module,
through the evaporator core, by the dual scroll blower assembly. The blower then pushes the air through the
remainder of the interior module. The temperature blend air door diverts air either through the heater core or
past it depending on the temperature selected for the outlet air. The air proceeds to the mode doors where the
doors direct the output air to both the defrost ducts, and the floor ducts. Figure 4E shows air passing through,
and around the heater core (temperature control set around midrange).
Figure 4F illustrates the system airflow when operating in the Defrost mode. The Defrost mode is identical to
the Bi-Level Defrost/Heat mode; except, the mode doors direct all of the output air to the defrost ducts.
S16053 11
A/C Refrigerant Flow
1. RAM AIR 10. COLD AIR

2. CONDENSER 11. EVAPORATOR
3. SERVICE PORT (HIGH 12. WARM AIR
PRESSURE) 13. FREEZE PROBE
4. DISCHARGE LINE 14. EXPANSION VALVE
5. COMPRESSOR 15. FILTER-DRIER
6. SUCTION LINE 16. HIGH PRESSURE GAS
7. PRESSURE TRANSDUCER 17. HIGH PRESSURE LIQUID
8. LOW PRESSURE SWITCH 18. LOW PRESSURE LIQUID
9. SERVICE PORT (LOW 19. LOW PRESSURE GAS
PRESSURE)
Figure 5 A/C Refrigerant Flow Diagram
The refrigerant cycle consists of four phases: compression, condensation, expansion, and evaporation.
Consider the starting point at the compressor.
12 S16053
When any air conditioning position is selected on the HVAC control panel, the clutch assembly mounted on the
front of the compressor becomes engaged. When engaged, the clutch armature assembly is magnetically
drawn to the pulley assembly on the compressor shaft, thereby engaging the clutch and driving the compressor.
The suction side of the compressor draws low pressure refrigerant vapor (34 to 345 kPa, or 5 to 50 psi) from
the low side of the system, coming from the evaporator, through the TXV. The compressor then compresses
the refrigerant vapor and discharges it at increased temperature and pressure (800 to 2,100 kPa, or 120 to 300
psi) through the high side line, which connects the compressor to the condenser.
An internal lubricating system uses the suction side intake crankcase pressure differential to coat internal parts
with a thin film of oil. This lubrication also travels along with the refrigerant throughout the air conditioning
system to lubricate various system components.
High pressure/high temperature refrigerant vapor from the compressor enters at the top of the condenser,
circulates down through the coils, and exits at the bottom of the condenser as high-pressure/high-temperature
refrigerant liquid. As the vapor condenses (changes state), some of its heat is released to the coils and fins of
the condenser. This heat is continually carried away by the outside air, which passes over the external fin
surfaces as it flows through the condenser.
The efficiency of the condenser operation is affected by ram air flowing through the condenser. For this reason,
it is important that the engine cooling fan be operating properly. Also, that the condenser cooling fins must
remain free of airborne contamination (leaves, insects, dirt, etc.), which can block the fins and cause system
temperatures to run higher than normal.
When operating properly, the condenser acts as an efficient heat exchanger, containing refrigerant vapor in
approximately two-thirds of the upper portion of its coils and condensed refrigerant liquid in the lower one-third
portion. A pressure transducer located in the output line of the condenser is used to control system operation
by providing inputs to the Body Controller. The condenser passes high temperature/high pressure liquid
refrigerant to the filter-drier. The primary function of the filter-drier is the removal of any moisture or solid
contamination from the refrigerant before it can cycle through the system and cause internal damage.
The next component in the refrigerant system is the expansion valve. The expansion valve is the dividing line
between the high- and low-pressure sides of the system. High-pressure liquid refrigerant enters the expansion
valve from the filter-drier. The valve senses the temperature of the refrigerant leaving the evaporator core.
Then, based on the sensed temperature, the valve regulates the amount of refrigerant that it passes to the
evaporator core. While leaving the expansion valve, the refrigerant starts to expand, entering the evaporator
core as a low-pressure, low-temperature liquid.
Within the evaporator core, the lower pressure permits the liquid refrigerant to boil or evaporate, changing its
state from a liquid to a low-pressure/low-temperature vapor; and absorbing heat from the evaporator core
and the air surrounding it. Cooling and dehumidifying of the cab’s interior takes place as the refrigerant vapor
passes through the evaporator’s finned tubes and absorbs heat from the cab air pulled through the evaporator
core by the system blower. Humidity condenses on the external surfaces of the cooled evaporator fins and
is channeled (drained) out of the interior module through drain valves. The refrigerant exits the evaporator
outlet as a low-pressure/low-temperature vapor and is drawn through the low-pressure side of the expansion
valve by the suction created by the compressor. The refrigerant pressure is monitored by a low pressure
switch that is mounted on the low-side of the filter-drier (suction line). The refrigerant pressure measured by
the low-pressure switch is monitored by the Body Controller, which is used to control A/C system operation
and detect system faults. A freeze probe is mounted on the evaporator core, to monitor the temperature and
prevent evaporator freeze up.
The compressor repressurizes the refrigerant, causing it to again become a high-pressure/high-temperature

vapor that is pumped to the condenser, where the cycle is repeated.
S16053 13
GENERAL DESCRIPTION COMPONENTS
2.2. COMPONENTS
1. INTERIOR MODULE 7. LOW PRESSURE SWITCH

2. RECIRCULATION FILTER 8. THERMOSTATIC EXPANSION
3. HVAC FILTER ACCESS COVER VALVE (TXV)
4. FRESH AIR MODULE 9. FREEZE PROBE
5. LOW SIDE SERVICE PORT 10. LINEAR POWER MODULE
6. DRAIN TUBE (LPM)
Figure 6 HVAC Unit
Thermostatic Expansion Valve (TXV)
The thermostatic expansion valve controls the amount of liquid refrigerant that enters the evaporator core. The
valve is connected to both the input and output lines of the evaporator core. By sensing the temperature of
the refrigerant at the output of the evaporator, the valve determines the amount of refrigerant needed at the
evaporator input to keep the evaporator operating within operational parameters.
Freeze Probe
The freeze probe is located in the fins of the evaporator, and is used to measure temperature so as to
prevent evaporator freeze up.
Low Pressure Switch
The low pressure switch is a device that disengages the compressor clutch when the system pressure drops
below a predetermined level. The low pressure switch is mounted in the evaporator outlet line (suction line).
The refrigerant pressure measured by the low pressure switch is monitored by the Body Controller, which is
used to control A/C system operation and detect system faults. The refrigerant system must be discharged
before removing and replacing the low pressure switch.
14 S16053
COMPONENTS GENERAL DESCRIPTION
Linear Power Module
The Linear Power Module (LPM) is mounted on the blower scroll housing (part of the interior module),
located in the cab under the passenger side of the instrument panel. The LPM establishes the blower speed
by reading the HVAC control panel output signal whose value is based on the setting of the blower speed
control knob. As the blower speed control is turned cw, the LPM increases the voltage across the blower
motor, and the blower speed increases.
Recirculation Filter
CAUTION
To prevent damage to HVAC components, maintain clean filters.
The recirculation filters are mounted in front of the recirculation inlets, on each side of the interior module. The
recirculation filters clean particles out of the air, during recirculation mode, that may damage or reduce the
performance of any of the HVAC unit components.
HVAC Control Panel
The HVAC control panel is located in the center console of the instrument panel. The control panel consists
of three knobs actuating three long-life potentiometers. Internally, the control panel contains circuitry that
electronically controls the blower motor speed and the three air door actuator motors. The blower speed
control is detented to provide seven distinct blower speeds, in addition to the OFF position. The temperature
control has fifteen detents. The mode control is used to select the HVAC operating mode, indicated by seven
mode icons and five dots (for ’in-between’ modes). The ’heat only’ system has five mode icons, and four
dots for ’in-between’ modes.
S16053 15
GENERAL DESCRIPTION INTERNAL COMPONENTS
2.3. INTERNAL COMPONENTS
1. HVAC FILTER 6. EVAPORATOR

2. HEATER CORE 7. RECIRCULATION FILTER
3. MODE DOOR ACTUATOR 8. FILTER-DRIER
4. BLEND DOOR ACTUATOR 9. RECIRCULATION DOOR
5. BLOWER MOTOR ACTUATOR
Figure 7 HVAC Unit (Side Housing Removed for Clarity)
Filter-Drier
The primary function of the filter-drier is to remove any moisture or solid contamination from the refrigerant
before it can cycle through the system and cause internal damage. A drying agent (desiccant) separates and
absorbs any moisture contained in the liquid refrigerant. The desiccant also contains a dye to allow easier
detection of refrigerant leaks.
The filter-drier itself is not repairable, and must be replaced if found to be defective. The filter-drier must
also be replaced whenever the system becomes contaminated due to an internal compressor failure or
any extended exposure to the atmosphere (30 minutes or longer). This action will help prevent subsequent
corrosion and damage to the system.
Heater Core
The heater core is located in the interior module mounted in the cab under the passenger side of the instrument
panel. The heater core is a heating assembly made of fin and tube construction, with inlet and outlet fittings for
connecting the heater hoses from the engine cooling system. The inlet and outlet fittings protrude through the
cowl next to the fresh air module. Engine coolant flows through the heater core at all times. The temperature of
the air output by the heating/air conditioning system is determined by diverting more or less of the input air
through the heater core. The heater core is serviced from inside the cab.
16 S16053
UNDER HOOD COMPONENTS GENERAL DESCRIPTION
Blower Assembly
The blower assembly is located in the blower scroll housing (part of the interior module), mounted in the cab
under the passenger side of the instrument panel. The blower assembly used in the heater or heater-air
conditioning system consists of a permanent magnet motor attached to a balanced ’squirrel-cage’ fan unit. The
motor speed is controlled by the left knob on the HVAC control panel on the instrument panel. The blower
provides air circulation through the heater core and evaporator, and delivery of the treated air throughout the
cab interior.
Evaporator Core
The evaporator core is located in the interior module mounted in the cab under the passenger side of
the instrument panel. The core is a cooling assembly made of tube and fin construction, with “C-plate”
block-style inlet and outlet fittings. Drain valves for both condensate and rain water are incorporated in the
bottom of the interior module.
HVAC Filter
CAUTION
To prevent damage to HVAC components, maintain clean filters.
The HVAC filter cleans particles out of the air, during fresh air mode, that may damage or reduce the
performance of any of the HVAC unit components. The HVAC filter is located inside the fresh air module. The
HVAC filter can be serviced through the HVAC filter access cover located on front of the fresh air module.
2.4. UNDER HOOD COMPONENTS

Pressure Transducer
The pressure transducer is a pressure-sensing device threaded into the condenser refrigerant output line. The
transducer provides an electrical signal to the Body Controller, which monitors and controls the operation of the
A/C system. The refrigerant system does not have to be discharged to replace the pressure transducer.
Compressor and Clutch
The system uses a compressor configured with a proprietary international head to accommodate the “C-plate”
block-style fittings. It is mounted on the engine and is belt-driven through an electromagnetic clutch, which
acts to engage (turn ON) or disengage (turn OFF) the compressor in response to the air conditioning system
controls (HVAC control panel and Body Controller). When engaged, the clutch armature assembly is
magnetically drawn to the pulley assembly on the compressor shaft, thereby engaging the clutch and allowing
the drive belt to drive the compressor. A pressure-relief valve on the compressor offers protection to the
compressor in extreme high-pressure conditions.
Condenser
The air conditioning condenser is located at the front of the vehicle between the engine radiator and the
grille. The condenser is a heat exchanger made of fin and tube construction, with “C-plate” block-style inlet
and outlet fittings.
A/C Plumbing
C-plate style block fittings are utilized on all refrigerant line connections except the TXV. This block fitting
incorporates a secondary moisture and dirt seal within a unique plate inserted in the block fitting. The primary
O-ring seal has a large cross section for improved sealing. The nylon barrier type of hose used prevents the
S16053 17
GENERAL DESCRIPTION HVAC ELECTRICAL SYSTEM OVERVIEW
refrigerant from escaping through the walls of the hose into the atmosphere. When servicing air conditioning
systems, use only replacement hoses approved for air conditioning systems.
2.5. HVAC ELECTRICAL SYSTEM OVERVIEW

The heater/ventilation/air conditioning (HVAC) system contains both mechanical and electrical components.
The mechanical and electrical system is described in this manual. For information covering the electrical part
of the system, refer to ELECTRICAL TROUBLESHOOTING in this manual.
Malfunctions in the HVAC system could be attributed to either mechanical or electrical failures in the system.
Diagnosis of a malfunctioning system should always begin by performing the procedures in the DIAGNOSIS
AND TROUBLESHOOTING section (See DIAGNOSIS AND TROUBLESHOOTING, page 113) to determine
what part of the system is malfunctioning.
General Operation Of The HVAC Electrical System
The controls on the HVAC control head are used to adjust the cab air temperature mix, select the blower
speed, and select the system operating mode, including recirculation and distribution of cab air. The blower
speed is controlled by varying the amount of voltage applied to the blower motor. The temperature mix and
system operating mode are selected by electronically controlling the actuators that position the airflow doors
located in the interior module. The HVAC control head also communicates with the body controller to request
compressor turn on (for AC and defrost operation).
The control head communicates fault conditions to the body controller for certain conditions monitored by the
control head (operation of the air door actuator motors). If the HVAC control head detects a fault condition, the
body controller will log a diagnostic trouble code.
The body controller controls the cycling of the air conditioner compressor. In general the body controller
monitors the refrigerant sensors (transducer, freeze probe, and the low pressure switch) and other system
parameters to determine if all parameters are within acceptable limits. If parameters are acceptable, the body
controller will turn on the compressor when requested by the HVAC control head, and will cycle the compressor
to keep the system within acceptable operating parameters.
When the body controller detects readings outside of the acceptable ranges, it will generate and log a
diagnostic trouble code. If the body controller determines that continued operation would be destructive, it
shuts down the A/C system by preventing the compressor from turning on.
18 S16053
SYSTEM OPERATION
3. SYSTEM OPERATION
The operation of the Blend-Air system is based on standard automotive air conditioning and heating principles.
NOTE – The following descriptions cover the ’heater/air conditioner’ version of the system. Operation
of the ’heater only’ system (available on some models) is nearly identical, except all air conditioning
information can be ignored.
3.1. CONTROL ASSEMBLY
1. BLOWER FAN SPEED CONTROL 4. HEATER ONLY CONTROL

2. TEMPERATURE CONTROL 5. AIR CONDITIONER/HEATER
3. MODE CONTROL CONTROL
Figure 8 HVAC Control Panel Assembly
All major functions of the A/C-heater system are controlled from the control panel assembly. It consists of three
rotary knobs, which electronically control the blower fan speed, the A/C compressor clutch, and the actuators
that move the air doors used to control system air distribution and temperature.
3.2. BLOWER FAN SPEED CONTROL

This control regulates the amount of air provided to the vents in any mode you select. Turn the knob clockwise
to increase fan speed. Turning the control to the OFF position will shut off the fan, but does not prevent
outside air from entering the vehicle. (On vehicles equipped with A/C, moving the mode knob to the MAX A/C
position will close the fresh air door preventing outside air from entering the vehicle.) Turning off the fan speed
control prevents the A/C compressor from operating.
3.3. TEMPERATURE CONTROL

This control regulates the temperature of the air discharged from the vents. The blue area of the control
indicates cooler temperatures while the red area indicates warmer temperatures. This control operates
the blend door that determines what portion of the air flowing through the system is deflected through the
heater core. As the temperature control is rotated clockwise, more air is deflected through the heater core,
increasing the temperature of the air entering the cab.
3.4. MODE CONTROL

This control selects the operating mode of the system (HEAT, VENTILATE, DEFROST, and A/C) and controls
which outlets in the cab are used to distribute the air. This is accomplished by electronically controlling the A/C
compressor clutch, as well as three air doors located in the in-cab interior module. In addition to the modes
indicated by icons, the mode control can select ’in between’ modes indicated by dots. These positions allow
fine tuning of the air distribution by providing a distribution mix that is between the mixes provided by the icons
on either side of the selected dot (refer to Table 1).
S16053 19
SYSTEM OPERATION MODE CONTROL
The air conditioning settings are indicated by icons with snowflakes.
Table 1 Air Distribution Chart
CONTROL KNOB POSITION AIRFLOW

Air Conditioner Systems Heater Only Systems Panel Floor Windshield
MAX A/C PANEL 100%
NORM A/C 100%
DOT 1 50% 50%
BI-LEVEL DOT 1 75% 25%
DOT 2 BI-LEVEL 50% 50%
PANEL 100%
DOT 3 DOT 2 25% 75%
FLOOR FLOOR 100%
DOT 4 DOT 3 75% 25%
MIX BLEND 50% 50%
DOT 5 DOT 4 25% 75%
DEFROST DEFROST 100%
MAX Air Conditioning Mode
In this mode, all airflow is directed to the panel air outlets, and the air is recirculated inside the vehicle. In the
MAX A/C mode, the fresh/recirculate air door is in the recirculate position; outside air is blocked by the door.
Use this mode to block out any outside odors, smoke, or dust and to cool the interior rapidly upon initial startup
in very hot or humid weather. When this mode is selected, the HVAC control panel (control head) sends a
signal to the Body Controller requesting that the A/C compressor be turned on.
NOTE – Continuous use of the Recirculate mode may make the inside air stuffy. Use of this mode for
longer than fifteen minutes is not recommended.
NORM Air Conditioning Mode
In this mode, all airflow is directed to the panel air outlets. Fresh (outside) air is used to cool the vehicle in
this mode. When this mode is selected, the HVAC control panel (control head) sends a signal to the Body
Controller requesting that the A/C compressor be turned on.
20 S16053
DEHUMIDIFYING SYSTEM OPERATION
Bi-Level Air Conditioning Mode
In this mode, 75% of the airflow is directed to the panel air outlets, 25% of the airflow is directed to the floor air
outlets, and fresh (outside) air is circulated inside the vehicle.
Vent Mode
In this mode, all airflow is directed to the panel air outlets and fresh (outside) air is circulated inside the vehicle.
Floor Mode
In this mode, all airflow is directed to the floor air outlets and fresh (outside) air is circulated inside the vehicle.
Mix Mode
In this mode, 50% of the airflow is directed to the defrost and side demist air outlets, 50% of the airflow is
directed to the floor air outlets, and fresh (outside) air is circulated inside the vehicle. The A/C compressor
turns on automatically when in this mode to reduce humidity levels and help reduce moisture buildup on the
windshield. To improve defroster efficiency, remove ice and/or snow from the windshield prior to starting
the vehicle.
Defrost
In this mode, all of the airflow is directed to the defrost and side demist air outlets, and fresh (outside) air is
circulated inside the vehicle. The A/C compressor turns on automatically, when in this mode, to reduce
humidity levels and help reduce moisture build up on the windshield. To improve defroster efficiency, remove
ice and/or snow from the windshield prior to starting the vehicle.
3.5. DEHUMIDIFYING
In mild weather with high humidity conditions, the heater system can be operated simultaneously with the air
conditioner to dehumidify moist air. Set the mode control to either the NORM or A/C bi-level position, place
the fan speed control to any setting, and move the temperature control towards HOT (clockwise) until a
comfortable temperature is maintained. The air conditioner will remove the humidity while the heater keeps the
cab comfortable.
S16053 21
SERVICE PROCEDURES FOR R-134A
4. SERVICE PROCEDURES FOR R-134A

Vehicle received for service/repair:
1. Sealant check
2. Refrigerant identification
3. Leak check (if a leak is suspected)
4. Diagnose A/C system (may include A/C system performance test – A/C SYSTEM TEST MODE)
5. Discharge A/C system (RECYCLE)
6. Repair A/C (may include a leak check)
7. Flush A/C system (if contaminated)
8. Evacuate A/C system (includes a leak test to verify repair)
9. Charge A/C system (CHARGE)
10. Calculate and add refrigerant oil
11. Perform A/C system performance test (A/C SYSTEM TEST MODE)
22 S16053
R-134A SERVICE PRECAUTIONS SERVICE PROCEDURES FOR R-134A
4.1. R-134A SERVICE PRECAUTIONS
WARNING
To prevent personal injury or death, before doing any of the work below, read the
SERVICE WARNINGS. Failure to read the Service Warnings, and to be aware of the
dangers involved when working with refrigerant could lead to serious personal injury
or death.
CAUTION

IRTI4608032100 if they are present in the refrigerant intended for recovery. Detection
devices are readily available to check for the presence of these chemicals and are highly
recommended to protect the IRTI4608032100.
CAUTION

