2010 Dodge Caliber R/T

2010 HVAC Heating & Air Conditioning - Service Information - Caliber

DESCRIPTION

An electronic Manual Temperature Control (MTC) single zone type heating-A/C system, electronic MTC
heater-only system and an electronic Automatic Temperature Control (ATC) single zone type heating-A/C
system are available on this model, depending on market.

To maintain the performance level of the Heating, Ventilation and Air Conditioning (HVAC) system, the
engine cooling system must be properly maintained. The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser will reduce the performance of the A/C and engine
cooling systems.

The engine cooling system includes the radiator, thermostat, radiator hoses and the engine coolant pump.
See appropriate cooling system service information for more information before opening or attempting any
service to the engine cooling system.

Fig. 1: Exploded View Of Heating, Ventilation & Air Conditioning (HVAC) System
Courtesy of CHRYSLER LLC

The heating-A/C system combines A/C, heating, and ventilating capabilities in a single HVAC housing
mounted within the passenger compartment beneath the instrument panel. All vehicles are equipped with a
common HVAC housing that includes:

Blend-air door and actuator (1)

Evaporator temperature sensor (2) (when A/C equipped)
A/C evaporator (3) (when A/C equipped)
Mode-air doors (4)
Mode door actuator (5)
Recirculation-air door and actuator (6) (when A/C equipped)
Particulate air filter (7) (when equipped)
Blower motor (8)
Blower motor resistor or power module (9) (depending ATC/MTC application)
Heater core (10)

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On heater-only systems, the A/C evaporator is omitted from the HVAC housing and is replaced with an air
restrictor plate.

NOTE: An electric positive temperature coefficient (PTC) heater is used on vehicles

when equipped with the 2.2L diesel engine. The PTC heater unit
compensates for the lower engine coolant temperatures produced by the
diesel engine. The PTC heater unit is mounted in the HVAC air distribution
housing, downstream of the heater core. For more information. See Heating
and Air Conditioning/Cabin Heater/UNIT, Heater - Description.

Based upon the system mode selected, conditioned air can exit the HVAC housing through one or a
combination of the three main housing outlets: defrost, panel or floor. The defrost and panel outlets are
located on the top of the HVAC air distribution housing and the floor outlets are located on each side of the
distribution housing. Once the conditioned air exits the HVAC housing, it is further directed through molded
plastic ducts to the various outlets within the vehicle interior. These outlets and their locations are as
follows:

Defroster Outlet - A single large defroster outlet is located in the center of the instrument panel, near
the base of the windshield.
Side Window Demister Outlets - There are two side window demister outlets, one is located at each
outboard end of the instrument panel top cover, near the belt line at the A-pillars.
Panel Outlets - There are four panel outlets in the instrument panel, one located near each outboard
end of the instrument panel facing the rear of the vehicle and two located near the top of the
instrument panel center bezel.
Front Floor Outlets - There are two front floor outlets, one located on each side the floor panel
center tunnel behind the instrument panel.
Rear Seat Floor Outlets - There are two rear seat floor outlets, one located on each side of the floor
panel near the front of each rear seat foot well.

OPERATION
OPERATION

The Manual Temperature Control (MTC) heating-A/C system, MTC heater-only system and the Automatic
Temperature Control (ATC) heating-A/C system are blend-air type systems. In a blend-air system, a blend-
air door controls the amount of conditioned air that is allowed to flow through, or around, the heater core.
The temperature control determines the discharge air temperature by operating the blend door actuator,
which moves the blend-air door. This design allows almost immediate control of output air temperature.

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 2: Blend Air System Schematic

Courtesy of CHRYSLER LLC

NOTE: Typical blend-air type HVAC system shown.

The heating-A/C system pulls outside (ambient) air through the fresh air intake (4) located at the cowl panel
at the base of the windshield and into the air inlet housing above the heating, ventilation and air conditioning
(HVAC) housing. On models equipped with A/C, the air passes through the A/C evaporator (7). Air flow is
then directed either through or around the heater core (2). This is done by adjusting the position of the
blend-air door (3) with the temperature control located on the A/C-heater control in the instrument panel.
Air flow is then directed out the floor outlet (8), instrument panel outlet (10) or the defroster outlet (1) in
various combinations by adjusting the position of the mode-air doors (9 and 11) using the mode control
located on the A/C-heater control. The mode control uses a control cable to operate the mode-air doors.