In addition to the Safety Precautions, special attention to the following rules during servicing, and component
remove and install, will aid in avoiding unnecessary and time-consuming problems.
1. Perform service inside a warm, well-ventilated dry shop.
2. When working on the A/C system, keep the work area and tools as clean as possible. Also, clean all
connections, ports or fittings before disconnecting or removing components.
3. Never use hot steam to clean the inside of the system. Flushing the system with the IRTI4608032100 A/C
Servicing System is recommended for this purpose.
4. All A/C component and refrigerant line openings should be immediately plugged during removal and
remain so until re-installation to prevent the entry of dirt, moisture and other foreign material. Even the
slightest particle can cause problems if carried to a vulnerable place within the system.
5. Never remove protective caps from components until the moment of assembly into the system.
6. Never install non-sealed components.
S16053 23
SERVICE PROCEDURES FOR R-134A R-134A SERVICE PRECAUTIONS
1. O-RING 2. C-PLATE
Figure 9 Fitting C-Plate and O-Ring
7. Anytime an A/C fitting is disconnected, the O-ring and C-plate must be replaced. The new O-ring must be
lubricated with MINERAL-BASED oil (P/N ZGGR6912). The C-plate does not require lubrication. Never
use grease, penetrating oil, motor oil, Ester or PAG oil, etc. to lubricate O-rings and fittings.
8. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original positions.
Never bend a hose to a radius less than ten times the diameter of the hose.
Never route a hose any closer than four inches from the exhaust manifold or related piping.
Periodically inspect hoses for leaks or brittleness. Replace lines immediately if damaged.
9. All fittings must be tightened as specified in the TORQUE CHART (See Table 20, page 135). Use only a
torque wrench known to be accurate.
10. Whenever possible, use a backup wrench when loosening or tightening fittings.
11. Replace the filter-drier on any system, which has been opened for more than a short period (approximately
30 minutes); after the system has been flushed; and/or when the system has become contaminated (such
as due to an internal compressor failure). If the filter-drier is one of multiple components being installed in
the system, the filter-drier should be one of the last components installed. This reduces the amount of
time that the filter-drier desiccant is exposed to atmospheric moisture.
12. Refrigerant oil quickly absorbs moisture. Store oil only in moisture-free containers and keep oil containers
closed until ready to use. Close refrigerant oil container immediately after use.
13. The air conditioning system must be flushed any time the system has become contaminated (such as
due to an internal compressor failure). Refer to FLUSHING THE AIR CONDITIONING SYSTEM, (See
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM, page 38).
14. Whenever the system is discharged, the refrigerant oil level must be checked and/or replaced as specified
in OIL FILL GUIDELINES, (See OIL FILL GUIDELINES, page 42).
15. Any system that has been discharged due to leakage, or opened to replace a component, must be
evacuated (and the system oil quantity must be returned to normal).
16. Use extreme care to prevent moisture from entering the system. Moisture can freeze at the thermostatic
expansion valve and block refrigerant flow during system operation. Always properly evacuate the system
after service to remove any moisture and air from the system.
24 S16053
RECOMMENDED SERVICE TOOLS SERVICE PROCEDURES FOR R-134A
17. Spare components should be sealed and stored in a warm, dry facility.
4.2. RECOMMENDED SERVICE TOOLS

The service procedures provided in this manual are written around the following recommended service tools;
the IRTI4608032100 Servicing System, 12401-NAV Air Conditioning Oil and Dye Injection Equipment and the
ITNOD400. For more information on these tools, refer to SPECIAL TOOLS.
It is the servicer’s responsibility to obtain, read, and understand the operator manuals for all service equipment.
If other equivalent service tools are used, refer to the instructions provided by the tool manufacturer.
4.3. SEALANT DETECTION

CAUTION

Before any work is done on an A/C system, the refrigerant should be checked for sealants and leak stop
chemicals.
Sealants and leak stop chemicals in A/C systems may cause serious damage to the IRTI4608032100 if they
are present in the refrigerant intended for recovery. Detection devices are readily available to check for the
presence of these chemicals and are highly recommended to protect the IRTI4608032100. If a sealant is
detected, do not service vehicle.
S16053 25
SERVICE PROCEDURES FOR R-134A REFRIGERANT IDENTIFICATION
4.4. REFRIGERANT IDENTIFICATION

CAUTION

CAUTION

check refrigerant I.D. hose for oil or UV dye contamination before connecting. Replace
hose if necessary.
NOTE – The procedures described below, refer to the IRTI4608032100 A/C Servicing System refrigerant
identifier to verify R-134A refrigerant. If a different refrigerant identifier is being used, refer to the
instructions provided by the tool manufacturer.
Before any work is done on an AC system, the refrigerant should be identified.
Figure 10 Refrigerant Identifier Hose
The refrigerant identifier hose is found on the rear of the IRTI4608032100. The IRTI4608032100 screen will
guide you through connection and refrigerant sample process. If vehicle A/C system contains less than
98% R-134a, or substances other than R-134a, do not service vehicle. A system with some or all air in it,
would indicate a leak that can be repaired.
26 S16053
LEAK DETECTION SERVICE PROCEDURES FOR R-134A
4.5. LEAK DETECTION

NOTE – Refrigerant leaks are often indicated by an oily residue at the point of the leak.
There are several methods of refrigerant leak detection including: the IRTI4608032100 (in high pressure
mode), the ITNOD400 Leak Detector, an Ultraviolet Lamp, and high pressure Nitrogen with an Ultrasonic
Sensor. Navistar recommends using the IRTI4608032100 and the ITNOD400 Leak Detector whenever
practical. If different leak detection tools are used, refer to the instructions provided by the tool manufacturer.
The methods used to locate a refrigerant leak depend on how and when the leak is discovered.
A. If the system is received with a known or suspected leak, start the leak search BEFORE
discharging the system.
1. Perform the sealer detection check and refrigerant identification check. refer to
SEALANT DETECTION and REFRIGERANT IDENTIFICATION.
2. Visually inspect the system for component damage and/or oily leak residue.
3. Use the Ultraviolet (UV) Lamp to inspect the system for signs of phosphor dye,
indicating a leak point.
4. If the system still contains refrigerant, use the ITNOD400 Leak Detector to check all
connections and fittings. The connections and joints of the condenser and evaporator
should also be checked with the leak detector.
5. Use the IRTI4608032100 to recover the refrigerant; then use the High Pressure Leak
Detect mode and the ITNOD400 Leak Detector to check for leaks in the A/C system,
or individual components. When the leak check is complete, the refrigerant in the
system or component must be recovered before repairing the leak.
6. As an alternate method the discharged A/C system can be charged with high pressure
nitrogen and an ultrasonic leak detector used to locate the leak site.
B. If the leak is first detected by the IRTI4608032100 during the evacuation mode leak test;
follow the on-screen instructions to locate the leak by using the High Pressure mode and the
D-400A/ID440A-NAV Leak Detector.
IRTI4608032100 Leak Detection
The IRTI4608032100 automatically detects leaks during the AUTOMATIC and VACUUM (evacuation) modes.
The IRTI4608032100 determines that a leak is present when the A/C system being evacuated is unable to
reach or maintain a specified vacuum level. Once the leak is detected, the IRTI4608032100 will stop the
current operation and display a failure message.
To provide a method of locating a detected leak, follow the on-screen instructions to place the IRTI4608032100
into the High Pressure Leak Detect mode. This mode overcharges the A/C system with R-134A refrigerant
causing the leak to become more detectable by other tools, such as the ITNOD400 Leak Detector.
S16053 27
SERVICE PROCEDURES FOR R-134A LEAK DETECTION
CAUTION
To prevent damage to the A/C compressor, the vehicle A/C system must not be started if
the High Pressure Leak Detect procedure was used. The A/C system must be discharged
(RECYCLE) following the High Pressure Leak Detect procedure.
NOTE – The A/C system must be discharged before it can be opened for repairs.
Once the leak is located select the RECYCLE mode and follow the on-screen instructions to discharge the
system and disconnect the blue and red hoses from the service ports.
ITNOD400 Leak Detector
1. ITNOD400 LEAK DETECTOR

Figure 11 Leak Detectors
The ITNOD400 Leak Detector is hand-held devices having a flexible probe used to seek out refrigerant leaks.
An audio leak indicator signals a warning in the presence of a leak. It is important to become familiar with the
leak detector instructions. The speed at which the probe is moved over the component being checked is very
important in locating larger than permissible leaks. Leak check procedure should be in accordance with SAE
J2791. The detectors are also listed in the SPECIAL TOOLS section (See SPECIAL TOOLS).
Before using this detector to look for leaks, it is recommended to clean away all oil or grease, and blow away
refrigerant residue from fittings and A/C components. All suspected areas should be cleaned using soap and
water, not a solvent. A detected leak should be a flow of refrigerant, not a residual condition of refrigerant that
is trapped under an oil film, etc. A detected leak rate in excess of 1.0 oz./year is unacceptable.
Ultrasonic Leak Detectors
An ultrasonic leak detector listens for the distinctive “sound” of a gas passing through an opening. To use
this type of detector effectively, the refrigerant system is first discharged, and then pressurized to 2,068 kPa
(300 psi) using dry nitrogen and a manifold gauge set. Refer to REFRIGERANT LEAK TESTING WITH
NITROGEN. The detector is then used to scan the suspected joints or components. Depending on the detector
being used, a leak may be indicated by a visual or audible signal. Suspected leaks should not be cleaned
with a soap solution prior to scanning with this tool, as any solution remaining at the leak site may mask the
leak. The unit is a hand-held device and may include attachments to vary the directional sensitivity of the unit.
28 S16053
LEAK DETECTION SERVICE PROCEDURES FOR R-134A
Because this type of sensor does not sample the gas used in the system, it may be used with any refrigerant
system. It may also be used to detect leaks in the vehicle air system. It is important to become familiar with
the instructions for the leak detector being used.
Refrigerant Leak Testing with Nitrogen
1. LOW PRESSURE VALVE AND 3. NITROGEN CYLINDER AND

GAUGE (MANIFOLD GAUGE REGULATOR
SET)
2. HIGH PRESSURE VALVE AND
GAUGE (MANIFOLD GAUGE
SET)
Figure 12 Using Nitrogen to Pressurize the A/C System
NOTE – Before pressurizing the system with nitrogen the system refrigerant must be recovered.
When checking for refrigerant leaks using an ultrasonic detector, the refrigerant in the system must first be
recovered; then, the system must be pressurized to 2,068 kPa (300 psi) with dry nitrogen, as follows.
1. Connect a manifold gauge set to the A/C system. Refer to Figure 19.
A. Initially keep both gauge valves on manifold gauge set closed.

B. High pressure hose (red) to high pressure port on vehicle. (Open quick connect valve.)
C. Low pressure hose (blue) is not connected. (Keep gauge valve and quick connect valve
closed.)
S16053 29
SERVICE PROCEDURES FOR R-134A LEAK DETECTION
CAUTION
Opening the low pressure gauge valve while the system is pressurized may damage the
low pressure gauge.
2. Connect pressurized nitrogen cylinder to the manifold gauge set and pressurize A/C system to 2,068
kPa (300 psi).
A. Connect manifold gauge set yellow hose to nitrogen source.

B. Set output pressure at nitrogen cylinder regulator to 2,068 kPa (300 psi).
C. Slowly open high side gauge valve on manifold gauge set to pressurize A/C system (high
side gauge should read 2,068 kPa/300 psi).
3. Test for leaks using an ultrasonic detector.
4. After locating the leak, set the nitrogen cylinder regulator to 0 kPa (0 psi).
WARNING
To prevent personal injury or death, in the following step, the pressure must be released
in a manner that does not trap pressure in the A/C system.
5. Before disconnecting the manifold gauge set, slowly release the pressure from the A/C system by partially
disconnecting a fitting until the pressure is released.
6. Remove the manifold gauge set from the A/C system and repair the leak.
7. Evacuate the system; refer to EVACUATING THE SYSTEM.
8. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM.
30 S16053
AUTOMATIC MODE SERVICE PROCEDURES FOR R-134A
4.6. AUTOMATIC MODE

CAUTION

CAUTION

NOTE – The procedures below describe using the automatic mode of the IRTI4608032100 A/C Servicing
System to perform the recycle, vacuum, and charge operations on the A/C system. If a different A/C
servicing system is being used, refer to the instructions provided by the tool manufacturer.
In the automatic mode, the IRTI4608032100 can be used to perform a fully automatic A/C service. The
technician will be prompted for entry of data such as charge amount, and given options like vacuum leak test.
If the internal A/C database is used, some data will be provided based on the vehicle information entered.
Entry data can also be found in the specifications section of this manual, refer to SPECIFICATIONS. Once the
necessary data has been entered, the IRTI4608032100 will automatically perform the complete A/C service
(recycle, vacuum, and charge) and alert the technician for interaction or that the service is complete.
Tips for fastest refrigerant recovery:
1. Run truck with hood closed, cab heat set to floor or vent, and temperature set full clockwise
(HOT). The A/C and defrost modes must not be selected. Run until heater air is very warm (the
warmer the better).
2. Turn engine off, and return key to ON (engine off), set mode control to MAX A/C and blower to
LOW. (This blows warm air over the evaporator during the refrigerant recovery process.)
3. Recover or Recycle refrigerant with A/C machine.
4. Turn ignition key off after refrigerant recovery (to save truck battery life).
The Automatic Mode is NOT to be used for discharging the system to make repairs on the A/C system; the
automatic mode will automatically charge the system when it is complete. The intended use of the automatic
mode is for complete service (recycle, vacuum, and charge) of the system and/or to verify the level of
charge when a system appears to be undercharged or overcharged, and possibly to start a leak check. Use
“RECYCLE” mode when opening the A/C system is necessary for making repairs.
S16053 31
SERVICE PROCEDURES FOR R-134A AUTOMATIC MODE
1. CONDENSER TO EVAPORATOR 3. COMPRESSOR TO

LINE CONDENSER LINE
2. HIGH SIDE PRESSURE PORT 4. LOW SIDE PRESSURE PORT
Figure 13 A/C Service connection location
NOTE – Ensure that the oil drain bottle has enough remaining capacity to perform a service. Adjust
the o-ring slider so it is level with the oil in the oil drain bottle, and note amount of oil recovered once
automatic mode is completed.
1. Remove the protection caps from both service ports.
2. Review “Tips for fastest refrigerant recovery”.
3. Turn machine on, select Automatic on the IRTI4608032100 A/C Service System and follow on-screen
instructions.
4. Once automatic mode is complete, follow the on-screen instructions to disconnect the blue and red hoses
from the service ports on the vehicle and add oil to the system. Refer to AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT and OIL FILL GUIDELINES.
5. Ensure that protection caps are reinstalled on service ports (with inner gaskets).
NOTE – If the IRTI4608032100 detects a problem such as a leak while operating in Automatic mode, the
machine will halt operation and display a message on the screen. If this occurs follow the on-screen
instructions.
32 S16053
DISCHARGING THE SYSTEM (RECYCLE MODE) SERVICE PROCEDURES FOR R-134A
4.7. DISCHARGING THE SYSTEM (RECYCLE MODE)

CAUTION

CAUTION

CAUTION
To prevent damage HVAC components, the amount of oil lost during the recovery
process, component replacement, or purging/flushing must be replaced with new oil.
The method for determining how much refrigerant oil must be added to the A/C system
is located in the OIL FILL GUIDELINES (See OIL FILL GUIDELINES, page 42).
CAUTION
To prevent damage HVAC components, do not re-use recovered oil. Be sure to dispose
of recovered oil properly to avoid an environmental hazard.
NOTE – The procedures below describe using the RECYCLE mode of the IRTI4608032100 A/C Servicing
System to discharge R-134A refrigerant from the A/C system. If a different A/C servicing system is being
used, refer to the instructions provided by the tool manufacturer.
NOTE – If the system is being discharged because a leak is suspected, it may be helpful to begin leak
detection before discharging the system. This depends on the method of leak detection used. Refer to
LEAK DETECTION.
The IRTI4608032100 keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE)
to allow the technician to jump directly to any one of these functions. Recycle mode is used to discharge
the system (refrigerant recovery). The system must be discharged prior to removal and replacement of
malfunctioning components.
Tips for fastest refrigerant recovery:
1. Run truck with hood closed, cab heat set to floor or vent, and temperature set full clockwise
(HOT). The A/C and defrost modes must not be selected. Run until heater air is very warm (the
warmer the better).
2. Turn engine off, and return key to ON (engine off), set mode control to MAX A/C and blower to
LOW. (This blows warm air over the evaporator during the refrigerant recovery process.)
3. Recover or Recycle refrigerant with A/C machine.
4. Turn ignition key off after refrigerant recovery (to save truck battery life).
S16053 33
SERVICE PROCEDURES FOR R-134A DISCHARGING THE SYSTEM (RECYCLE MODE)
NOTE – Ensure that the oil drain bottle has enough remaining capacity to perform a service. Adjust the
o-ring slider so it is level with the oil in the oil drain bottle and note amount of oil recovered once recycle
mode is completed.
Refer to Figure 13 for the following steps:
3. Turn machine on, select Recycle on the IRTI4608032100 A/C Servicing System and follow on screen
instructions.
4. Once the recycle mode is complete, follow on-screen instructions to disconnect the blue and red hoses
from the service ports on the vehicle.
5. Record the amount of oil recovered by discharging the system and ensure that protective caps (with
inner gaskets) are reinstalled on service ports.
6. Work may now begin on the air conditioning system.
34 S16053
EVACUATING THE SYSTEM (VACUUM MODE) SERVICE PROCEDURES FOR R-134A
4.8. EVACUATING THE SYSTEM (VACUUM MODE)

CAUTION

CAUTION

sealants and leak-stop chemicals in A/C systems may cause serious damage to the
NOTE – The procedures below describe using the vacuum mode of the IRTI4608032100 A/C Servicing
System to evacuate the A/C system. If a different A/C servicing system is being used, refer to the
instructions provided by the tool manufacturer.
Whenever the air conditioning system has been discharged, the system must be completely evacuated of air
and moisture before being recharged.
NOTE – If the A/C system is to be flushed an/or purged, those procedures must be completed prior to
evacuating and recharging the system.
NOTE – If the A/C system being evacuated required replacement of the refrigerant compressor, the
correct amount of refrigerant oil must be added to the new compressor prior to evacuation of the system.
The amount of oil required must be determined (refer to OIL FILL GUIDELINES), and that amount of oil
should be added to the new compressor prior to installation.
The IRTI4608032100 keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE) to
allow the technician to jump directly to any one of these functions. Vacuum mode is used to evacuate the
system and test the system for leaks.
When this mode is initiated, the IRTI4608032100 will draw a vacuum on the system for a specified time. Then
the vacuum level will be monitored for 60 seconds. If the vacuum level rises above a specified level, an error
screen will be displayed (refer to LEAK DETECTION). If the vacuum level is maintained for 60 seconds,
the IRTI4608032100 will resume drawing a vacuum on the system for an additional specified time. At the
completion of the evacuation cycle, the system vacuum should measure 1000 microns or less. If this value
cannot be reached, refer to LEAK DETECTION. Specified times and vacuum levels used during the evacuation
mode are established on the IRTI4608032100 SETUP/DEFAULT VALUES screens.
S16053 35
SERVICE PROCEDURES FOR R-134A EVACUATING THE SYSTEM (VACUUM MODE)
3. Turn machine on, select Vacuum on the IRTI4608032100 A/C Servicing System and follow on screen
instructions.
4. If any leaks are detected repair accordingly or refer to Leak Detection in this manual.
5. Once the Vacuum mode is complete, the system is ready to be charged, DO NOT disconnect the blue and
red hoses from the service ports, until instructed to do so.
36 S16053
CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE) SERVICE PROCEDURES FOR R-134A
4.9. CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE)

CAUTION
To prevent damage to HVAC components, use only new or recycled R-134a refrigerant;
not any of the so called “direct replacement” refrigerants. Use of equipment dedicated
for R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility
concerns.
CAUTION
To prevent damage HVAC components, when charging the A/C system the refrigerant
tank must be kept upright. If the tank is not in the upright position, liquid refrigerant may
enter the system and cause compressor damage.
NOTE – The procedures below describe using the CHARGE mode of the IRTI4608032100 A/C Servicing
System to charge the A/C system with R-134a refrigerant. If a different A/C servicing system is being
used, refer to the instructions provided by the tool manufacturer.
Perform the Charging procedures, using new or recycled refrigerant, only after the following actions have
been completed:
• System components repaired and/or replaced.

• System flushed or purged (if required).
• System oil level restored (only necessary if compressor replaced)
• System completely evacuated.
The IRTI4608032100 keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE)
to allow the technician to jump directly to any one of these functions. Charge mode is used to charge the
system to a full charge.
1. The IRTI4608032100 red and blue hoses should still be connected as they were during the evacuation
operation.
2. Determine the amount of refrigerant to be charged. This information can be found in the SPECIFICATIONS
(See Table 18) section of this manual.
3. Select Charge on the IRTI4608032100 A/C Servicing System and follow on screen instructions.
4. Once the charge operation is complete, follow the on-screen instructions to perform A/C SYSTEM
PERFORMANCE TEST.
5. Once the A/C SYSTEM PERFORMANCE TEST is complete, follow the on-screen instructions to clear the
hoses; then disconnect the blue and red hoses from the service ports on the vehicles service port fittings.
6. Add the appropriate amount of refrigerant oil to the system. Refer to AIR CONDITIONING OIL AND DYE
INJECTION EQUIPMENT and OIL FILL GUIDELINES.
7. Install the protective caps (with inner gaskets) on both of the vehicle service port fittings.
S16053 37
SERVICE PROCEDURES FOR R-134A FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM
4.10. FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM

CAUTION
To prevent damage to HVAC components, never flush more than one component with
one attached hose at a time.
Systems that have had an internal compressor failure, been overcharged with refrigeration oil, or been left
open for an extended period of time will need to be flushed, purged, or both. Flushing and purging remove
contaminants that would have a negative effect on the life and operation of the air conditioning system, if
not removed.
Flushing removes contamination, excessive refrigerant oil, and moisture from A/C system components. When
a component is flushed, a liquid flushing agent (refrigerant or a solvent) is forced through it in a reverse
direction; the liquid cleans the part, picks up contaminants and flushes them out.
Purging can be performed in place of flushing when the system has not been contaminated by a compressor
failure. Purging must always be performed after using a solvent to flush the system. Purging removes flushing
solvent, excessive refrigerant oil, damp air, and loose particles from A/C system components. This assures
that A/C system components are dry and free of any contaminants.
Flushing and purging are performed on a system after the refrigerant has been recovered and before the
system is reassembled and evacuated. The only components that can be flushed or purged are the condenser,
evaporator, and hoses. The compressor, filter-drier, and expansion valve cannot be flushed or purged, and
must be replaced if contaminated.
When performing flushing and/or purging operations, adapters are required to connect the service equipment
to the HVAC system components. Refer to FLUSH/PURGE FITTING ADAPTERS for complete information on
these service adapters.
38 S16053
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM SERVICE PROCEDURES FOR R-134A
Flushing Using the IRTI4608032100 (Recommended Method)
NOTE – The procedures below describe using the REFRIGERANT FLUSH mode of the IRTI4608032100
A/C Servicing System . If a different A/C servicing system is being used, refer to the instructions
provided by the tool manufacturer.
The use of the IRTI4608032100 A/C Servicing System is recommended if the A/C system becomes
contaminated. A refrigerant flush, performed by the RTI machine, will force liquid refrigerant in a reverse
flow through a component, or components, to remove contaminants and oil. Contaminants are captured in
an external filter before returning the refrigerant to the service equipment. Because refrigerant is used as
the flushing agent in this method, a purging procedure is not required after flushing the system with the
RTI machine.
The following procedures must be observed whenever a component or system is flushed.
• Never flush the entire system. Flush the system in segments (never larger than one component and
one hose).
• Never flush the compressor, thermostatic expansion valve (TXV), or filter-drier.
• Flush each system section or component in the opposite direction of normal refrigerant flow.
• If the system has experienced an internal compressor failure (or other source of heavy contamination),
replace the compressor, the TXV, and the filter-drier prior to evacuating and charging the system. Refer to
OIL FILL GUIDELINES.
• If the system did not experience an internal compressor failure (or other source of heavy contamination),
change oil in the compressor (refer to OIL FILL GUIDELINES), reinstall the TXV, and replace the filter-drier
prior to evacuating and charging the system.
NOTE – The following procedures for flushing are general. The actual fittings and adapters required for
each procedure will vary according to the component or components being connected.
S16053 39
SERVICE PROCEDURES FOR R-134A FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM
1. RTI MACHINE 6. TYPICAL COMPONENT

2. BLUE HOSE 7. ADAPTER
3. FLUSH FILTER 8. RED HOSE
4. YELLOW HOSE 9. TYPICAL HOSE
5. EVAPORATOR CORE
Figure 14 Typical Flush Filter Hook-up
1. Select REFRIGERANT FLUSH on the IRTI4608032100 screen and press START.
2. Using the keypad, enter how long the component is to be flushed. Typical flush time is 10 minutes, times
may vary dependent on which component is being flushed and the severity of contamination.
NOTE – It is recommended 10 minutes per component as a base line to flush the component. Then to
evaluate the system and do another 10 minutes, repeating this until clean.
3. Follow the on-screen instructions. When instructed, connect flush filter and component to be flushed to
the IRTI4608032100.
4. When screen indicates that flush is finished, verify that the pressure gauges indicate 0 kPa (0 psi) or less
before carefully removing the connections from the component under test. If the pressure gauges indicate
pressure greater than 0 kPa (0 psi), perform the RECYCLE mode before disconnecting the component.
5. Following the on-screen instructions, empty the oil bottle and replace the flush filter.
40 S16053
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM SERVICE PROCEDURES FOR R-134A
Alternate Method for Flushing (and Purging) the A/C System
While flushing the system with IRTI4608032100 is the recommended method, the system can be flushed
and/or purged using pressurized dry nitrogen gas and a flushing solvent. A flush gun and adapters are also
required if this method is used. As this is an alternate method, step-by-step procedures are not provided.
WARNING
To prevent personal injury or death, dry nitrogen gas is recommended for flushing and/or
purging. Do not use nitrogen at pressures over 1378 kPa (200 psi). Personal injury or
death may result from doing so. Commercial cylinders of dry nitrogen contain pressures
in excess of 13780 kPa (2000 psi). This pressure must be reduced, using a pressure
regulator, to 1378 kPa (200 psi) for purging.
CAUTION
To prevent damage and/or contamination to HVAC components and R-134a refrigerant,

when flushing and/or purging components of the system use only dry nitrogen. The
introduction of compressed air into the A/C system may cause contamination of the
system.
When using this method, heavier contamination must be flushed using the pressurized nitrogen to force a
liquid flushing solvent through components. Purging components of lighter contamination and moisture or
leftover flushing solvent can be accomplished using only the pressurized nitrogen.
Flushing is generally necessary only after an internal compressor failure has contaminated the refrigerant
system. Purging must always be performed: after flushing the system with a solvent; any time there is
excessive refrigerant oil found in the system; or, when the system has been left open for an extended period
of time. Purging removes flushing solvent, excessive refrigerant oil, damp air, and loose particles from A/C
system components by passing a stream of inert, dry nitrogen gas through parts of the system or individual
components.
Flushing and purging are performed on a system after the refrigerant has been recovered and before the
system is reassembled and evacuated.
The following procedures must be observed whenever a component or system is flushed or purged:
• Never flush or purge the entire system. Flush or purge the system in segments (never larger than one
component and one hose) to lessen the chance of blowing contaminants throughout the system.
• Never flush or purge the compressor, thermostatic expansion valve (TXV), or filter-drier.
• Flush or purge each system section or component in the opposite direction of normal refrigerant flow.
• If the system requires purging only, change oil in the compressor (refer to OIL FILL GUIDELINES), reinstall
the TXV, and replace the filter-drier prior to evacuating and charging the system.
• If the system requires both flushing and purging, replace the compressor, the TXV, and the filter-drier prior
to evacuating and charging the system. Refer to OIL FILL GUIDELINES.
S16053 41
SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES
4.11. OIL FILL GUIDELINES
WARNING
To prevent personal injury or death, before doing any of the work below, read the
SERVICE WARNINGS. Failure to read the Service Warnings, and to be aware of the
dangers involved when working with refrigerant could lead to serious personal injury
or death.
CAUTION

do not re-use recovered oil. Be sure to dispose of recovered oil properly to avoid an
environmental hazard.
CAUTION
Replacement compressors contain a quantity of oil when shipped. To prevent damage

to HVAC components, this oil must be drained from the new compressor to verify and/or
adjust the quantity before refilling the compressor (and system) with the correct amount
of oil. Oil drained from a new compressor may be used to refill the compressor prior to
installation.
CAUTION
During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system
are removed, some of the refrigerant oil will go with the component. To prevent damage
to HVAC components and maintain the original total oil charge, it is necessary to
compensate for the oil lost by adding oil to the system with the new part.
The correct volume of refrigerant oil in the A/C system is critical for proper system operation. Insufficient
oil will result in compressor failure. Too much oil decreases cooling efficiency, resulting in poor system
cooling performance. In general, when servicing the system, ensure that the amount of oil (retained or
added) in the repaired system (compressor and components) equals the total system capacity indicated in
SPECIFICATIONS (See SPECIFICATIONS, page 135). Replacement oil may be added directly into the
compressor before evacuation, or injected into the system at any time after recharge. The following paragraphs
describe how to determine the quantity of refill oil needed under the most common conditions.
NOTE – Unless stated otherwise, the following procedures assume that the system is not being flushed
and/or purged.
A. If the refrigerant was only recovered for the purpose of measuring the refrigerant charge, or
to replace a low pressure switch, add the amount of oil removed from the system during the
refrigerant recovery procedure.
• Total replacement oil quantity = oil from refrigerant recovery procedure.
42 S16053
OIL FILL GUIDELINES SERVICE PROCEDURES FOR R-134A
B. If a compressor is replaced (and the system was not contaminated and had no leaks) refill
the new compressor with the amount of oil removed from the system during the refrigerant
recovery procedure, plus the quantity of oil that was contained in the old compressor. NOTE: New
compressors must be drained of shipping oil to verify and/or adjust the quantity before refilling the
compressor with the correct amount of oil. Refer to CHECKING COMPRESSOR OIL LEVEL, that
follows, for the procedures to drain and fill the oil in the refrigerant compressor.
• Total replacement oil quantity = oil from refrigerant recovery procedure + oil drained from
old compressor.
C. If a component other than the compressor is replaced, and there is no oil leak, add the amount of
oil removed from the system during the refrigerant recovery procedure, plus the amount indicated
for the replaced component in table 16.
• Total replacement oil quantity = oil from refrigerant recovery procedure + oil indicated in
component table.
D. If the amount of oil in the system is unknown (due to an oil leak, ruptured hose, etc.); refer to
EXCESSIVE OIL LOSS DUE TO REFRIGERANT LEAK, below.
E. Whenever the refrigerant system has become contaminated; make the necessary repairs, flush
the system, and replace the compressor, expansion valve, and filter-drier. The new compressor
must be drained of shipping oil to verify and/or adjust the quantity before refilling the compressor
with the correct amount of oil. Refer to CHECKING COMPRESSOR OIL LEVEL that follows, for
the procedures to drain and fill the oil in the refrigerant compressor. The replacement oil should be
added directly to the compressor before installing it. Refill the system with a full refill of oil.
• Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 135) .
Table 2 Oil Capacity by Component
Typical oil amount
Component cc fl.oz.
Evaporator 60 2.0
Condenser 30 1.0
Filter-drier 15 0.5
Expansion valve 0 0
Hoses (normal length) 10 0.3
Low Pressure Switch 0 0
Oil Separation During Refrigerant Recovery
The oil removed from the system during the refrigerant recovery process must be replaced. Always empty
the refrigerant station oil catch bottle before recovering the refrigerant. After recovering the refrigerant, check
the calibrated bottle to determine how much oil has been removed from the system. This quantity is used
to help determine the amount of oil that must be added to the system before or after the recharging of the
A/C system. Do not use recovered refrigerant oil.
S16053 43
SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES
Excessive Oil Loss Due to Refrigerant Leaks
CAUTION
After servicing the A/C system, always use new O-rings and C-plates when reassembling
the system components. O-rings must be lubricated with mineral oil.
When there is a significant refrigerant leak, an unknown amount of oil escapes from the system with the
refrigerant. When a significant leak is detected, perform the following procedures to replace the old system
oil with a full refill of new oil.
1. Use the service equipment and observation to determine the location of the leak. Refer to LEAK
DETECTION .
2. Discharge the system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE).
3. Make any necessary repairs.
4. If the refrigerant system appears contaminated, such as after an internal compressor failure, it must be
flushed. Refer to FLUSHING THE AIR CONDITIONING SYSTEM (See FLUSHING AND PURGING
THE AIR CONDITIONING SYSTEM, page 38).
5. If the refrigerant system DOES NOT appear to be contaminated, either;
• flush the system using the IRTI4608032100 A/C Servicing System. Refer to FLUSHING USING
THE IRTI4608032100.
• or purge the system using the alternate method for flushing (and purging) the A/C system. Refer to
ALTERNATE METHOD FOR FLUSHING (AND PURGING) THE A/C SYSTEM.
6. If the system was not contaminated:
A. Reinstall the expansion valve (removed for flushing).

B. Drain and discard the old oil from the compressor. Refer to CHECKING COMPRESSOR OIL
LEVEL that follows.
C. Refill compressor with new oil and then install the compressor.
Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 135).
D. Install a new filter-drier.
44 S16053
OIL FILL GUIDELINES SERVICE PROCEDURES FOR R-134A
7. If the system was contaminated:
A. Install a new expansion valve.

B. Replace the compressor. Verify that the new compressor contains the correct amount of oil.
The new compressor must be drained of shipping oil to verify and/or adjust the quantity before
refilling the compressor with the correct amount of oil. Refer to CHECKING COMPRESSOR
OIL LEVEL that follows. The replacement oil should be added directly to the compressor
before installing it.
Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 135).
C. Install a new filter-drier.
8. Evacuate the system; refer to EVACUATING THE SYSTEM (VACUUM MODE).
9. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE).
10. After repairing a leak, remove all traces of the fluorescent dye from the repaired area before retesting the
area. The dye can be removed with UV Dye Cleaner, ZTSE4618–2.
11. After running the system, retest the repaired area to verify the repair.
S16053 45
SERVICE PROCEDURES FOR R-134A CHECKING COMPRESSOR OIL LEVEL
4.12. CHECKING COMPRESSOR OIL LEVEL
WARNING
To prevent personal injury or death, do not remove the oil fill plug to check the oil level in
the refrigerant compressor after the A/C system has been charged with refrigerant. The
crankcase side of the compressor is under pressure and personal injury or death may
result.
It is not possible to check the oil level in the compressor on an A/C system that is under system pressure. If it is
suspected that there is not enough oil in the A/C system, it will be necessary to remove all of the oil currently in
the system and refill the system with a full oil charge.
The compressor oil level can be accurately checked only by removing the compressor from the vehicle and
draining the oil into a clean, calibrated container.
1. Verify that the system is discharged.
2. Remove the compressor.
Figure 15 Drain as Much Oil as Possible
3. Remove the oil plug and drain as much oil as possible into a suitable clean, calibrated container.
4. Remove the caps (if present) from the suction and discharge ports.
46 S16053
CHECKING COMPRESSOR OIL LEVEL SERVICE PROCEDURES FOR R-134A
Figure 16 Drain Oil While Turning Shaft
5. Drain remaining compressor oil from the suction and discharge ports, into the calibrated container, while
turning the shaft (clockwise only) by hand or with a socket wrench on the armature retaining nut. Turn
shaft one half turn every minute for approximately 3 minutes. Replace the caps on the suction and
discharge ports.
6. Measure and record the amount of oil drained from the compressor.
7. Inspect the oil for signs of contamination such as discoloration or foreign material.
8. If the oil shows signs of contamination, replace the compressor. Verify that the new compressor contains
the correct amount of oil (continue this procedure starting at step 3).
S16053 47
SERVICE PROCEDURES FOR R-134A CHECKING COMPRESSOR OIL LEVEL
Figure 17 Add New Oil to Compressor
9. If the oil is not contaminated, add the correct amount of oil to the compressor as determined by the OIL
FILL GUIDELINES (See OIL FILL GUIDELINES, page 42).
NOTE – Oil drained from a NEW compressor may be used to refill the compressor. DO NOT USE
recovered oil or oil drained from a used compressor.
10. Install oil fill plug taking care not to twist the O-ring seal. Replace the O-ring if damaged. Torque oil plug to
15 to 20 N•m (11 to 15 lbf-ft). Do not over-tighten plug to stop a leak. Stop leaks first by fixing any seat
damage, removing dirt and installing a new O-ring.
48 S16053
REMOVE AND INSTALL PROCEDURES
5. REMOVE AND INSTALL PROCEDURES

WARNING
To prevent personal injury or death, always turn the vehicle ignition key OFF before
performing Removal and Installation procedures.
NOTE – Special attention to the following, during component removal and installation, will aid in avoiding
unnecessary and time-consuming problems.
1. O-RING 2. C-PLATE
Figure 18 A/C Fitting C-Plate and O-Ring
A. When working on the A/C system keep the work area and tools as clean as possible. Also, clean
all connections, ports or fittings before disconnecting or removing components.
B. All A/C component and refrigerant line openings should be immediately covered or plugged
during removal and remain so until re-installation to prevent the entry of dirt, moisture and other
foreign material. Even the slightest particle can cause problems if carried to a vulnerable place
within the system.
C. Never remove protective caps from components until the moment of assembly into the system.
D. Never install non-sealed components.
E. If the filter-drier is one of multiple components being installed in the system, it should be the last
component installed. This reduces the amount of time that the filter-drier desiccant is exposed to
atmospheric moisture.
F. Anytime an A/C fitting is disconnected, the O-ring and/or C-plate must be replaced (Figure 18). The
new O-ring must be lubricated with MINERAL-BASED oil. The C-plate does not require lubrication.
Never use grease, penetrating oil, motor oil, Ester or PAG oil, etc. to lubricate O-rings and fittings.
G. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original
positions.
Never bend a hose to a radius less than ten times the diameter of the hose.
Never route a hose any closer than four inches from the exhaust manifold or related piping.
H. Whenever possible use a backup wrench when loosening or tightening fittings.
I. All fittings must be tightened as specified in the TORQUE CHART (See Table 20, page 135). Use
only a torque wrench known to be accurate.
S16053 49
REMOVE AND INSTALL PROCEDURES PRESSURE TRANSDUCER
NOTE – The following figures and procedures cover most typical engine/chassis configurations. Some
configurations may differ slightly due to component mounting locations and/or hose routings.
5.1. PRESSURE TRANSDUCER

CAUTION
The pressure transducer is not interchangeable with a pressure switch. To prevent

damage to the A/C system, replace a defective pressure transducer only with the
recommended part.
NOTE – The pressure transducer can be removed and installed without removing the refrigerant from
the A/C system.
The pressure transducer is located on the condenser-to-evaporator refrigerant line.
Pressure Transducer – Removal
1. PRESSURE TRANSDUCER 3. ELECTRICAL CONNECTOR

2. CONDENSER-TO-EVAPORATOR 4. RADIATOR
LINE
Figure 19 Pressure Transducer
1. Disconnect electrical connection to pressure transducer.
2. Unscrew pressure transducer from condenser-to-evaporator refrigerant line and cap open fitting.
50 S16053
PRESSURE TRANSDUCER REMOVE AND INSTALL PROCEDURES
Pressure Transducer – Installation
1. Install a new O-ring on pressure transducer fitting and lubricate O-ring and threads with mineral-based
oil (Figure 19, Item 1).
2. Screw pressure transducer onto condenser-to-evaporator line (Figure 19, Items 1 and 2) and tighten to 7
to 14 N•m (62 to 124 lbf-in).
3. Connect electrical connector-to-pressure transducer (Figure 19, Items 1 and 3).
S16053 51
REMOVE AND INSTALL PROCEDURES LOW PRESSURE SWITCH
5.2. LOW PRESSURE SWITCH
WARNING
To prevent personal injury or death, the low pressure switch CANNOT be removed and
installed without removing the refrigerant from the AC system.
Low Pressure Switch – Removal
1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE).
1. SUCTION LINE 3. ELECTRICAL CONNECTOR