The velocity of the air flow out of the outlets can be adjusted with the blower speed control located on the
A/C-heater control.

The fresh air intake can be shut off by pressing the Recirculation button on the A/C-heater control. This will
operate the electrically actuated recirculation-air door (5), which closes off the fresh air intake. With the
fresh air intake closed, the conditioned air within the vehicle is pulled back into the HVAC housing through
the recirculation air intake (6) located within the passenger compartment.

The A/C compressor can be engaged by pressing the A/C (snowflake) button on the A/C-heater control. It
will automatically engage when the mode control is set in any Mix to Defrost position. This will remove
heat and humidity from the air before it is directed through or around the heater core. The mode control on
the A/C-heater control is used to direct the conditioned air to the selected system outlets.

The front and rear floor outlets receive airflow from the HVAC housing through the front and rear floor
ducts. The front floor outlets are integral to the molded plastic front floor ducts, which are secured to each
side of the HVAC housing. Two molded plastic rear seat ducts are attached to the two molded plastic rear
floor ducts, which are secured to the rear of the HVAC housing. The rear seat ducts direct airflow beneath
the carpet to the outlets located near the front of each rear seat foot well. None of the floor outlets can be
adjusted.

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The panel outlets receive airflow from the HVAC housing through the center air distribution duct and
molded plastic panel outlet ducts. The airflow from each of the panel outlets is adjustable. A thumbwheel
located at the bottom of each panel outlet grille is used to adjust a center diffuser that changes the airflow
direction, and a knob on the outer edge of each panel outlet grille opens or closes a shutter to turn airflow on
or off through that outlet.

The defroster outlet receives airflow from the HVAC housing through the molded plastic defroster duct,
which is secured to the top of the instrument panel. The airflow from the defroster outlet is directed by fixed
vanes in the defroster outlet grille and cannot be adjusted.

The side window demister outlets receive airflow from the HVAC housing through the defroster duct and
molded plastic demister ducts. The airflow from the side window demister outlets is directed by fixed vanes
in the demister outlet grilles and cannot be adjusted. The side window demister outlet grilles are integral to
the instrument panel cover and direct air from the HVAC housing through the outlets on the top corners of
the instrument panel. The demisters operate when the mode control is set in any Floor to Defrost position.

DIAGNOSIS AND TESTING

A/C PERFORMANCE

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

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

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

A/C PERFORMANCE TEST

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow the warnings and
cautions could result in possible serious or fatal injury.

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CAUTION: The use of an A/C recycling/charging station for purposes of

determining the actual charge level of an A/C system is not
recommend. Service recycling/charging stations do not reflect the
correct amount of refrigerant charge in the A/C system after a single
"reclaim" cycle. Tests have shown that it can take two or more
"reclaim" cycles to remove all of the refrigerant charge, depending on
the equipment being used. Use only the following procedure for
determining the proper charge level.

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

1. Check for Diagnostic Trouble Codes (DTCs) using a scan tool. If no DTCs are found in the
Powertrain Control Module (PCM) or Engine Control Module (ECM) (depending on engine
application), Gateway Module or the Totally Integrated Power Module (TIPM), go to 2. If any DTCs
are found, repair as required, then proceed to 2.
2. Connect a tachometer and a manifold gauge set or an A/C recycling/charging station.

NOTE: The ambient air temperature of the vehicle and the location where the
vehicle will be tested must be a minimum of 21° C (70° F) before
performing this test. Place the vehicle in the testing area until the
temperature within the vehicle reaches a minimum of 21° C (70° F).

3. Operate the heating-A/C system under the following conditions.

Engine at idle and operating temperature
Doors or windows open
Transaxle in Park or Neutral with parking brake set (depending on transaxle application)
A/C-heater controls set to Recirculation mode (max-A/C), full cool, panel mode, high blower
and A/C on.
4. Insert a thermometer in the driver side center panel air outlet and operate the vehicle a minimum of
ten minutes to allow the thermometer temperature to stabilize.

NOTE: This procedure requires the technician to know what the temperature
and relative humidity is at the time of the test. The temperature must be
combined with the relative humidity to calculate the apparent ambient
temperature ("feels like" temperature), when the temperatures are
above 21° C (70° F). Use the current ambient temperature and the
relative humidity in your location. This information can be obtained
from multiple sources, such as the internet or local news media.