2. LOW PRESSURE SWITCH
Figure 20 Low Pressure Switch
2. Cut wires ties as necessary.
3. Disconnect electrical connector from low pressure switch.
4. Unscrew low pressure switch from its fitting in the suction line and cap open fitting.
52 S16053
LOW PRESSURE SWITCH REMOVE AND INSTALL PROCEDURES
Low Pressure Switch – Installation
1. Ensure a new O-ring is installed on the new low pressure switch, and lubricate O-ring and threads with
mineral-based oil.
2. Screw low pressure switch into its fitting (Figure 20, Item 2) and tighten to 7 to 14 N•m (62 to 124 lbf-in).
3. Connect electrical connector to low pressure switch and secure with wire ties as necessary (Figure 20,
Items 2 and 3).
4. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES
c. AUTOMATIC MODE
S16053 53
REMOVE AND INSTALL PROCEDURES FREEZE PROBE
5.3. FREEZE PROBE

Freeze Probe – Removal
1. Remove blower scroll housing. Refer to BLOWER SCROLL HOUSING.
1. ELECTRICAL CONNECTOR 4. FREEZE PROBE

2. GROMMET 5. EVAPORATOR
3. INTERIOR MODULE
Figure 21 Freeze Probe
2. Cut wires ties as necessary and disconnect freeze probe electrical connector.
3. Press grommet through interior module with electrical connector.
NOTE – Prior to removing freeze probe, note how deep the freeze probe is inserted.
4. Gently pull the freeze probe out of face of the evaporator.
54 S16053
FREEZE PROBE REMOVE AND INSTALL PROCEDURES
Freeze Probe – Installation
1. Gently push the freeze probe into the face of the evaporator to the depth noted during removal (Figure 21,
Items 4 and 5).
2. Pull electrical connector through interior module with grommet. Ensure grommet seats properly in interior
module (Figure 21, Items 1, 2, and 3).
3. Connect freeze probe electrical connector and secure with wire ties as necessary (Figure 21, Items 1
and 4).
4. Install blower scroll housing. Refer to BLOWER SCROLL HOUSING.
S16053 55
REMOVE AND INSTALL PROCEDURES HVAC AIR FILTER
5.4. HVAC AIR FILTER

HVAC Air Filter – Removal
1. Unlatch and raise hood.
1. HVAC FILTER COVER 3. FILTER ELEMENT

2. FASTENERS 4. FRESH AIR MODULE
Figure 22 HVAC Filter
2. Locate HVAC filter cover and remove two fasteners securing it to the fresh air module.
3. Remove HVAC filter cover from fresh air module..
NOTE – Some early vehicles may be manufactured with a spar in the center of the fresh air module intake,
preventing removal of the HVAC filter. If a spar is present it must be removed in order to service the filter.
Use an appropriate cutting device to remove the spare. Make sure not to damage any A/C components
during removal.
4. Firmly grasp HVAC filter, and remove HVAC filter from fresh air module
HVAC Air Filter – Installation
1. Install a new (or cleaned) HVAC filter into fresh air module (Figure 22, Items 3 and 4).
2. Install HVAC filter cover and secure with two fasteners (Figure 22, Items 1 and 2).
3. Lower and latch hood.
56 S16053
REFRIGERANT LINE REMOVE AND INSTALL PROCEDURES
5.5. REFRIGERANT LINE

The three A/C refrigerant hoses/lines are connected in the same way; however, the number of mounting straps
and clamps may be different for each hose. Also, the routing of each hose varies for each vehicle model.
Depending on the vehicle model, replacement of specific A/C refrigerant lines may require the removal of
nearby assemblies (splash panel, fixed grille, or recirculation shield) to gain access to the fittings, or to remove
the A/C lines. Refer to Manual S09016 for additional procedures.
Refrigerant Line – Removal
1. HOSE SUPPORT CLAMP 5. CONNECTION FITTING

2. SUCTION LINE 6. COMPRESSOR
3. EVAPORATOR-TO-COMPRESSOR 7. CONDENSER
LINE 8. PRESSURE TRANSDUCER
4. CONDENSER-TO-EVAPORATOR
LINE
Figure 23 Refrigerant Lines
NOTE – When removing Condenser-to-Evaporator line, disconnect electrical connection to pressure

transducer.
2. Disconnect fitting at each end of hose/line being removed.
3. Unclip or remove all hose support clamps and strap locks used to secure hose/line. Note location and
orientation of each clamp and strap lock to allow for correct routing during installation.
4. Remove A/C hose/line.
S16053 57
REMOVE AND INSTALL PROCEDURES REFRIGERANT LINE
NOTE – When replacing Condenser-to-Evaporator line, remove pressure transducer from old line for
transfer to new line.
Refrigerant Line – Installation
NOTE – Before installing a new Condenser-to-Evaporator line, it may be necessary to transfer pressure
transducer from the old line to the new line.
1. If A/C system is to be flushed, perform that operation before reassembling the system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM.
2. Place new A/C hose/line in its approximate location.
NOTE – Always lubricate O-rings with mineral-based oil during installation.
3. Using new O-rings and C-plates connection fittings at each end of the A/C line (Figure 23), torque C-plate
nuts to 19 to 21 N•m (14 to 15 lbf-ft).
4. Secure the hose/line using all support clamps and strap locks removed during removal (Figure 23, Item 1).

c. AUTOMATIC MODE
58 S16053
FILTER-DRIER REMOVE AND INSTALL PROCEDURES
5.6. FILTER-DRIER
The filter-drier inlet and outlet lines are part of the filter-drier assembly.
NOTE – If the filter-drier is one of multiple components being replaced in the system, the filter-drier
should be one of the last components installed. This reduces the amount of time that the filter-drier
desiccant is exposed to atmospheric moisture.
Depending on the vehicle model, replacement of specific A/C refrigerant components may require the removal
of nearby assemblies (passenger side splash panel, etc.) to gain access to the components or related A/C
lines. Refer to Manual S09016 for additional procedures.
Filter-Drier – Removal
1. EXPANSION VALVE 7. FILTER-DRIER COVER SCREWS

2. LOCK PLATE SCREW 8. FILTER-DRIER COVER
3. FILTER-DRIER 9. LOW PRESSURE SWITCH
4. CONDENSER-TO-EVAPORATOR 10. ELECTRICAL CONNECTOR,
LINE LOW PRESSURE SWITCH
5. NUT
6. EVAPORATOR-TO-COMPRESSOR
LINE
Figure 24 Filter-Drier
2. Disconnect electrical connector from low pressure switch.
3. Remove low pressure switch and retain for install.
S16053 59
REMOVE AND INSTALL PROCEDURES FILTER-DRIER
4. Remove nut and disconnect condenser-to-evaporator line from filter-drier.
5. Remove nut and disconnect evaporator-to-compressor line from filter-drier.
6. Remove lock plate screw from locking plate on front of the expansion valve.
7. While supporting filter-drier, remove filter-drier cover screws from filter-drier cover. Slide filter-drier cover
down and remove.
8. Remove filter-drier by lifting it free of expansion valve.
Filter-Drier – Installation
NOTE – During installation, always lubricate O-rings on fittings with mineral-based oil.
2. Install and lubricate O-rings on tubes of the expansion valve. While supporting the filter-drier in place,
insert the tubes into the expansion valve. Secure the filter-drier by installing the filter-drier cover with
filter-drier cover screws (Figure 24). Torque filter-drier cover screws to 2.3 N•m (20 lbf-in).
3. Install locking plate with one lock plate screw to secure the tubes to the expansion valve (Figure 24, Item 2).
4. Using a new O-ring and C-plate, connect evaporator-to-compressor line to filter-drier and secure with nut
(Figure 24, Items 3, 5, and 6). Torque nut to 19 to 20 N•m (14 to 15 lbf-ft).
5. Using a new O-ring and C-plate, connect condenser-to-evaporator line to filter-drier and secure with nut
(Figure 24, Items 3, 4, and 5). Torque nut to 19 to 20 N•m (14 to 15 lbf-ft).
6. Install low pressure switch (Figure 24, Item 9).
7. Connect electrical connector to low pressure switch (Figure 24, Items 9 and 10).

c. AUTOMATIC MODE
9. Install passenger side splash panel, if previously removed.
60 S16053
THERMOSTATIC EXPANSION VALVE (TXV) REMOVE AND INSTALL PROCEDURES
5.7. THERMOSTATIC EXPANSION VALVE (TXV)

lines. Refer to Manual S09016 for additional procedures.
CAUTION
To prevent damage to HVAC components, while handling the TXV in the following
procedures, it is important to keep it and the entire A/C system as dirt-free as possible.
Thermostatic Expansion Valve (TXV) – Removal
2. Remove filter-drier. Refer to FILTER-DRIER.
1. REAR LOCKING PLATE 3. ALLEN SCREW

2. THERMOSTATIC EXPANSION
VALVE (TXV)
Figure 25 Expansion Valve (TXV)
3. With front locking plate removed from expansion valve, remove two Allen head screws from TXV. Remove
and retain rear locking plate.
4. Remove TXV from vehicle.
S16053 61
REMOVE AND INSTALL PROCEDURES THERMOSTATIC EXPANSION VALVE (TXV)
Thermostatic Expansion Valve (TXV) – Installation
NOTE – During installation always lubricate O-rings on fittings with mineral-based oil.
NOTE – Before installing new O-rings in the following steps, ensure that the old O-rings have been
removed.
2. Ensure that new lubricated O-rings are installed on all lines being connected to TXV.
3. Position rear locking plate over evaporator inlet and outlet lines (Figure 25).
4. Install TXV on rear locking plate over the inlet and outlet lines and secure TXV with two Allen head screws
(Figure 25). Torque screws to 4 N•m (35 to 38 lbf-in).
5. Install filter-drier. Refer to FILTER-DRIER.

c. AUTOMATIC MODE
62 S16053
FRESH AIR MODULE REMOVE AND INSTALL PROCEDURES
5.8. FRESH AIR MODULE

lines. Refer to S09016 Manual for additional procedures.
Fresh Air Module – Removal
1. Remove engine air filter housing and mounting brackets (if applicable).
2. If necessary, remove passenger side splash panel.
3. Remove cab cowl tray. Refer to S16052 CAB Service Manual.
1. FRESH AIR MODULE 3. ENGINE

2. NUT
Figure 26 Engine Side of Fresh Air Module
4. Remove nut from engine side of fresh air module.
S16053 63
REMOVE AND INSTALL PROCEDURES FRESH AIR MODULE
1. NUT 2. FRESH AIR MODULE

Figure 27 Fresh Air Module
5. Remove three nuts from fresh air module.
6. Carefully remove fresh air module from engine side of cowl panel.
Fresh Air Module – Installation
1. Using a new gasket/seal, install fresh air module onto mounting studs located on cowl panel using four
nuts (Figure 26, Items 1, and 2 and Figure 27). Torque nuts to 7 N•m (58 lbf-in).
2. Install cab cowl tray. Refer to appropriate CAB Service Manual.
3. If engine air cleaner and mounting bracket were removed:

a. Install engine air cleaner mounting bracket.
b. Install engine air cleaner on mounting bracket.
c. Connect electrical connections to all components mounted on air cleaner mounting bracket.
d. Connect air tube and wiring to engine air cleaner housing.
4. Install passenger side splash panel, if previously removed.
64 S16053
INTERIOR MODULE TRIM COVER REMOVE AND INSTALL PROCEDURES
5.9. INTERIOR MODULE TRIM COVER

The interior module trim cover must be removed prior to removing any of the HVAC components located under
the passenger side of the instrument panel (IP). Removal and installation of the interior module trim cover may
require the removal of other trim panels. Refer to the S16052 CAB Service Manual for additional procedures.
Interior Module Trim Cover – Removal
1. Remove fuse panel cover from passenger side instrument panel by pulling top of cover away from IP to
release spring clips and then lift cover up.
2. Remove trim panels, as necessary, to gain access to mounting screws for interior module trim cover.
1. INTERIOR MODULE 3. SCREW

2. INTERIOR MODULE TRIM
COVER
Figure 28 Interior Module Trim Cover
3. Remove two screws from interior module trim cover.
4. Remove cover by pulling it straight back.
S16053 65
REMOVE AND INSTALL PROCEDURES INTERIOR MODULE TRIM COVER
Interior Module Trim Cover – Installation
1. Secure interior module trim cover to interior module with two screws (Figure 28). Torque screws to 2.26
N•m (20 lbf-in).
2. Install all additional trim panels removed to gain access to interior module trim cover.
3. Install fuse panel cover by inserting two tabs at bottom of cover into sockets in IP; then press top of
cover toward IP to engage spring clips.
66 S16053
FRESH/RECIRCULATE DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES
5.10. FRESH/RECIRCULATE DOOR ACTUATOR

The interior module trim cover must be removed prior to removing any of the HVAC components located under
the passenger side of the instrument panel (IP). Removal and installation of the interior module trim cover may
require the removal of other trim panels. Refer to S16052 CAB Service Manual for additional procedures.
Fresh/Recirculate Door Actuator – Removal
1. Remove interior module. Refer to INTERIOR MODULE.
1. MODE DOOR ACTUATOR 4. BLEND DOOR ACTUATOR

2. FRESH/RECIRCULATE DOOR 5. ELECTRICAL CONNECTOR
ACTUATOR 6. SCREW
3. INTERIOR MODULE
Figure 29 Fresh/Recirculate Door Actuator
2. Disconnect electrical connector from fresh/recirculate door actuator.
3. Remove three screws from fresh/recirculate door actuator and remove fresh/recirculate door actuator.
Fresh/Recirculate Door Actuator – Installation
CAUTION
To prevent damage to actuator, in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, perform the following
procedure. Forcing the drive collar may result in a broken actuator.
S16053 67
REMOVE AND INSTALL PROCEDURES FRESH/RECIRCULATE DOOR ACTUATOR
1. Install actuator by rotating door until flats on door shaft align with actuator drive collar, then carefully slip
the actuator onto end of door shaft so that mounting holes are properly aligned, if possible. If actuator
drive collar must be moved to allow alignment, do the following:
a. Place the actuator in its approximate position.
b. Connect a 9-volt battery across pins A and F of the actuator connector, to rotate the drive collar.
(Reverse the connection to rotate the drive collar in the opposite direction.)
c. Allow drive collar to rotate until it is aligned with door shaft and blend door actuator mounting screws
can be inserted. Then, disconnect the battery.
2. Secure fresh/recirculate door actuator to interior module using three screws (Figure 29, Items 2, 3, and 6).
Torque screws to 2.26 N•m (20 lbf-in).
3. Connect electrical connector to fresh/recirculate door actuator (Figure 29, Items 2 and 5).
NOTE – In the following step, the actuator may also be recalibrated by disconnecting the vehicle battery
for 15 seconds; however, this method may result in disrupting other electrical equipment (radio presets,
etc.).
4. Recalibrate the fresh/recirculate air door by disconnecting the HVAC control panel assembly for at least
15 seconds. Refer to HVAC CONTROL PANEL.
5. Install interior module. Refer to INTERIOR MODULE.
68 S16053
BLEND DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES
5.11. BLEND DOOR ACTUATOR

Accessing the temperature blend door actuator may require the removal of trim panels not described in this
manual. The panels that must be removed vary by vehicle model and trim level. Refer to S16052 CAB
Service Manual for additional procedures.
Blend Door Actuator – Removal
1. Remove interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.
1. MODE DOOR ACTUATOR 5. ELECTRICAL CONNECTOR

2. BLEND DOOR ACTUATOR 6. FRESH/RECIRCULATE DOOR
3. SCREW ACTUATOR
4. INTERIOR MODULE
Figure 30 Blend Door Actuator
2. Disconnect electrical connector from blend door actuator.
3. Remove three screws from blend door actuator and remove blend door actuator.
S16053 69
REMOVE AND INSTALL PROCEDURES BLEND DOOR ACTUATOR
Blend Door Actuator – Installation
CAUTION
To prevent damage to actuator in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, complete the following
1. Install blend door actuator by rotating door until flats on door shaft align with blend door actuator drive
collar, if possible. Then carefully slip the blend door actuator onto end of door shaft so that mounting holes
are properly aligned. If blend door actuator drive collar must be moved to allow alignment, do the following:
a. Place blend door actuator in its approximate position.
b. To rotate drive collar, connect a 9-volt battery across the active pins of the blend door actuator
connector (check mating connector, if necessary). (Reverse connection to rotate drive collar in
opposite direction.)
2. Secure blend door actuator to interior module using three screws (Figure 30, Items 2, 3, and 4). Torque
screws to 2.26 N•m (20 lbf-in).
3. Connect electrical connector to blend door actuator (Figure 30, Items 2 and 5).
NOTE – In the following step, the actuator may also be recalibrated by disconnecting the vehicle battery
etc.).
4. Recalibrate temperature blend door by disconnecting HVAC control panel assembly for at least 15
seconds. Refer to HVAC CONTROL PANEL.
5. Install interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.
70 S16053
MODE DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES
5.12. MODE DOOR ACTUATOR

Accessing the mode door actuator may require the removal of trim panels not described in this manual. Refer
to S16052 CAB Service Manual for additional procedures.
Mode Door Actuator – Removal
1. Remove interior module. Refer to INTERIOR MODULE.
1. SCREW 5. BLEND DOOR ACTUATOR

2. MODE DOOR ACTUATOR 6. FRESH/RECIRCULATE DOOR
3. ELECTRICAL CONNECTOR ACTUATOR
4. INTERIOR MODULE
Figure 31 Mode Door Actuator
2. Disconnect electrical connector from mode door actuator.
3. Remove three screws securing mode door actuator to interior module, and pull mode door actuator
straight off of mode door shaft.
Mode Door Actuator – Installation
CAUTION
To prevent damage to actuator, in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, complete the following
S16053 71
REMOVE AND INSTALL PROCEDURES MODE DOOR ACTUATOR
1. Carefully slip mode door actuator onto end of mode door shaft so that mounting holes are properly aligned,
if possible. If mode door actuator drive collar must be moved to allow alignment complete the following:
a. Place mode door actuator in its approximate position.
b. To rotate drive collar, connect a 9-Volt battery across the active pins of the mode door actuator
connector (check mating connector if necessary). (Reverse connection to rotate drive collar in
opposite direction.)
2. Secure mode door actuator to interior module using three screws (Figure 31, Items 1, 2 and 4). Torque
screws to 2.26 N•m (20 lbf-in).
3. Connect electrical connector to mode door actuator (Figure 31, Items 2 and 3).
NOTE – In the following step the actuator may also be recalibrated by disconnecting the vehicle battery
etc.).
4. Recalibrate mode door by disconnecting HVAC control panel assembly for at least 15 seconds. Refer
to HVAC CONTROL PANEL.
72 S16053
FRESH/RECIRCULATE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
5.13. FRESH/RECIRCULATE DOOR GEAR TRAIN

Fresh/Recirculate Door Gear Train – Removal
1. Remove interior module from vehicle. Refer to INTERIOR MODULE.
2. Remove fresh/recirculate door actuator. Refer to FRESH/RECIRCULATE DOOR ACTUATOR.
3. Remove left side recirculation filter. Refer to RECIRCULATION FILTERS.
1. RECIRCULATE FILTER CAGE 2. SCREW

Figure 32 Recirculate Filter Cage
4. Remove two screws from recirculate filter cage and remove recirculate filter cage.
NOTE – Make note of the location of each gear prior to removal.
S16053 73
REMOVE AND INSTALL PROCEDURES FRESH/RECIRCULATE DOOR GEAR TRAIN
1. UPPER DOOR CONTROL 3. FRESH/RECIRCULATE DOOR

LINKAGE GEAR
2. LOWER DOOR CONTROL
LINKAGE
Figure 33 Recirculate Door Gear
5. Remove two door control linkages and fresh/recirculate door gear.
Fresh/Recirculate Door Gear Train – Installation
NOTE – An indexing tooth is on the fresh/recirculate gear to ensure proper timing of the fresh/recirculate
door and to prevent incorrect installation. Fresh/Recirculate gear will install only one way, do not force
gears in place.
74 S16053
FRESH/RECIRCULATE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
1. UPPER DOOR CONTROL 4. FRESH/RECIRCULATE DOOR

LINKAGE GEAR
2. FRESH/RECIRCULATE DOOR 5. LOWER DOOR CONTROL
3. INDEXING TEETH LINKAGE
Figure 34 Fresh/Recirculate Gear Indexing Teeth
1. Align indexing teeth of fresh/recirculate door gear with fresh/recirculate door and install with upper and
lower door control linkages.
NOTE – Check for proper operation of fresh/recirculate door by turning fresh/recirculate gear by hand.
Ensure lower door control linkage is not installed backwards.
2. Install recirculation filter cage and secure with two screws (Figure 32, Items 1 and 2). Torque screws to
9 to 10 N•m (80 to 90 lbf-in).
3. Install left side recirculation filter. Refer to RECIRCULATION FILTERS.
4. Install fresh/recirculate door actuator. Refer to FRESH/RECIRCULATE DOOR ACTUATOR.
S16053 75
REMOVE AND INSTALL PROCEDURES BLEND DOOR GEAR TRAIN
5.14. BLEND DOOR GEAR TRAIN

Blend Door Gear Train – Removal
2. Remove blend door actuator. Refer to BLEND DOOR ACTUATOR.
1. SCREW 2. BLEND DOOR GEAR TRAIN

COVER
Figure 35 Blend Door Gear Train Cover
3. Remove three screws from blend door gear train cover and remove blend door gear train cover.
76 S16053
BLEND DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
1. TOP GEAR 3. INTERIOR MODULE

2. CAM LEVER GEAR 4. CAM LEVER
Figure 36 Blend Door Cam Lever
4. Remove cam lever and cam lever gear from interior module.
5. Remove top gear from interior module.
S16053 77
REMOVE AND INSTALL PROCEDURES BLEND DOOR GEAR TRAIN
1. BOTTOM GEAR 2. INTERIOR MODULE

Figure 37 Blend Door Bottom Gear
6. Remove bottom gear from interior module.
Blend Door Gear Train – Installation
NOTE – An indexing tooth is on each gear to ensure proper timing of the blend doors and to prevent
incorrect installation. Gears will install only one way, do not force gears in place.
78 S16053
BLEND DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
1. TOP GEAR 4. CAM LEVER

2. CAM LEVER GEAR 5. INDEXING TEETH
3. BOTTOM GEAR
Figure 38 Blend Door Gears Indexing Teeth
1. Install bottom gear with cam lever into interior module.
2. Ensure indexing teeth are aligned properly, and install top gear with cam lever gear into interior module.
3. Install blend door gear train cover and secure with three screws (Figure 35, Items 1 and 2).
4. Install blend door actuator. Refer to BLEND DOOR ACTUATOR.
S16053 79
REMOVE AND INSTALL PROCEDURES MODE DOOR GEAR TRAIN
5.15. MODE DOOR GEAR TRAIN

Mode Door Gear Train – Removal
2. Remove mode door actuator. Refer to MODE DOOR ACTUATOR.
1. SCREW 2. MODE DOOR GEAR TRAIN

COVER
Figure 39 Mode Door Gear Train Cover
3. Remove three screws from mode door gear train cover and remove mode door gear train cover.
80 S16053
MODE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
1. CAM LEVER 2. CAM LEVER GEAR

Figure 40 Mode Door Cam Lever
4. Remove cam lever and cam lever gear together.
S16053 81
REMOVE AND INSTALL PROCEDURES MODE DOOR GEAR TRAIN
1. INTERIOR MODULE 3. FRONT GEAR

2. IDLER GEAR 4. REAR GEAR
Figure 41 Mode Door Gears
5. Remove remaining three gears from interior module.
Mode Door Gear Train – Installation
NOTE – An indexing tooth is on each gear to ensure proper timing of the mode doors and to prevent
incorrect installation. Gears will install only one way; do not force gears in place.
82 S16053
MODE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES
1. REAR GEAR 4. CAM LEVER

2. INDEXING TEETH 5. FRONT GEAR
3. IDLER GEAR 6. CAM LEVER GEAR
Figure 42 Mode Door Gears Indexing Teeth
1. Align indexing teeth and install idler gear and rear gear onto interior module.
2. Align indexing teeth of front gear and cam lever gear.
3. Install cam lever, cam lever gear, and front gear onto interior module.
4. Install mode door gear train cover and secure with three screws (Figure 39, Items 1 and 2).
5. Install mode door actuator. Refer to MODE DOOR ACTUATOR.
S16053 83
REMOVE AND INSTALL PROCEDURES RECIRCULATION FILTERS
5.16. RECIRCULATION FILTERS

Recirculation Filters – Removal
1. HVAC UNIT 3. SCREW

2. DUCT TRIM PANEL
Figure 43 Duct Trim Panel
1. Remove two screws from duct trim panel.
2. Carefully pull duct trim panel away from HVAC unit and remove duct trim panel.
84 S16053
RECIRCULATION FILTERS REMOVE AND INSTALL PROCEDURES
1. INTERIOR MODULE 3. RIGHT RECIRCULATION FILTER

2. RECIRCULATION FILTER CAGE 4. LEFT RECIRCULATION FILTER
Figure 44 Recirculation Filters
4. Carefully pull right recirculation filter out of recirculation filter cage.
5. Carefully pull left recirculation filter out of recirculation filter cage.
Recirculation Filters – Installation
1. Carefully press left recirculation filter into recirculation filter cage, making sure not to damage filter. Make
sure recirculation filter goes all the way in so recirculation filter cage secures filter in place (Figure 44,
Items 2 and 4).
2. Carefully press right recirculation filter into recirculation filter cage, making sure not to damage filter. Make
sure recirculation filter goes all the way in so recirculation filter cage secures filter in place (Figure 44,
Items 2 and 3).
3. Install duct trim panel over interior module. Snap duct trim panel in place and secure with two screws
(Figure 43, Items 2 and 3).
S16053 85
REMOVE AND INSTALL PROCEDURES LINEAR POWER MODULE (LPM)
5.17. LINEAR POWER MODULE (LPM)

Linear Power Module (LPM) – Removal
1. HVAC UNIT 3. SCREW

2. DUCT TRIM PANEL
Figure 45 Duct Trim Panel
1. Remove two screws from duct trim panel.
2. Carefully pull duct trim panel away from HVAC unit and remove duct trim panel.
86 S16053
LINEAR POWER MODULE (LPM) REMOVE AND INSTALL PROCEDURES
1. ELECTRICAL CONNECTOR 3. SCREW

2. INTERIOR MODULE 4. LINEAR POWER MODULE (LPM)
Figure 46 Linear Power Module (LPM)
3. Locate LPM on interior module and disconnect two electrical connectors.
4. Remove two screws from LPM and remove LPM.
Linear Power Module (LPM) – Installation
1. Install LPM to interior module and secure with two screws (Figure 46). Torque screws to 2.26 N•m (20
lbf-in).
2. Connect two electrical connectors to LPM (Figure 46, Items 1 and 4).
3. Install duct trim panel over interior module. Snap duct trim panel in place and secure with two screws
(Figure 45 Items 2 and 3).
S16053 87
REMOVE AND INSTALL PROCEDURES BLOWER ASSEMBLY
5.18. BLOWER ASSEMBLY

Blower Assembly – Removal
1. FRONT VIEW OF BLOWER 4. REAR VIEW OF BLOWER

SCROLL HOUSING SCROLL HOUSING
2. GROMMET 5. SCREW
3. ELECTRICAL CONNECTOR 6. BLOWER ASSEMBLY
Figure 47 Blower Assembly
2. Remove two screws from front of blower scroll housing.
3. Carefully pull grommet and electrical connector through blower scroll housing.
4. Remove two screws from rear of blower scroll housing and remove blower assembly.
Blower Assembly – Installation
1. Insert blower assembly into blower scroll housing and secure with four screws (Figure 47, Items 4, 5, and
6). Torque screws to 2.26 N•m (20 lbf-in).
2. Pull electrical connector through blower scroll housing (Figure 47, Items 1, 3, and 4).
3. Secure grommet in blower scroll housing (Figure 47, Items 2 and 4).
88 S16053
HEATER CORE REMOVE AND INSTALL PROCEDURES
5.19. HEATER CORE

Access to the heater hoses may require the removal of other assemblies (such as passenger side splash panel
and/or air filter). The assemblies that must be removed vary by vehicle model. Refer to S09016 Service
Manual for additional procedures.
• For most other-under hood assemblies that may require removal, refer to the S09016 HOOD, GRILLE, and
FENDERS Service Manual.
Heater Core – Removal
WARNING
Allow the engine to cool down before removing the pressure cap from the deaeration
tank. ALWAYS INSULATE the cap by wrapping it with a thick, heavy cloth. To prevent
personal injury or death from scalding water or steam, DO NOT pull the pressure cap off
immediately when it has been loosened to the first "notch." Pause momentarily to allow
time for excess pressure to release through the overflow tube.
1. Drain engine coolant from heater core and connected heater lines. Refer to the S12036 COOLING
Service Manual.
NOTE – Before removing heater hoses in the following step, label hoses to ensure correct installation.

2. HEATER HOSE 4. SPRING CLAMP
Figure 48 Heater Hoses
2. Remove two spring clamps and disconnect both heater hoses from heater core tubes on engine side of
cowl.
S16053 89
REMOVE AND INSTALL PROCEDURES HEATER CORE
3. From inside cab, remove blower scroll housing. Refer to BLOWER SCROLL HOUSING.
1. INTERIOR MODULE 2. HEATER CORE

Figure 49 Heater Core
NOTE – The heater core is mounted at a slight angle and therefore retains a small amount of coolant in
the core. Be careful to keep the core in an upright position until the coolant can be drained.
4. Pull heater core out of interior module.
Heater Core – Installation
NOTE – In the following step, make sure that the interior module seal that surrounds the heater core
tubes does not become dislodged while installing the heater core.
1. From inside cab, carefully position heater core in interior module so that tube ends of core protrude
through cowl panel seal (Figure 49).
NOTE – In the following step, position the heater hose clamps to allow easy access for their next removal.
3. On engine side of cowl, install heater hoses and spring clamps (Figure 48).
4. Fill cooling system with coolant. Refer to the S12036 COOLING Service Manual, or the Operator Manual
supplied with the vehicle.
NOTE – Verify that coolant system is leak-free.
90 S16053
HVAC CONTROL PANEL ASSEMBLY REMOVE AND INSTALL PROCEDURES
5.20. HVAC CONTROL PANEL ASSEMBLY

HVAC Control Panel Assembly – Removal
CAUTION
To prevent damage to vehicle electrical system, place the ignition key in the OFF position
before removing or installing the HVAC control panel.
1. The decorative center bezel on center section of IP is secured by spring clips. Carefully pry the bezel
from center section of the IP.
2. Remove four screws securing HVAC control panel to IP.
1. INSTRUMENT PANEL (IP) 3. DECORATIVE CENTER BEZEL

2. HVAC CONTROL PANEL 4. SCREW
Figure 50 Front HVAC Control panel
3. Remove HVAC control panel from instrument panel by pulling it straight out of its IP mounting cavity.
4. Disconnect wiring connector from rear of HVAC control panel.
HVAC Control Panel Assembly – Installation
CAUTION
To prevent damage to vehicle electrical system, place the ignition key in the OFF position
before removing or installing the HVAC control panel.
1. Connect wiring connector to rear of HVAC control panel (not shown).
2. With HVAC control panel correctly oriented, insert it straight into IP (Figure 50, Items 1 and 2).
3. Verify that HVAC control panel is fully seated, then secure assembly using four screws (Figure 50, Items 2
and 4). Torque screws to 2 to 3 N•m (20 to 27 lbf-in).
4. Install decorative center bezel in the center section of IP by aligning spring clips and carefully pressing
bezel into position (Figure 50, Items 1 and 3).
S16053 91
REMOVE AND INSTALL PROCEDURES COMPRESSOR/CLUTCH
5.21. COMPRESSOR/CLUTCH
Replacement of specific A/C refrigerant components may require the removal of nearby assemblies (driver
side splash panel, etc.) to gain access to the components or related A/C lines. Refer to S09016 Service
Manual for additional procedures.
Compressor/Clutch – Removal
2. Remove or loosen compressor belt.
1. DISCHARGE PORT/LINE 6. TOP VIEW

2. COMPRESSOR 7. W/ REAR PORTS
3. MOUNTING BOLTS 8. W/ TOP PORTS
4. SUCTION PORT/LINE 9. REAR VIEW
5. ELECTRICAL CONNECTOR
Figure 51 A/C Compressor (Typical Installation)
3. Disconnect compressor clutch wiring connector from engine wire harness.
4. Disconnect both refrigerant line fittings at compressor.
CAUTION
When removing mounting bolts from side mounted compressors, support compressor
to prevent damage to mounting bolts and/or compressor.
5. Remove four compressor mounting bolts, noting location and orientation of any brackets secured by
mounting bolts.
6. Remove compressor assembly from engine.
92 S16053
COMPRESSOR/CLUTCH REMOVE AND INSTALL PROCEDURES
Compressor/Clutch – Installation
NOTE – Verify that the clutch is installed on the compressor before performing steps in the following
installation procedure.
1. If A/C system is to be flushed, perform that operation before reassembling system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM (See FLUSHING AND PURGING THE AIR
CONDITIONING SYSTEM, page 38).
2. Before installing compressor, refer to OIL FILL GUIDELINES (See OIL FILL GUIDELINES, page 42). The
oil shipped in new compressors must be drained when determining the correct amount of refrigerant
oil to be added to the system.
3. Install compressor assembly including any brackets previously secured by the compressor mounting bolts
(Figure 51, Items 2 and 3). Tighten to 23 to 29 N•m (17 to 21 lbf-ft).
NOTE – Always lubricate O-rings with mineral-based oil during installation.
4. Using new O-rings and C-plates, connect refrigerant line fittings at compressor (Figure 51, Items 1, 2, and
4). Torque C-plate nuts to 19 to 20 N•m (14 to 15 lbf-ft ) (not shown).
5. Connect compressor clutch electrical connector to engine harness (Figure 51, Items 2 and 5).
6. Install and align compressor belt (not shown).

c. AUTOMATIC MODE
8. Install any assemblies that were removed to gain access to the compressor.
S16053 93
REMOVE AND INSTALL PROCEDURES A/C CONDENSER
5.22. A/C CONDENSER

For A/C condenser removal and installation, refer to S12036 COOLING Service Manual.
5.23. HEATER HOSES/LINES
WARNING
personal injury or death, from scalding water or steam, DO NOT pull the pressure cap off
Engine coolant is routed to and from the heater core using a combination of hoses and hard lines that vary by
vehicle model. Most hoses and lines are replaced using common practices, standard hose clamps, or threaded
fittings. Only new or unique equipment is described in this section. In all cases, replacement hoses and lines
must be routed and secured in the same manner as the original equipment. Additional information for the
coolant system may be found in S12036 COOLING Service Manual.
Some heater line connections now employ a peanut fitting that is sealed with an O-ring and secured with one
nut. Before installing a peanut fitting, always verify that a new O-ring is in place.
• The cab cowl tray exists in several variations. Refer to S16052 CAB Service Manual for procedures
covering cab cowl trays.
• For most other under hood assemblies that may require removal, refer to S09016 HOOD, GRILLE, and
FENDERS Service Manual.
• For information on draining and filling engine coolant, refer to S12036 COOLING Service Manual.
94 S16053
EVAPORATOR REMOVE AND INSTALL PROCEDURES
5.24. EVAPORATOR
Evaporator – Removal
3. Remove expansion valve. Refer toTHERMOSTATIC EXPANSION VALVE (TXV).
1. GROMMET 3. EVAPORATOR
2. EVAPORATOR TUBE 4. INTERIOR MODULE
Figure 52 Evaporator
4. Carefully press grommet through interior module housing. It may be helpful to use a flat-tip screwdriver to
work grommet seal off.
5. Carefully maneuver evaporator out of interior module. Use caution not to damage evaporator tubes
or the evaporator itself.
6. Once evaporator is out of the interior module, remove the grommet from the evaporator tubes.
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REMOVE AND INSTALL PROCEDURES EVAPORATOR
Evaporator – Installation
1. Install grommet onto evaporator tubes (Figure 52, Items 1 and 2).
NOTE – Installation may require additional personnel to aid with grommet installation while the
evaporator is being installed.
NOTE – Lubrication may be required when installing the grommet.
2. Install evaporator into interior module while guiding the evaporator tubes and grommet through cowl panel.
Make sure grommet seats properly (Figure 52, Item 1).
3. Install expansion valve. Refer to EXPANSION VALVE.

c. AUTOMATIC MODE
96 S16053
BLOWER SCROLL HOUSING REMOVE AND INSTALL PROCEDURES
5.25. BLOWER SCROLL HOUSING

The blower scroll housing must be removed prior to removing the heater core, the evaporator, the interior
module, or any of the components within the interior module. Accessing the blower scroll housing may require
the removal of trim panels not described in this manual (refer to S16052 cab service manual for vehicle
being serviced).
Blower Scroll Housing – Removal
1. Remove interior module trim panel. Refer to INTERIOR MODULE TRIM PANEL.
1. ACTUATORS 5. LPM ELECTRICAL CONNECTOR

2. BLOWER SCROLL HOUSING 6. LINEAR POWER MODULE (LPM)
3. INTERIOR MODULE 7. SCREW
4. HVAC/BODY HARNESS
ELECTRICAL CONNECTOR
Figure 53 Blower Scroll Housing
2. Remove wire ties as necessary; disconnect electrical connectors from three actuators and position
wiring out of the way
3. Disconnect electrical connector from LPM.
4. Remove eight screws from blower scroll housing.
5. Remove blower scroll housing from interior module.
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REMOVE AND INSTALL PROCEDURES BLOWER SCROLL HOUSING
Blower Scroll Housing – Installation
1. Position blower scroll housing on interior module and secure with eight screws (Figure 53, Items 2, 3 and
7). Torque screws to 2.26 N•m (20 lbf-in).
2. Route wiring across blower scroll housing, secure with wire ties, and connect electrical connectors to
three door actuators (Figure 53, Item 1).
3. Connect electrical connector to LPM (Figure 53, Items 5 and 6).
4. Install interior module trim panel. Refer to INTERIOR MODULE TRIM PANEL.
98 S16053
SPLITTING/SEPARATING BLOWER SCROLL HOUSING REMOVE AND INSTALL PROCEDURES
5.26. SPLITTING/SEPARATING BLOWER SCROLL HOUSING

Splitting/Separating Blower Scroll Housing – Removal
2. Remove blower assembly. Refer to BLOWER ASSEMBLY.
3. Remove blend door actuator. Refer to BLEND DOOR ACTUATOR.
4. Remove blend door gear train. Refer to BLEND DOOR GEAR TRAIN.
1. BLOWER SCROLL HOUSING 2. SCREW

Figure 54 Blower Scroll Housing
5. Remove four screws from blower scroll housing.
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REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING BLOWER SCROLL HOUSING
1. RIGHT SIDE OF BLOWER 3. LEFT SIDE OF BLOWER

SCROLL HOUSING SCROLL HOUSING
2. BLEND DOOR 4. HEATER SCRUB DOOR
Figure 55 Splitting/Separating Blower Scroll Housing
6. Carefully pull right side of blower scroll housing away from left side of blower scroll housing.
NOTE – To aid in ease of installation, mark position of heater scrub and blend doors prior to removal.
7. Once blower scroll housing is separated, heater scrub door and blend door may be removed.
Splitting/Separating Blower Scroll Housing – Installation
1. Install heater scrub door and blend door into left side of blower scroll housing (Figure 55).
NOTE – Ensure heater scrub door and blend door are installed correctly before continuing to next step.
2. Attach right side of blower scroll housing to left side of blower scroll housing and secure with four screws
(Figure 55).
3. Install blend door gear train. Refer to BLEND DOOR GEAR TRAIN.
4. Install blend door actuator. Refer to BLEND DOOR ACTUATOR.
5. Install blower assembly. Refer to BLOWER ASSEMBLY.
100 S16053
INTERIOR MODULE REMOVE AND INSTALL PROCEDURES
5.27. INTERIOR MODULE

NOTE – Removing and installing the interior module requires detaching and raising the Instrument
Panel (IP), gauge cluster, and several trim panels. Refer to S16052 CAB Service Manual for additional
procedures. Replacement of the interior module is necessary only if either the mode door mechanism or
the interior module itself is damaged. If mode/recirc doors or any mode/recirculation door mechanism
is damaged, the interior module must be removed and the case ’split’. If interior module itself is
damaged the entire interior module is replaced as an assembly.
The Instrument Panel (IP) must be detached and raised prior to removing the interior module. Accessing the IP
mounting hardware may require the removal of trim panels not described in this manual. The panels that must
be removed vary by vehicle model and trim level. The procedures provided here cover a basic installation.
Interior Module – Removal
2. Remove engine housing cover and any required trim panels.
4. Remove passenger side seat.
5. Inside cab, remove A-pillar trim from driver’s side.
6. Remove assist handle and A-pillar trim from passenger’s side.
7. Remove or disconnect trim panels from under IP to allow access to IP mounting hardware removed
in the following steps.
1. TOP INSTRUMENT PANEL 3. SIDE INSTRUMENT PANEL

MOUNTING BOLTS MOUNTING BOLT
2. STEERING MODULE BOLT
Figure 56 Instrument Panel Mounting
8. Remove only the IP mounting hardware required to allow IP to be raised about one inch. More complete
procedures for removing the IP can be found in the S16052 CAB Service Manual. Typically, the following
mounting hardware must be removed:
a. Five top instrument panel mounting bolts securing top of IP to cowl panel (located near windshield).
S16053 101
REMOVE AND INSTALL PROCEDURES INTERIOR MODULE
b. Two steering module bolts securing steering column module to IP.

c. Two side instrument panel mounting bolts securing each side of IP to cowl panel.
NOTE – The driver side duct is connected to the interior module with a snap mount (slip-lock). This duct
is also mounted to the cowl panel with one mounting screw.
NOTE – There are two gaskets attached to the exterior of the interior module. There is one gasket where
the interior module mounts to the cowl panel; and another gasket where the IP rests on top of the interior
module. If the gaskets are damaged when moving the interior module or the IP, they must be replaced.
NOTE – In the following step, it will be necessary to raise the IP slightly while removing the interior
module. This may require a second or third person.
9. Lift the IP and support it so that it provides the greatest amount of clearance for removing interior module.
10. Remove gauge cluster to access driver side floor duct screw (bezel, cluster, connectors – wing panel bezel
first). Refer to S16052 CAB Service Manual for additional procedures.
1. COWL PANEL 5. SCREW

2. TOP GASKET 6. PASSENGER SIDE LOWER
3. SNAP MOUNT (SLIP-LOCK) DUCT
4. DRIVER SIDE FLOOR DUCT 7. INTERIOR MODULE
Figure 57 Duct Work
11. Disconnect passenger side lower floor duct from interior module.
a. Bottom section of passenger side lower floor duct is mounted to side of module with one alignment tab.
After removing passenger side lower floor duct from alignment tab, bottom section may be removed to
provide better access to top section.
b. Top section of passenger side lower floor duct is connected to module with a snap mount (slip-lock),
and is disconnected by pulling passenger side lower floor duct away from module.
12. Remove mounting screw from driver side floor duct and disconnect driver side floor duct (snap lock at
interior module) from interior module.
102 S16053
WARNING
personal injury or death, from scalding water or steam, DO NOT pull the pressure cap off
13. Drain engine coolant from heater core and connected heater lines. Refer to S12036 COOLING Service
Manual.
NOTE – Before removing heater hoses in the following step, label hoses to ensure correct installation.