5. Compare the air temperature at the center panel outlet and the A/C system pressures to the A/C
Performance Temperature and Pressure chart.

A/C PERFORMANCE TEMPERATURE AND PRESSURE

Ambient 21° C (70° 27° C (80° 32° C (90° 38° C (100° 43° C (110°
Temperature F) F) F) F) F)
(Apparent)

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Air 6 -15° C (42 7 -18° C (45 9 - 21° C 11 - 22° C 13 - 24° C

Temperature - 59° F) - 64° F) (48 - 69° F) (52 - 72° F) (56 - 75° F)
at Center
Panel Outlet
A/C High Side 1034 - 1896 1207 - 2068 1379 - 2241 1551 - 2413 1724 - 2241
Pressure kPa (150 - kPa (175 - kPa (200 - kPa (225 - kPa (250 -
275 psi) 300 psi) 325 psi) 350 psi) 375 psi)
A/C Low Side 214 - 365 248 - 407 283 - 476 317 - 483 359 - 496 kPa
Pressure kPa (31 - 53 kPa (36 - 59 kPa (41 - 69 kPa (46 - 70 (52 - 72 psi)
psi) psi) psi) psi)

6. If the air outlet temperature or the A/C system pressures are not within specifications, see the A/C
System Diagnosis table below.

A/C SYSTEM DIAGNOSIS

Condition Possible Causes Correction
Equal refrigerant pressures 1. No refrigerant in the 1. See REFRIGERANT SYSTEM
refrigerant system LEAKS. Test the refrigerant system for
leaks. Repair, evacuate and charge the
refrigerant system if required.
2. Inoperative A/C 2. See COMPRESSOR, A/C. Test the
compressor or clutch compressor and/or clutch and replace if
(depending on compressor required.
application)
3. Improperly installed or 3. See TRANSDUCER, A/C Pressure. Test
inoperative A/C pressure the transducer and replace if required.
transducer
4. Inoperative A/C-heater 4. See appropriate DTC Based Diagnostics
control, PCM/ECM service information. Test the A/C-heater
(depending on engine control, PCM/ECM (depending on engine
application), Gateway application), Gateway Module and TIPM and
Module or TIPM replace if required.
Normal refrigerant 1. Excessive refrigerant oil 1. See REFRIGERANT OIL LEVEL.
pressures, but A/C in system Recover the refrigerant from the refrigerant
Performance Test air system and inspect the refrigerant oil
temperatures at center content. Restore the refrigerant oil to the
panel outlet are too high proper level if required.
2. Blend door actuator 2. See ACTUATOR, Blend Door. Inspect
improperly installed or the actuator for proper operation. Replace the
inoperative actuator as required.
3. Blend door inoperative or 3. See HOUSING, HVAC. Inspect the blend
sealing improperly door for proper operation and sealing. Repair
if required.
The low side pressure is 1. Low refrigerant system 1. See REFRIGERANT SYSTEM
normal or slightly low, and charge LEAKS. Test the refrigerant system for
the high side pressure is leaks. Repair, evacuate and charge the
too low refrigerant system if required.
2. Refrigerant flow through 2. See EVAPORATOR, A/C. Replace the
A/C evaporator is restricted restricted A/C evaporator if required.

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3. Refrigerant flow through 3. See Plumbing. Inspect the refrigerant