2. HEATER HOSE 4. SPRING CLAMP
Figure 58 Heater Hoses
14. Remove two spring clamps and disconnect both heater hoses from heater core tubes on engine side of
cowl.
15. On engine side of cowl panel, remove two C-plate nuts from refrigerant lines and disconnect two refrigerant
lines (Figure 24, Items 4, 5, and 6).
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1. MOUNTING NUT 2. FRESH AIR MODULE

Figure 59 Interior Module Mounting
16. On engine side of cowl panel, remove four mounting nuts from interior module mounting studs.
104 S16053
1. INSTRUMENT PANEL 4. HVAC WIRING HARNESS

2. TOP GASKET CONNECTOR
3. REAR GASKET 5. INTERIOR MODULE
Figure 60 Interior Module
17. Disconnect HVAC wiring harness from instrument panel wiring harness.
18. Pull interior module to rear (to allow its mounting studs to clear cowl panel). Interior module should
now be clear to slide out from under IP.
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Interior Module – Installation
NOTE – In the following step, the instrument panel (IP) must be raised slightly while installing the interior
module. This may require a second or third person. To ensure proper alignment and compression of
the interior module top gasket, the IP must remain raised until the interior module is securely mounted.
NOTE – While performing the following steps, be careful not to damage the gaskets when moving the
interior module or the IP.
1. Lift and brace IP so that it provides adequate clearance for installing interior module (Figure 56).
2. With IP raised, carefully position interior module under passenger side instrument panel so that its mounting
studs protrude through matching holes in cowl panel (Figure 57, Items 1 and 7 and Figure 60, Item 1).
3. When installing:
a. Make sure the drain tube is in place and functioning correctly.
b. Start interior module mounting nuts, but leave loose (Figure 59, Item 1).
c. Connect driver side floor duct (snap lock) to interior module (Figure 57, Items 2 and 4).
d. Slip passenger side floor duct onto top section and secure to side of interior module alignment tab
(Figure 57, Items 4 and 5). Attach diffuser if it was removed .
e. Tighten interior module mounting nuts (Figure 59, Item 1). Torque nuts to 7 N•m (58 lbf-in).
NOTE – To aid in installation of the driver side floor duct screw, it is recommended to push screw through
sticky side of tape. Then fasten tape to socket, LIGHTLY. This keeps the screw from being dislodged and
should release once screw is tightened. If your socket connection is very loose, or your tape is fastened
to the socket too firmly, the socket may stay with the screw when the extension is removed.
4. Secure floor duct to cowl panel under instrument panel using its mounting screw (Figure 57). Attach
diffuser if it was removed .
5. Install gauge cluster (bezel, cluster, connectors). Refer to S16052 CAB Service Manual for additional
procedures.
NOTE – In the following step, position the heater hose clamps to allow easy access for their next removal.
6. On engine side of cowl, install heater hoses and clamps (Figure 58).
7. Fill cooling system with coolant. Refer to S12036 COOLING Service Manual, or the Operator Manual
supplied with the vehicle.
NOTE – Verify that coolant system is leak-free before proceeding with the following steps.
8. Carefully allow IP to return to its normal resting position (Figure 56).
9. Connect HVAC wiring harness to instrument panel wiring harness (Figure 60, Item 4).
10. Using a new lubricated, O-ring, and C-plate, connect refrigerant lines with two nuts (Figure 24, Items 4, 5,
and 6). Torque nuts to 19 to 20 N•m (14 to 15 lbf-ft).
11. Install IP mounting hardware that was removed earlier. More complete procedures for installing the IP can
be found in S16052 CAB Service Manual. Typically, the following mounting hardware must be installed:
106 S16053
a. Two side instrument panel mounting bolts securing each side of IP to cowl panel (Figure 56).
b. Two steering module mounting bolts securing steering column module to IP (Figure 56).
c. Five top instrument panel mounting bolts securing top of IP to cowl panel (located near windshield).
(Figure 56).
12. Install or reconnect any trim panels under the IP that were removed to provide access to IP mounting
hardware (Figure 56).
13. Inside cab, install assist handle and A-pillar trim on passenger’s side (not shown).
14. Install A-pillar trim on driver’s side (not shown).
15. Install interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.
16. Install engine housing cover and any required trim panels (not shown).
17. Install passenger side seat (not shown).

a. ADDING OIL AND DYE TO THE SYSTEM
c. AUTOMATIC MODE
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REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING INTERIOR MODULE
5.28. SPLITTING/SEPARATING INTERIOR MODULE

Splitting/Separating Interior Module – Removal
2. Remove mode door actuator and fresh/recirculate door actuator. Refer to MODE DOOR ACTUATOR
AND FRESH/RECIRCULATE DOOR ACTUATOR.
3. Remove mode door gear train, and fresh/recirculate door gear train. Refer to MODE DOOR GEAR TRAIN
and FRESH/RECIRCULATE DOOR GEAR TRAIN.
4. Remove the blower scroll housing. Refer to BLOWER SCROLL HOUSING.
5. Remove the heater core. Refer to HEATER CORE.
6. Remove thermostatic expansion valve (TXV). Refer to THERMOSTATIC EXPANSION VALVE (TXV).
1. SCREW 3. INTERIOR MODULE DRAIN PAN

2. REAR SEAL
Figure 61 Interior Module Drain Pan
7. Carefully remove rear seal from interior module.
8. Remove nine screws from interior module drain pan and remove interior module drain pan.
108 S16053
SPLITTING/SEPARATING INTERIOR MODULE REMOVE AND INSTALL PROCEDURES
1. EVAPORATOR GROMMET 3. EVAPORATOR

2. INTERIOR MODULE
Figure 62 Evaporator
9. Carefully press evaporator grommet through interior module and remove evaporator from interior module.
S16053 109
REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING INTERIOR MODULE
1. TOP SEAL 3. LEFT SIDE OF INTERIOR

2. RIGHT SIDE OF INTERIOR MODULE
MODULE 4. SCREW
Figure 63 Splitting/Separating Interior Module
10. Using a utility knife, cut the top seal along the seam of the interior module.
11. Remove 10 screws from the interior module and separate the left side of the interior module from the
right side.
110 S16053
SPLITTING/SEPARATING INTERIOR MODULE REMOVE AND INSTALL PROCEDURES
1. LEFT SIDE OF INTERIOR 4. RIGHT SIDE OF INTERIOR

MODULE MODULE
2. MODE DOOR 5. FRESH/RECIRCULATE DOOR
3. MODE DOOR
Figure 64 Recirculate/Mode/Blend Doors
NOTE – To aid in ease of installation, mark position of fresh/recirculate and mode doors prior to removal.
12. Once left and right side of interior module have been separated, the fresh/recirculate and mode doors
can be removed.
Splitting/Separating Interior Module – Installation
1. Install fresh/recirculate and mode doors into right side of interior module (Figure 64).
2. With the aid of an assistant, align doors with left side of interior module (Figure 64).
3. Secure left side of interior module to right side of interior module with 10 screws (Figure 63, Items 2,
3, and 4).
4. Install fresh/recirculate door gear train and mode door gear train. Refer to FRESH/RECIRCULATE DOOR
GEAR TRAIN and MODE DOOR GEAR TRAIN.
5. Install fresh/recirculate door actuator and mode door actuator. Refer to FRESH/RECIRCULATE DOOR
ACTUATOR and MODE DOOR ACTUATOR.
NOTE – Ensure fresh/recirculate and mode doors are operating properly prior to next step.
S16053 111
REMOVE AND INSTALL PROCEDURES FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS
NOTE – Evaporator installation may require additional personnel to aid with grommet installation while
the evaporator is being installed.
NOTE – Lubrication may be required when installing the grommet.
6. Install evaporator into interior module, while guiding the evaporator tubes and grommet through outside the
interior module. Ensure grommet seats properly (Figure 62).
7. Install interior module drain pan and secure with nine screws (Figure 61, Items 1 and 3).
8. Install rear seal onto interior module (Figure 61, Item 2).
9. Install heater core. Refer to HEATER CORE.
11. Install thermostatic expansion valve (TXV). Refer to THERMOSTATIC EXPANSION VALVE (TXV).
12. Install interior module into vehicle. Refer to INTERIOR MODULE.
5.29. FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS

The fresh/recirculate and mode air doors can be replaced after removing and splitting/separating the interior
module. Refer to SPLITTING/SEPARATING INTERIOR MODULE.
The heater scrub and blend air door can be replaced after removing the blower scroll housing. Refer to
BLOWER SCROLL HOUSING.
112 S16053
DIAGNOSIS AND TROUBLESHOOTING
6. DIAGNOSIS AND TROUBLESHOOTING

6.1. PRELIMINARY CHECKS
The following preliminary checks should be performed to identify some common causes of A/C system
problems.
Check for Obvious Damage
Perform a simple visual check of the HVAC system to verify that no obvious physical problems are present.
With the engine off, inspect the following items:
• compressor and clutch mounting

• compressor clutch coil wiring and connection
• compressor drive belt and tension
• all A/C and heater hoses and connections
• condenser mounting
• condenser fins (and blockage by debris)
• receiver-drier mounting
• expansion valve mounting
• filter element
• fresh air module drains
• fresh air module mounting and overall condition
• electrical connections to pressure transducer and low pressure switch
• electrical connections to actuators for airflow doors (recirculate, temperature, and mode doors)
Refrigerant Identification
NOTE – Before connecting any service equipment to the refrigerant system, the refrigerant in the system
must be identified. Failure to identify system refrigerant before connecting equipment could result in
contamination of service equipment and any refrigerant stored in the equipment.
Identify the refrigerant currently in the HVAC system to protect shop equipment and to identify a possible cause
of poor system operation. Refer to REFRIGERANT IDENTIFICATION.
Check for Noncondensable Gases
Verify that the system does not contain air or some other noncondensable gas, which can be a common cause
of poor system operation. When a Refrigerant Identifier is not available, a check of the system contents
should be performed (Table 3). This procedure can be performed in addition to refrigerant identification to
check for overcharged and undercharged conditions. The A/C system must be at ambient temperature when
performing this check.
S16053 113
DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS
Table 3 Check for Noncondensable Gases
NOTE – The engine must not be running and A/C system must be at ambient temperature when
performing this check.
1. Connect IRTI4608032100 A/C Servicing System • If gauges are >69 kPa (10 psig) higher
to A/C system. than the table listings, system contains air
or some noncondensable gas. Discharge,
2. Using a temperature probe (refer to A/C System
evacuate, and recharge the system.
Test Mode), determine ambient temperature
Refer to SECTION 4. (See SERVICE
within a degree or two.
PROCEDURES FOR R-134a, page 22).
3. Record system pressures indicated (refer to A/C
System Test Mode). • If gauges are >69 kPa (10 psig) lower than
the table listings, system is undercharged.
4. Compare gauge readings to Table 4 (See Table
4, page 114). Inspect all joints and seals using a leak
detector. Refer to LEAK DETECTION.
Repair any leaks.
Service the A/C system (discharge,

evacuate, and recharge the system OR
use Automatic mode). Refer to SERVICE
PROCEDURES FOR R-134A (See
SERVICE PROCEDURES FOR R-134a,
page 22).
Table 4 System Pressure Versus Ambient Temperature
Temperature °C (°F) R134A kPa (PSIG) Temperature °C (°F) R134A kPa (PSIG)
4 °C (40 °F) 241.80 kPa (35.07) 27 °C (80 °F) 599.78 kPa (86.99 PSIG)
7 °C (45 °F) 276.27 kPa (40.07 PSIG) 29 °C (85 °F ) 656.59 kPa (95.23 PSIG)
10 °C (50 °F) 313.44 kPa (45.46 PSIG) 32 °C (90 °F) 719.12 kPa (104.30 PSIG)
1008.91 kPa (146.33
21 °C (70 °F) 490.29 kPa (71.11 PSIG) 43 °C (110 °F)
PSIG)
24 °C (75 °F) 542.34 kPa (78.66 PSIG)
NOTE: The table is part of the Performance AC Chart TMT-3416.
6.2. PHYSICAL CHECKS

These Physical Checks are provided as general supplemental information. While not as precise as the
step-by-step procedures, these checks provide a simple convenient method of determining the condition of
the refrigerant system.
Physical Check Procedure
1. Start the engine and set the air conditioning control panel for maximum cooling, as follows:
A. Turn the knob fully clockwise to set blower speed control to highest speed.
B. Turn the knob fully counterclockwise to set temperature control for maximum cooling.
114 S16053
PHYSICAL CHECKS DIAGNOSIS AND TROUBLESHOOTING
C. Turn the knob fully counterclockwise to set mode control to MAX.
2. Set the engine speed at 1500 RPM or above, and run the air conditioning system for at least 5 minutes.
WARNING
To prevent personal injury or death, avoid contact with moving belts, pulleys and/or
fan when making the following checks. Beware of extremely high temperatures at
compressor outlet (discharge) hoses and tubing, as personal injury may result.
3. With the system operating, feel all air conditioning system components and refrigerant lines for proper
operating temperatures, as indicated in the following paragraphs.
In general, from the discharge side of the compressor along the high-pressure line, through the condenser
and up to the filter-drier, everything should be hot or warm to the touch. The filter-drier is normally at
outside temperature. The expansion valve, evaporator, and all the lines on the low-pressure side leading
back to the compressor should be cool to the touch. Any deviation from the above conditions may indicate
a malfunction in the system.
Malfunctions or stoppages may be indicated by extreme cold or frosted areas (example: a cold filter-drier
frosted part way up indicates a stoppage or serious restriction in the filter-drier). A stoppage or severe
restriction in the refrigerant system can be located by looking for these indications. The following is a brief
description of symptoms or conditions that could exist if the vehicle air conditioning system is malfunctioning.
The conditions are listed by system component.
Refrigerant Compressor
NOTE – If the ambient temperature is very low, the engine may have to reach operating temperature
before the body controller will energize the compressor. After warm-up, underhood heat will allow the
compressor to cycle on at very low ambient temperatures.
Compressor problems are usually revealed in one of 5 ways: abnormal noise, seizure, leakage, high suction
pressure, or low discharge pressure.
CAUTION
To prevent damage to the compressor in the following step, the compressor should be
turned in a clockwise (cw) direction only (as viewed from the front).
Resonant noises are not a cause for alarm. Irregular noise or rattles are likely caused by broken parts. To
check for seizure, turn the engine off to de-energize the magnetic clutch and see if the drive plate can be
turned. If it will not turn, the compressor has seized.
Inspect the fittings, oil fill plug, and all gasket joints on the compressor for signs of refrigerant leakage.
Verify that the wires to the compressor clutch are in good condition and have not become disconnected.
Condenser
The condenser is usually trouble-free. Normally, the temperature of the condenser outlet line is noticeably
cooler than the inlet line.
S16053 115
DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS
When road debris (such as leaves or dirt) cakes up, airflow over the condenser fins is reduced and the air is
not able to absorb enough heat to turn the hot refrigerant gas into a liquid. High discharge pressure will result.
In these cases, carefully clean off the outer surface of the condenser with soap and water and compressed air;
be careful not to bend the fins.
High discharge pressure will also occur if the condenser’s tubing is abnormally bent, restricting or blocking the
flow of refrigerant. Frost will appear at the point where the flow of refrigerant is restricted.
Internal blockage (foreign material or metallic grit buildup) is less common and will restrict or stop the flow of
refrigerant.
Inspect the fittings and the condenser tubing for signs of refrigerant leakage.
Reduced performance may also result from excess oil in the refrigerant system. This excess oil tends to
collect in the bottom of the condenser.
Pressure Transducer
Verify that the wires to the pressure transducer are in good condition and have not become disconnected.
Inspect the transducer mounting for signs of refrigerant leakage.
Low Pressure Switch
Verify that the wires to the low pressure switches are in good condition and have not become disconnected.
Inspect the low pressure switch mountings for signs of refrigerant leakage.
Filter-Drier
The filter-drier is normally at or near outside temperature. To the touch, the entire length of the unit should be
the same temperature. If noticeable cold spots exist, replace the filter-drier.
A blockage at the filter-drier will cause high head pressure and little or no cooling.
Thermostatic Expansion Valve (TXV)
Problems that start in the TXV show up as follows:
• When stuck closed, the evaporator core and TXV will be at outside temperature, and the system will
not cool.
• When stuck open, both the evaporator core and the TXV will be extremely cold with possible frost or
ice buildup.
Because the TXV channels are very small, blockage in the system is usually found here (the TXV is very
sensitive to contamination). Usually the contamination is water. Less than a drop of water is all it takes to
make the TXV inoperative. When water reaches the TXV, the extreme cold that results from the pressure drop
freezes the water, forming an ice blockage. After the system shuts down and the TXV warms up, the TXV
operates again, only to freeze up when the moisture returns and the temperature drops.
Intermittent TXV freeze up indicates that the filter-drier is not removing the moisture from the system.
116 S16053
A/C SYSTEM TEST MODE DIAGNOSIS AND TROUBLESHOOTING
Evaporator
The evaporator core is basically trouble-free when airflow over the fins is not blocked. Normally, the evaporator
outlet tube will feel cool to cold. External blockage or (less often) internal blockage will cause low suction
pressure and as little or no cooling.
Evaporator freeze-ups are the result of the moisture in the air condensing and then freezing on an evaporator
core that is operating below 32°F. The ice on the fins blocks the airflow through the evaporator and stops
the cooling until the ice melts. Evaporator freeze-up may be caused by a faulty TXV or a problem with the
freeze probe.
A flooded evaporator occurs when there is too much refrigerant flowing into the evaporator, and is generally
caused by a faulty TXV. A starved evaporator occurs when there is not enough refrigerant flowing into the
evaporator. Starvation can be caused by a faulty TXV or a low refrigerant charge. A starved evaporator may
cause the evaporator outlet tube to feel warmer than usual, at or near ambient temperature.
If a leak exists in the system, and it cannot be traced to other parts or fittings, suspect damage to the
evaporator core.
The evaporator is the most difficult of all the components to inspect visually because of its enclosed location.
To detect airflow blockage due to debris, bent fins, and/or refrigerant leaks (oil smudges), inspect the inlet
side of the evaporator.
CAUTION
Never force the fresh/recirculate air door open. If the door position must be changed,
turn on ignition, set mode control to FLOOR, and turn off ignition. Forcing the door will
result in a broken door shaft and a costly repair.
Line Restrictions
A restricted suction line causes low suction pressure at the compressor and little or no cooling. A restriction
in a line between the compressor and the TXV can cause high discharge and low suction pressure, and
poor cooling. Generally, if the line is not entirely blocked, the area immediately after the restriction will be
cold. A completely blocked line will result in high head pressures and no cooling, but no physical symptoms
at the blockage.
6.3. A/C SYSTEM TEST MODE

Perform this procedure when referenced from the troubleshooting tables. This test is used to determine if the
air conditioning system is properly charged with refrigerant and the refrigerant cycle is functioning correctly.
The test is performed using the IRTI4608032100 A/C Servicing System (IRTI4608032100), two temperature
probes (a third temperature probe is used with sleeper applications), and the ITNOD400 Leak Detector. When
a fault is detected, perform the repairs indicated.
After making repairs involving the refrigerant system, repeat this test to verify correct operation.
S16053 117
DIAGNOSIS AND TROUBLESHOOTING A/C SYSTEM TEST MODE
WARNING
During system pressure tests the recovery machine is only being used to read high
and low pressures. DO NOT open either hand valve on recovery station for any reason.
Equipment can be damaged, and personal injury can result.
CAUTION
To prevent damage to the test equipment, make sure test equipment and all connections
are clear of all moving parts in the engine compartment.
NOTE – Before connecting any service equipment to the refrigerant system, the refrigerant in the system
must be identified. Failure to identify system refrigerant before connecting equipment could result in
contamination of your service equipment and any refrigerant stored in the equipment.
NOTE – In rare conditions, vehicles using a viscous fan drive and being operated with no load may
need to place a fan in front of the condenser large enough to develop airflow comparable to normal ram
airflow.
1. Prior to performing performance testing be sure to:
A. Park the vehicle so there is no solar loading and no wind.

B. Always conduct performance testing with blower motor, door position, and temperature probe
positioned as described.
C. Note humidity and ambient temperature, and then consult the appropriate system pressure
test chart to determine system performance.
D. Always troubleshoot the HVAC system using the Diagnostic Trouble Codes and Service
Manual.
E. Always make sure to use the correct system pressure test chart for the vehicle being serviced.
NOTE – Each temperature probe has a number on its tip end, either 1, 2, or 3.
2. Position the sensing end of the T1 temperature probe approximately 12 to 24 inches in front of the vehicle
grill to measure ambient temperature of air entering the condenser. Connect the other end to the #1 (top)
position on the IRTI4608032100 A/C Servicing System.
3. Verify that the valves are closed at the quick-disconnect fittings by setting them in the fully counterclockwise
positions.
4. Connect the red hose to the high pressure service port.
5. Connect the blue hose to the low pressure service port.
6. Turn the knobs clockwise to open the valves on the quick-disconnect fittings connected to the service
ports on the vehicle.
7. If the vehicle has a solenoid controlled fan drive, engage it. The fan can be operated with a jumper wire
or by disconnecting the solenoid valve, depending on the system.
8. Slowly close the hood, being careful not to damage the test equipment connections.
118 S16053
A/C SYSTEM TEST MODE DIAGNOSIS AND TROUBLESHOOTING
• Insert a second temperature probe cable (T2) into the passenger side, right instrument panel vent.
Do not allow temperature probe (T2) to touch the side of the duct. Connect the other end to the #2
(middle) position on the IRTI4608032100 A/C Servicing System.
• The IRTI4608032100 A/C Servicing System is equipped with a third temperature probe (T3) for testing
the performance of the A/C system within the bunk area, if so equipped.
9. Run the engine at 1500 RPM.
10. Open the windows and close both cab doors.
11. Set the air conditioning control panel as follows:
A. Mode control to NORM A/C.

B. Blower control to high (full cw).
C. Temperature control to maximum cooling (full ccw).
12. Operate the system for at least 5 minutes or until the gauge readings settle.
13. Record the relevant readings from the LCD screen, ambient air temperature, relative humidity (RH), and
the cab air duct temperature.
14. Compare the pressure readings recorded previously to the pressures shown in Table 4. (The table is part
of the Performance AC Chart TMT-3416.)
15. If the pressure is more than 69 kPa (10 psig) higher than the pressure listed in the chart, the system
contains air or some noncondensable gas in the refrigerant system. The system needs to be discharged,
evacuated, and recharged (Automatic Mode). Refer to SERVICE PROCEDURES FOR R-134A (See
SERVICE PROCEDURES FOR R-134a, page 22).
EXAMPLE: If the ambient is 75°F, the system pressure should be in the 538-545 kPa (78-79 psig) range. If
the pressure is 620 kPa (90 psig) or higher, it indicates that there is air or some noncondensable gas in
the system.
NOTE – A refrigerant identifier can also be used to verify the contents of the system. Refer to Refrigerant
Identifier.
16. If the pressure is more than 69 kPa (10 psig) lower than the pressure listed in the chart, the system is
undercharged. The system needs to be discharged, evacuated, and recharged using the IRTI4608032100
A/C Servicing System. Undercharged systems should be inspected for a possible leak before being
discharged. Refer to SERVICE PROCEDURES FOR R-134A (See SERVICE PROCEDURES FOR
R-134a, page 22).
17. If the system is operating properly, the high and low pressure readings will be within the listed pressure
ranges in the following SYSTEM PRESSURE TEST CHART. If the gauges are not reading within the
System Pressure Test Chart ranges, refer to ABNORMAL READINGS .
S16053 119
DIAGNOSIS AND TROUBLESHOOTING A/C SYSTEM TEST MODE
Table 5 System Pressure Test Chart

Ambient Air Relative Vent Air Temperature Refrigerant Refrigerant Compressor
Temperature Humidity Right Passenger Pressure Pressure Cycling ?
High Side Low Side
Service Port Service Port
(°C) (°F) (% RH) (°C) (°F) kPa (psig) kPa (psig)
21.1 70 30-50 7.2-10.5 45-51 869-1006 186-221 Yes
(126-146) (27-32)
21.1 70 70-90 7.2-14.4 45-58 917-1055 214-248(31-36) Yes
(133-153)
26.7 80 30-50 7.8-13.3 46-56 1007-1145 179-213 Yes
(146-166) (26-31)
26.7 80 70-90 6.7-12.2 44-54 1055-1193 221-255 Yes
(153-173) (32-37)
32.2 90 30-50 7.2-11.7 45-53 1206-1344 221-255 Yes
(175-195) (32-37)
32.2 90 70 13.9-16.7 57-62 1303-1441 269-303 Yes
(189-209) (39-44)
37.8 100 30-50 12.2-15.6 54-60 1441-1579 262-296 Yes
(209-229) (38-43)
37.8 100 70 19.4-22.2 67-72 1600-1737 324- 358 Yes
(232-252) (47-52)
120 S16053
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING
6.4. TROUBLESHOOTING TABLES

NOTE – It is strongly recommended that Diamond Logic Builder® (DLB) software is used along with this
information to enhance diagnostic capabilities. See the diagnostic software manual for details on using
the software.
HVAC Control Circuit Test
NOTE – Ignition key must be in the ON position while performing HVAC Control Circuit Test.
Table 6 HVAC Control Circuit Test
STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

Does the HVAC Check HVAC control NO: Voltage is not within YES: 12 Vdc ± 1.5
control head have battery feed. Check specifications. Inspect . Voltage is within
battery voltage? voltage from HVAC for blown fuse F1 - B specifications. Continue
1.
control head (1200) (1010). Inspect A75D to step 2.
connector, pin A2 circuit for open. Repair
to ground. and retest circuit.
Does the HVAC Disconnect HVAC NO: Excessive YES: ≤1 ohm.
control head have control head 24-pin resistance is found or Resistance is within
proper ground? connector. Measure no continuity is present. specifications. HVAC
2. resistance from pin Inspect control head control head power
B6 to ground. ground circuit A74 - and ground is present.
G for open, loose, or Continue to step 3.
damaged connections.
Does the control Check for voltage from NO: Voltage is not YES: 12 Vdc ± 1.5
head have switched HVAC control head within specifications. Voltage is within
voltage from (1200) connector, pin Inspect fuse F4 - L specifications. Continue
3. ignition? A1 to ground. (1013). Inspect A73A to step 4.
circuit for open.
Repair and retest circuit.

Does the HVAC Check for voltage from NO: Voltage is not within YES: 12 Vdc. ± 1.5
control head have HVAC control head pin specifications.
A/C request signal A4 to ground. Voltage is within
present? Suspect faulty HVAC specifications.
4.
control head.
Continue to step 5.
Repair and retest
system.
S16053 121
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Does A/C control Key in ON position. NO: Voltage is not within YES: 12 Vdc ± 1.5
head supply voltage Air conditioner/heater specifications. Inspect
to the BC when control switch is ON. for open in A77 circuit Voltage is within
requesting A/C to Check for voltage at between the HVAC specifications.
operate? BC J3 connector, pin control head and BC.
A2 to ground. Repair and retest circuit.
5. NOTE – If HVAC
Control has power
and grounds present
and one or more
output features are
inoperative, suspect
internal control head
fault.
122 S16053
Mode Door Actuator Checks
1. BLOWER FAN SPEED CONTROL 5. MODE CONTROL WITH AIR

2. TEMPERATURE CONTROL CONDITIONING
3. MODE CONTROL
4. MODE CONTROL WITHOUT AIR
CONDITIONING
Figure 65 HVAC Control Head
NOTE – To establish a known starting position, the HVAC control head runs the actuator and door
through a calibration procedure when battery voltage is first applied to the HVAC control head, such
as cycling the ignition. Cycling ignition during diagnostic troubleshooting can cause false circuit
information.
NOTE – Whenever the door actuator motor is energized while disconnected (such as during testing), it
must be recalibrated after it is reconnected. After reassembling the door and actuator, and reconnecting
the actuator electrical connector, cycle the ignition key to initiate the calibration procedure.
NOTE – Ignition key must be in ON position.
NOTE – HVAC control head must be ON.
S16053 123
Table 8 Mode Door Actuator Circuit Test.
POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage being Check for voltage at YES: Voltage is not YES: 12 Vdc. ± 1.5
supplied by the HVAC control head, within specifications.
HVAC control pin B9. Operate mode Suspect faulty HVAC Voltage is being supplied
1.
head? switch. Test all switch control head. Refer from control head.
positions. to HVAC Control
Circuit Test. Continue to step 2.
Does the actuator Disconnect mode NO: Test light does YES: Test light illuminated.
operate in all mode actuator harness NOT illuminate on
settings? connector. Connect a specific Mode NOTE – It is important to
a test light between setting. Suspect physically verify actuator
cavity A and cavity faulty HVAC control door operation in addition to
B. Move mode switch head. electrical troubleshooting.
through ALL mode
settings, testing circuit Test light does NOT
2.
in each mode. illuminate on all
Mode settings.
Inspect A74 and
A74A circuits for
open or short.
Repair and retest

circuit.
124 S16053
Blend Door Actuator Checks
NOTE – To establish a known starting position, the control head runs the actuator and door through a
calibration procedure when battery voltage is first applied to the HVAC control head, such as cycling the
ignition. Cycling ignition during diagnostic troubleshooting can cause false circuit information.
NOTE – Ignition key must be in ON position.
Table 9 Blend Actuator Circuit Test
POSSIBLE
CAUSE
Is voltage being Check for voltage at NO: Voltage is not YES: 12 Vdc. ± 1.5
supplied by the HVAC control head, within specifications.
HVAC control pin B11. Operate Suspect faulty HVAC Voltage is within
1.
head? temperature switch control head. Refer specifications.
from full cold to full to HVAC Control
heat settings. Circuit Test. Continue to step 2.
Does the actuator Disconnect mode NO: Test light does YES: Test light illuminated.
operate in all actuator connector. not illuminate. Inspect
temperature Connect a test light A74B and A74C NOTE – It is important to
settings? between cavity circuits for open or physically verify actuator
B and cavity A. short. Repair and door operation in addition to
2.
Sweep temperature retest circuit. electrical troubleshooting.
switch through all
temperature settings,
testing for voltage in
all temp settings.
S16053 125
Fresh/Recirculate Door Actuator Checks
NOTE – To establish a known starting position, the control head runs the actuator and door through a
calibration procedure when battery voltage is first applied to the HVAC control head, such as cycling the
ignition. Cycling ignition during diagnostic troubleshooting can cause false circuit information.
NOTE – Ignition must be in ON position.
Table 10 Recirc Door Actuator Circuit Test
POSSIBLE
CAUSE
Is voltage being Mode Switch should NO: Voltage is not YES: 12 Vdc ± 1.5
supplied by the be in MAX air within specifications.
HVAC control conditioning mode. Suspect faulty HVAC Voltage is within specifications.
1.
head? Check for voltage control head. Refer
at HVAC control to HVAC Control Continue to step 2.
head, pin B1. Circuit Test.
Does the actuator Disconnect recirc. NO: Test light does YES: Test light Illuminated.
operate in all motor connector not illuminate. Inspect
positions? (4017). Connect a test A70D and A74E NOTE – It is important to
2.
light between cavity B circuits for open. physically verify actuator
and cavity A. Actuate Repair and retest door operation in addition to
mode actuator. circuit. electrical troubleshooting.
126 S16053
Linear Power Module/Blower Motor Checks
Table 11 LPM / Blower Motor Circuit Test

Does the linear Disconnect LPM (1220) NO: Voltage is not YES: 12 Vdc ±
power module have connector. within specifications. 1.5 Voltage is
battery voltage? Inspect for blown fuse within specifications.
1. Check voltage at the F6 - A (1015). Inspect Continue to step 2.
LPM connector, cavity A75 circuit for open
6 to ground. or shorts. Repair and
retest circuit.
Does the linear Check voltage at the NO: Voltage is not within YES: 12 Vdc ±
power module have LPM connector, cavity specifications. Inspect 1.5 Voltage is
2. voltage supplied by 4 to ground. A75A circuit for open within specifications.
the HVAC control? or shorts. Repair and Continue to step 3.
retest circuit.
Does the linear Check resistance NO: Resistance is too YES: ≤1 ohm.
power module have between cavity 5 of the high or no continuity Resistance is within
continuity to ground? LPM and ground plate. is present. Inspect specifications.
3. A75 - G ground circuit Connect LPM harness
for open, loose, or connector. Continue
damaged connections. to step 4.
Is full power being Operate blower motor at NO: Voltage is not YES: 5.0 Vdc ±
supplied to the HIGHEST speed setting. within specifications. 0.25 Voltage is
blower motor? Check voltage between within specifications.
connector cavity 4. Inspect A75A circuit Continue to step 5.
for open or short from
4.
HVAC control to LPM.
If no problems are
evident, perform HVAC
Control Circuit Test.
Is power being Operate blower motor NO: Voltage is not YES: 2.0 Vdc ± 0.5
supplied to the at LOWEST speed within specifications. Voltage is within
blower motor on setting (20% duty cycle). specifications.
the lowest setting? Check voltage between Inspect A75A circuit
connector cavity 4. for open or short from HVAC control head is
5.
HVAC control to LPM. operating properly.
If no problems are Continue to Step 6.

evident, perform HVAC
Control Circuit Test.
S16053 127
Table 11 LPM / Blower Motor Circuit Test (cont.)


6. Is the blower motor Disconnect blower motor NO: YES: Voltages are
operating on all harness connector from within specifications.
switch positions? LPM. Voltages are not within
specifications. If blower motor is still
Check for voltage at the inoperative, replace and
blower motor harness Suspect faulty LPM. retest blower motor.
connector pin A to pin B.
Operate blower motor

control switch in each
speed setting.
View voltages in each

speed setting, and
compare to Blower
Speed Voltage Table 11.
Table 12 Blower Speed Voltage Table
SPEED SETTING VOLTAGE

OFF 0 Vdc.
1 (Lowest) 1.7 ± 0.5 Vdc.
2 3.4 ± 0.5 Vdc.
3 5.1 ± 0.5 Vdc.
4 6.8 ± 0.5 Vdc
5 8.5 ± 0.5 Vdc
6 10.2 ± 0.5 Vdc
7 (Highest) 12 ± 0.5 Vdc
128 S16053
A/C Compressor Checks
NOTE – Diagnose HVAC control head DTC’s prior to circuit testing A/C compressor. Certain DTC’s will
inhibit compressor operation.
NOTE – Ensure A/C System pressures are within specifications and system is fully charged.
NOTE – Utilizing the Diamond Logic Builder® software, verify that the following signals are true:
• Ignition key is in the RUN position.

• A/C request is ON.
• Low pressure switch voltage is < 2 Vdc.
• Freeze probe thermistor (evaporator temperature) is above 38°F
• High pressure transducer pressure is < 2758 kPa (400 psi).
Table 13 A/C Compressor Clutch Circuit Test.

Is voltage being Check voltage at the NO: Voltage is not YES: 12 Vdc. ± 1.5
supplied to the body controller #J1 within specifications.
A/C compressor (1603) connector, pin No A/C compressor Voltage is within
by the BC? C to ground. output voltage supplied specifications.
1.
by BC. Verify operation
of all compressor inputs Continue to step 2.
to BC. Suspect faulty
body controller.
Is voltage present Check voltage at IP/ENG NO: Voltage is not within YES: 12 Vdc. ± 1.5
at the engine/IP 42 - way connector (1702 specifications. Open or
connector cavity 10? - 10) cavity 10 to ground. shorted A77A circuit. Voltage is within
2. Inspect for damaged specifications.
wires, loose, or corroded
connections. Repair Continue to step 3.
and retest circuit.
Does the A/C Check voltage at A/C NO: Voltage is not within YES: 12 Vdc. ± 1.5
compressor have compressor clutch specifications. Open
voltage? (6200) connector, cavity or shorted K77 circuit. Voltage is within
3. B to ground. Inspect for damaged specifications.
wires, loose, or corroded
connections. Repair Continue to step 4.
and retest circuit.
Does the A/C Disconnect A/C NO: Resistance is out YES: ≤1 ohm.
compressor have compressor clutch of specifications or no Resistance is within
proper ground? (6200) connector. continuity is present. specifications.
Measure resistance Inspect K77 - G ground Continuity is present.
4.
between cavity A to circuit for open, loose, or A/C compressor clutch
ground. damaged connections. circuits are operable.
Repair and retest circuit. Suspect faulty A/C
compressor clutch coil.
S16053 129
Pressure Transducer Checks
NOTE – Refer to latest circuit diagram information related to vehicles equipped with transmission oil
temperature gauges and air restriction.
NOTE – Ensure A/C system pressures are within specifications and system is fully charged.
NOTE – Ensure ignition key is in the ON position
NOTE – A/C request is ON.
Table 14 Pressure Transducer Circuit Test

Does the body Check voltage at body NO: Voltage is not within YES: 5 Vdc. Voltage
controller supply controller #J5 connector specifications. Verify is within specifications.
1. 5 Vdc. signal to (1602), pin E6 to ground. BC operation. Inspect Continue to step 2.
the A/C pressure J5 connector for loose
transducer? or damaged pins.
Is voltage present Check voltage at body NO: Voltage is not within YES: 0 Vdc. Voltage
at the pressure controller #J5 connector specifications. If voltage is within specifications.
transducer zero volt (1602), pin E3 to ground. is present, inspect circuit Continue to step 3.
2. reference circuit? A9Z and A9C for short
to voltage. Repair and
retest circuit.
Does the zero volt Disconnect A/C pressure NO: Resistance is not YES: ≤1 ohm. Continue
reference circuit transducer connector within specifications to step 4.
have low resistance? (6201). Disconnect BC OR no continuity is
#J5 connector (1602). present. Inspect A9Z
Measure resistance and A9C circuit for open
3. between transducer and source of high
connector, cavity A and resistance. Inspect zero
cavity E3 of the BC volt reference connector
#J5 connector. (1620) for loose or
damaged connections.
130 S16053
STEP POSSIBLE CAUSE

TEST/CHECK (cont.) NO: (cont.) YES: (cont.)
(cont.) (cont.)
NO: Voltages do
not directly relate to
pressures (Refer to
Pressure Transducer
Voltage Table 17).
Measure voltage from
BC #J3 connector If voltage is 5 Vdc:
YES: Voltage is
(1600), pin B12 to Inspect A77B and
Does the pressure directly related to A/C
ground. Using the K77B circuits for short
transducer signal pressures. As pressure
Diamond Logic Builder® to voltage.
4. voltage correctly increases, voltage
software, view the
relate to pressure increases. Refer to
A/C_High_Side_Pressure If voltage is 0 Vdc:
reading? Pressure Transducer
signal. Compare Inspect A77B and K77B
Voltage Table 17.
voltages to pressure circuits for open or
signal. short to ground.
If no problems are
evident with circuit(s):
Suspect faulty A/C
pressure transducer.
Table 16 Pressure Transducer Voltage Table
PRESSURE kPa 138 172 276 345 517 689 1,034 1,276 1,379
0 (0)
(psi) (20) (25) (40) (50) (75) (100) (150) (185) (200)
NOMINAL
0.25 0.42 0.48 0.62 0.71 0.92 1.15 1.59 1.90 2.03
VOLTAGE (VDC)
PRESSURE kPa 1,724 1,965 2,068 2,413 2,758 2,896 3,103 3,275 3,447
(PSI) Continued (250) (285) (300) (350) (400) (420) (450) (475) (500)
NOMINAL
VOLTAGE (VDC) 2.48 2.80 2.92 3.38 3.81 3.99 4.26 4.48 4.71
Continued
S16053 131
Freeze Probe Thermistor Checks
NOTE – Ensure A/C system pressures are within specifications and system is fully charged.
NOTE – Verify ignition key state for individual test.
NOTE – Ensure A/C control head is ON.
NOTE – Perform test with freeze probe thermistor connector (4019) disconnected from thermistor.
Table 17 Freeze Thermistor Circuit Test
POSSIBLE
CAUSE
Is voltage being Key in ON position. NO: Voltage is not within YES: 10 Vdc. ± 1.0
supplied to specifications. Inspect for
the HVAC unit Measure voltage at open or shorted circuit Voltage is within
1.
connector cavity HVAC unit connector between cavity G to BC specifications.
G? (1210) cavity G to #J3 connector. Repair
ground. and retest circuit. Continue to step 2.
Does the freeze Disconnect HVAC unit NO: No continuity is YES: < 1 ohm.
thermistor zero volt connector (1210) and present. Check for open
reference circuit BC #J5 connector(1602). circuits between HVAC unit Resistance is within
2. have continuity Measure continuity from connector (1210) cavity specifications.
to ground? cavity H to BC #J5 H and BC connector #J5
cavity E3. (1602) pin E3. If no open Continue to step 3.
exist, suspect faulty BC.
Does freeze Key in OFF position. NO: Resistance YES: Voltage is within
thermistor measurements do not specifications.
resistance Measure resistance agree with temperature:
measurement between thermistor Replace thermistor
correctly relate terminals A to B. (freeze probe)
3.
to temperature?
Refer to Thermistor Resistance
Cross Reference Table measurements agree
21 for specifications. with temperature:
Suspect faulty BC.
132 S16053
Low Pressure Switch Checks
NOTE – Ensure A/C System pressures are within specifications and system is fully charged.
NOTE – Verify ignition key state for individual test.
NOTE – Ensure A/C control head is ON.
NOTE – Perform test with low pressure switch connector (4018) disconnected from thermistor.
Table 18 Low Pressure Switch Circuit Test
POSSIBLE
CAUSE
Is voltage present Key in ON position. NO: Voltage is not within YES: 10 Vdc. ± 1.0
at the HVAC Unit specifications Inspect
(1210) connector Measure voltage from for an open or shorted Voltage is within
cavity J? HVAC Unit (1210) circuit between harness specifications.
1. connector cavity J connector cavity J and
to ground. BC #J3 connector (1600) Continue to step 2.
pin B5. If no circuit faults
exist, suspect BC. Repair
and retest circuit.
Does the low Disconnect HVAC unit NO: No continuity is YES: < 1 ohm. Resistance
pressure switch 0 connector (1210) and present. Check for is within specifications.
voltage reference BC #J5 connector open circuits between Continue to step 3.
circuit have (1602). Measure HVAC unit connector
2.
continuity to continuity from cavity K (1210) cavity K and BC
ground? to BC #J5 cavity E3. connector #J5 (1602)
pin E3. If no open exist,
suspect faulty BC.
Does low Key in OFF position. NO: Resistance YES: Refer to Thermistor
pressure switch measurements do not Cross Reference Table 21
resistance Measure resistance agree with pressure: for specifications.
measurement between low pressure Replace thermistor (low
relate to switch (4018) terminals pressure switch).
3.
temperature? A to B.
Resistance
measurements agree
with pressure: Suspect
faulty BC.
S16053 133
Table 19 Thermistor Cross Reference
TEMP. TEMP. MIN. RESISTANCE NOMINAL RESISTANCE MAX. RESISTANCE

(°C) (°F) (kohms) (kohms) (kohms)
-15 5 35.03 35.67 36.32
-10 14 26.65 27.06 27.48
-5 23 20.46 20.72 20.98
0 32 15.84 16.00 16.16
5 41 12.30 12.46 12.61
10 50 9.626 9.771 9.918
15 59 7.589 7.722 7.856
20 68 6.025 6.144 6.265
25 78 4.816 4.922 5.030
30 86 3.874 3.968 4.064
134 S16053
SPECIFICATIONS
7. SPECIFICATIONS
7.1. TORQUE CHART
Table 20 Torque Chart
Torque Value
Figure No. (Item Item Description
No.) Lbf-ft
N•m
(Lbf-in)
Figure 19 (Item
60 to 120
1) and Figure 23 Pressure Transducer 7 to 14
lbf-in
(Item 8)
60 to 120
Figure 20 (Item 2) Low Pressure Switch 7 to 14
lbf-in
Figure 23 (Item
14 to 15
5) and Figure 24 Front C-plate Nuts 19 to 20
lbf-ft
(Item 5)
Figure 24 (Item 7) Filter-Drier Cover Screws 2.3 20 lbf-in
35.4 to 38
Figure 25 (Item 3) Expansion Valve Screws 4 to 4.3
lbf-in
Figure 26 (Item
1) and Figure 27 Fresh Air Module Nuts 7 58 lbf-in
(Item 2)
Figure 28 (Item 1) Interior Module Trim Screws 2.26 20 lbf-in
Figure 29 (Item 6) Fresh/Recirc Door Actuator Screws 2.26 20 lbf-in
Figure 30 (Item 3) Blend Door Actuator Screws 2.26 20 lbf-in
Figure 31 (Item 1) Mode Door Actuator Screws 2.26 20 lbf-in
80 to 90
Figure 32 (Item 2) Front Lock Plate Screw 9 to 10
lbf-in
Figure 46 (Item 3) LPM Screws 2.26 20 lbf-in
Figure 47 (Item 5) Blower Assembly Screws 2.26 20 lbf-in
20 to 27
Figure 50 (Item 4) HVAC Control Panel Screws 2 to 3
lbf-in
17 to 21
Figure 51 (Item 3) Compressor Mounting Bolts 23 to 29
lbf-ft
Figure 53 (Item 7) Blower Scroll Housing Screws 2.26 20 lbf-in
Figure 59 (Item 1) Interior Module Mounting Nuts 7 58 lbf-in
S16053 135
SPECIFICATIONS AIR CONDITIONING SYSTEM
7.2. AIR CONDITIONING SYSTEM

Table 21 Air Conditioning System Specifications
ITEM SPECIFICATION
Refrigerant Type R-134a
Refrigerant Quantity (Full Charge)
• WorkStar® • 1.25 kg
(2.75 lbs)
(44 oz.)
• TranStar® • 1.13 kg
(2.5 lbs)
(40 oz.)
Compressor Oil Type PAG Oil
P/N ZGGR725028
Compressor Oil Capacity (All Models) 300 cc (10.14 fl.oz.)
Lubricating Oil Type (O-rings, threads, etc.) Do NOT P/N ZGGR6912
use as compressor refrigerant oil.
(Mineral Oil)
Compressor Belt Drive Tension Controlled by auto-tensioner.
136 S16053
SPECIAL TOOLS
8. SPECIAL TOOLS
CAUTION
The servicing tools recommended for this system were designed specifically for use
with R-134a systems. Servicing tools designed and/or used for R-12 systems must not
be used when servicing R-134a systems unless they are specifically identified as being
compatible with both systems.
Servicing air conditioning efficiently and effectively requires proper tools and equipment. The recommended
tools, as well as alternate service tools are shown and discussed below.
The tools listed in the following table can be ordered through the tool supplier. For special tools that are
obtained locally refer to TOOLS OBTAINED LOCALLY.
Table 22 Special Service Tools
DESCRIPTION PART NO.
Air Conditioning Recovery, Recycling, and Recharge Machine.

IRTI4608032100
Refrigerant tracer oil and dye kit ITRA125401NAV
ITNOD400 Refrigerant Leak Detector ITNOD400
Electronic Service Tool (EST), EZ-Tech
and Interface Communications Cable
Table 23 Frequently Used A/C Servicing System Consumable Items
ISN PART NUMBER REFERENCE RTI P/N ITEM DESCRIPTION

IRTI0288003505 028 80035 05 HOSE RED 15 FT .5 ACME X M14-1.5
IRTI0288003605 028 80036 05 HOSE BLU 15 FT .5 ACME X M14-1.5
IRTI0238009500 023 80095 00 COUPLING FSC HIGH RED M14-1.5 215010
IRTI0238009600 023 80096 00 COUPLING FSC LOW BLUE M14-1.5 215011
IRTI3608217500 360 82175 00 KIT FILTER MAINTENANCE FOR RHS980C-NAV
IRTI0118000400 011 80004 00 OIL VACUUM PUMP (QUART) 217020
IRTI0258011419 025 80114 19 CORD POWER 5-15 PLUG 5-15 RECEP 120"
IRTI0258040400 025 80404 00 THERMISTOR PROBE 10K 1/4IN 2PIN 20FT
IRTI3608173300 360 81733 00 SEALER IDENTIFIER KIT
IRTI0268048200 026 80482 00 EQUIPMENT STORAGE COVER RHS 980C-NAV
IRTI3608161800 360 81618 00 FILTER, INLINE MICRON FOR MACHINES, 10 PK
O-RING REPAIR SET FOR R134a SERVICE
IRTI3608067200 360 80672 00
COUPLERS
IRTI3608221900 360 82219 00 KIT REPLACEMENT ID SAMPLE HOSE RHS980C-N
IRTI0268030900 026 80309 00 SEALANT DETECTOR CARTRIDGE, 25 PK.
S16053 137
SPECIAL TOOLS
Table 23 Frequently Used A/C Servicing System Consumable Items (cont.)

ISN PART NUMBER REFERENCE RTI P/N ITEM DESCRIPTION
IRTI3608001200 360 80012 00 OIL VACUUM PUMP (12 QT CASE)
REPLACEMENT BATTERY FOR CIRCUIT
IRTI3608229200 360 82292 00
BOARD CR1025
All consumable items can be ordered through Navistar parts.
138 S16053
SERVICING SYSTEM (IRTI4608032100) SPECIAL TOOLS
8.1. SERVICING SYSTEM (IRTI4608032100)
Figure 66 Servicing System (IRTI4608032100)
Servicing System (RHS980C-NAV) is the recommended air conditioning service machine, meeting SAE J2788
standards. If other recovery tools (meeting SAE J2788) are used, refer to the instructions provided by the tool
manufacturer (this includes the current Robinair machine).
The IRTI4608032100 can be used to perform a fully automatic service. The technician will be prompted for
entry of data such as charge amount and given options like vacuum leak test. Once the necessary data has
been entered, the IRTI4608032100 will automatically perform the complete service and alert the technician for
interaction or that the service is complete.
The IRTI4608032100 can also be used to perform individual functions like recycle, vacuum, or charge. The
keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM, and CHARGE) to allow the technician to
jump directly to any one of these functions.
Units of measure displayed can be changed at any time by repeatedly pressing the U/M key.
A setup routine can be used to select options, set default values, perform maintenance operations, and
manage fluid capacities processed.
For any additional operating instructions refer to the operators manual supplied with the IRTI4608032100.
S16053 139
SPECIAL TOOLS SERVICING SYSTEM (IRTI4608032100)
CAUTION
Sealants and leak stop chemicals in A/C systems may cause serious damage to the
NOTE – The new SAE Standard J2788 dictates that the filter must be changed at set intervals to ensure
that recycled refrigerant is pure.
The IRTI4608032100 has one filter, which must be changed after recycling every 68 KG (150 lbs) of
refrigerant.
The technician will be alerted when the filter life is at 45 KG (100 lbs). This allows time to order a
replacement filter kit.
When the filter has purified 68 KG (150 lbs) of refrigerant, the IRTI4608032100 will shut down and not
perform any function.
A new filter must be installed to re-activate the IRTI4608032100 controller.
140 S16053
IRTI4608032100 TEMPERATURE PROBES SPECIAL TOOLS
8.2. IRTI4608032100 TEMPERATURE PROBES

Three temperature probes are used with the IRTI4608032100 for testing and diagnostics. Temperature probes
provide a simple, accurate way to read relative humidity, pressures, and ambient air temperature.
8.3. REFRIGERANT IDENTIFIER
Figure 67 Refrigerant Identifier Hose (Found On The Rear Of The IRTI4608032100)
In today’s environment, there are a lot of alternative and blended refrigerants; International® only recognizes
R-134a for this system. The only way to know for sure if you can safely recover the refrigerant in a system
is through the use of a refrigerant identifier. If the IRTI4608032100 has a refrigerant identifier installed, the
refrigerant identifier samples the refrigerant, then displays the type and purity of the refrigerant in the system.
The refrigerant identifier hose is found on the rear of the IRTI4608032100 and connects to the vehicle low side
service port. The refrigerant identifier is supplied as part of a kit which includes the necessary hoses and
fittings. The refrigerant identifier is an optional item and can be installed in the field.
S16053 141
SPECIAL TOOLS ITNOD400 REFRIGERANT LEAK DETECTOR
8.4. ITNOD400 REFRIGERANT LEAK DETECTOR
1. ITNOD400 LEAK DETECTOR

Figure 68 Refrigerant Leak Detectors
The ITNOD400 features a long life heated sensor technology that is designed to detect the more current and
difficult HFC refrigerants, such as R-134a, in addition to all HCFC and CFC refrigerants including hydrocarbon
“blends”. The ITNOD400 unique digital leak size indicator takes the guesswork out of whether or not to repair a
small leak. The ITNOD400 dose not require rechargeable batteries. The ITNOD400 is SAE J2791 compliant.
142 S16053
AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT SPECIAL TOOLS
8.5. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
Figure 69 125401NAV Air Conditioning Oil And Dye Injection Equipment
Replacing the proper amount of oil during service is critical to compressor survival and extended customer
satisfaction. During service, additional lubrication is required to replace lubricant removed during component
replacement. The traditional method of replacing lubrication has several short-falls.
With the objective of making a tech’s job easier and ensuring the highest quality repairs, Navistar decided
to transition to the cartridge oil injection method. At any point in the service, the tech could add the lube to
the component or the system, whether under a vacuum, or charged. The tool also has check valves, which
means no mess.
For additional information refer to the documentation supplied with the 125401NAV Air Conditioning Oil
and Dye Injection Equipment.
8.6. FLUSH/PURGE FITTING ADAPTERS

Navistar flush/purge fitting adapters (RTI P/N 560 80533 00) are available to convert existing Navistar A/C
solvent flush/purge fittings to liquid refrigerant flush fittings. When the fittings are used in conjunction with the
IRTI4608032100 a liquid refrigerant flush can be performed. For more information on Navistar flush/purge
fitting adapters, refer to the instructions provided with the kit.
S16053 143
SPECIAL TOOLS TOOLS OBTAINED LOCALLY
8.7. TOOLS OBTAINED LOCALLY
1. NITROGEN CYLINDER, 3. DRAIN HOSE WITH

REGULATOR AND CART COMPRESSION FITTING
2. FLUSH GUN AND ADAPTERS
Figure 70 Service Tools that may be Obtained Locally
WARNING
The nitrogen supplied to the flush gun must not exceed 517 kPa (75 psi).
If the refrigerant system has been contaminated, such as due to an internal compressor failure, it must be
flushed and purged before it can be repaired and recharged. A flush gun (Figure 71, Item 2) is used, along
with compressed dry nitrogen, to force a flushing agent through the hoses and components of the refrigerant
system. The flush gun and drain hose with compression fitting/adapter can be obtained locally.
1. MALE ADAPTER (1/2 INCH), 3. FEMALE ADAPTER (1/2 INCH),

ZTSE4503 ZTSE4504
2. MALE ADAPTER (3/4 INCH), 4. FEMALE ADAPTER (3/4 INCH),
ZTSE4501 ZTSE4502
Figure 71 Block Fitting Adapters
When performing flushing and/or purging operations, adapters are required to connect the service equipment
to the HVAC system components.
144 S16053
ELECTRONIC SERVICE TOOL (EST), EZ-TECH SPECIAL TOOLS
8.8. ELECTRONIC SERVICE TOOL (EST), EZ-TECH
Figure 72 Electronic Service Tool, EZ-Tech
The EZ-Tech electronic service tool (refer to Figure 73), running Diamond Logic Builder® (DLB) software
allows the servicer to monitor the HVAC electrical circuits. The EZ-Tech is connected to the vehicle
diagnostic connector through an interface communications cable. When used in conjunction with the electrical
troubleshooting, the EZ-Tech allows the servicer to isolate electrical faults efficiently. See the Diamond Logic
Builder® software site at https://evalueb.internationaldelivers.com/dlb/dlb/ for details on using the software.
S16053 145

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SERVICE MANUAL

SERVICE MANUAL SECTION

HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010

3. SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

4. SERVICE PROCEDURES FOR R-134A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

TABLE OF CONTENTS (CONT.)

5. REMOVE AND INSTALL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

TABLE OF CONTENTS (CONT.)

6. DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

TABLE OF CONTENTS (CONT.)

Check for Noncondensable Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

8. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

To prevent personal injury or death, be certain that pressurized refrigerant containers

To prevent personal injury or death, always use approved refrigerant recycling

To prevent damage to engine and/or HVAC components, after replacing a compressor,

To prevent damage and/or contamination to the IRTI4608032100 and R-134a refrigerant,

To prevent damage and/or contamination to the IRTI4608032100 and R-134a refrigerant,

1. INTERIOR MODULE 6. CONDENSER

1. FUSE PANEL COVER 3. HVAC CONTROL PANEL

2.1. SYSTEM OPERATIONAL DESCRIPTION

1. HVAC AIR INLET 9. TEMPERATURE BLEND DOOR

Air Distribution (Air Conditioning)

Figure 4 System Airflow by Mode

Air Distribution (Heat and Ventilation)

Air Distribution (Defrost)

A/C Refrigerant Flow

1. RAM AIR 10. COLD AIR

The compressor repressurizes the refrigerant, causing it to again become a high-pressure/high-temperature

1. INTERIOR MODULE 7. LOW PRESSURE SWITCH

Thermostatic Expansion Valve (TXV)

Low Pressure Switch

Linear Power Module

To prevent damage to HVAC components, maintain clean filters.

HVAC Control Panel

2.3. INTERNAL COMPONENTS

1. HVAC FILTER 6. EVAPORATOR

To prevent damage to HVAC components, maintain clean filters.

2.4. UNDER HOOD COMPONENTS

Compressor and Clutch

2.5. HVAC ELECTRICAL SYSTEM OVERVIEW

General Operation Of The HVAC Electrical System

3.1. CONTROL ASSEMBLY

1. BLOWER FAN SPEED CONTROL 4. HEATER ONLY CONTROL

3.2. BLOWER FAN SPEED CONTROL

3.3. TEMPERATURE CONTROL

3.4. MODE CONTROL

The air conditioning settings are indicated by icons with snowflakes.

Table 1 Air Distribution Chart

CONTROL KNOB POSITION AIRFLOW

MAX A/C PANEL 100%

NORM A/C 100%

DOT 1 50% 50%

BI-LEVEL DOT 1 75% 25%

DOT 2 BI-LEVEL 50% 50%

DOT 3 DOT 2 25% 75%

FLOOR FLOOR 100%

DOT 4 DOT 3 75% 25%

MIX BLEND 50% 50%

DOT 5 DOT 4 25% 75%

DEFROST DEFROST 100%

MAX Air Conditioning Mode

NORM Air Conditioning Mode

Bi-Level Air Conditioning Mode