refrigerant lines is restricted lines for kinks, tight bends or improper
routing. Correct the routing or replace the
refrigerant line if required.
4. Inoperative A/C 4. See COMPRESSOR, A/C. Replace the
compressor compressor if required.
The low side pressure is 1. Inoperative radiator 1. See appropriate Cooling system
normal or slightly high, cooling fan information. Test the radiator cooling fan
and the high side pressure and replace if required.
is too high 2. A/C condenser air flow 2. See CONDENSER, A/C. Check the A/C
restricted condenser for damaged fins, foreign objects
obstructing air flow through the condenser
fins and missing or improperly installed air
seals. Clean, repair or replace components as
required.
3. Refrigerant flow through 3. See DRIER, A/C Receiver. Replace the
the A/C receiver/drier is restricted receiver/drier if required.
restricted
4. Refrigerant flow through 4. See Plumbing. Inspect the refrigerant
refrigerant lines is restricted lines for kinks, tight bends or improper
routing. Correct the routing or replace the
refrigerant line if required.
5. Refrigerant system 5. See REFRIGERANT SYSTEM
overcharged CHARGE. Recover the refrigerant from the
refrigerant system. Charge the refrigerant
system to the proper level if required.
6. Air in the refrigerant 6. See REFRIGERANT SYSTEM
system LEAKS. Test the refrigerant system for
leaks. Repair, evacuate and charge the
refrigerant system if required.
7. Engine overheating 7. See appropriate Cooling system service
information. Test the engine cooling system
and repair if required.
The low side pressure is 1. Accessory drive belt 1. See appropriate Cooling system service
too high, and the high side slipping information. Inspect the accessory drive belt
pressure is too low condition and tension. Replace the accessory
drive belt or tensioner if required.
2. Inoperative A/C 2. See VALVE, A/C Expansion. Test the
expansion valve expansion valve and replace if required.
3. Inoperative A/C 3. See COMPRESSOR, A/C. Replace the
compressor compressor if required.
The low side pressure is 1. Restricted refrigerant 1. See Plumbing. Inspect the refrigerant
too low, and the high side flow through the refrigerant lines for kinks, tight bends or improper
pressure is too high lines routing. Correct the routing or replace the
refrigerant line if required.
2. Restricted refrigerant 2. See VALVE, A/C Expansion. Test the
flow through the A/C expansion valve and replace if required.
expansion valve
3. Restricted refrigerant 3. See CONDENSER, A/C. Replace the

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flow through the A/C restricted condenser if required.

condenser

HEATER PERFORMANCE

Before performing the following tests, see appropriate Cooling system service information for the
procedures to check the engine coolant level and flow, engine coolant reserve/recovery system operation,
accessory drive belt condition and tension, radiator air flow and the fan drive operation.

WARNING: Do not remove radiator cap when engine is hot. Failure to follow this
instruction may result in serious injury.

If vehicle has been run recently, wait 15 minutes before removing the radiator cap. Place a rag over the cap
and turn it to the first safety stop. Allow pressure to escape through the overflow tube. When the system
pressure stabilizes, remove the cap completely.

MAXIMUM HEATER OUTPUT

Engine coolant is delivered to and from the heater core through two heater hoses. With the engine idling at
normal operating temperature, set the temperature control to the full hot position, the mode control to the
floor position, and the blower motor control to the highest speed position. Using a test thermometer, check
the temperature of the air being discharged at the front floor outlets. Compare the test thermometer reading
to the Heater Temperature Reference chart.

HEATER TEMPERATURE REFERENCE

Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahrenheit Celsius Fahrenheit
16° 60° 54° 130°
21° 70° 56° 132°
27° 80° 57° 134°
32° 90° 58° 136°

See appropriate Cooling system service information if the heater outlet air temperature is below the
minimum specification. Both of the heater hoses should be hot to the touch. The coolant return heater hose
should be slightly cooler than the coolant supply heater hose. If the return hose is much cooler than the
supply hose, locate and repair the engine coolant flow obstruction in the cooling system.

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow are as follows:

Low coolant level

Inoperative water pump
Inoperative thermostat
Pinched or kinked heater hoses
Improper heater hose routing
Plugged heater hoses or supply and return ports at the cooling system connections
Plugged heater core

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

MECHANICAL PROBLEMS

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

Obstructed cowl air intake

Obstructed heater system outlets
Inoperative engine thermostat
Inoperative blower motor system
Inoperative A/C-heater control
Inoperative blend door actuator
Inoperative, obstructed or improperly installed blend-air door

TEMPERATURE CONTROL

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

Inoperative A/C-heater control

Inoperative blend door actuator
Inoperative, obstructed or improperly installed blend-air door
Improper engine coolant temperature

SPECIFICATIONS
A/C SYSTEM

Item Description Notes

A/C Compressor Denso 10SRE18 fixed ND-8 PAG oil
displacement - All 2.2L
Diesel engine models

Denso 6SEU16 variable

displacement - All Gasoline
engine models
Freeze-up Control Evaporator temperature Input to A/C-heater control, HVAC
sensor housing mounted - sets compressor to
destroke/disengage 2° C (36° F) below
evaporator target temperature (minimum
5° C (41° F)) and activates/engages
compressor when within 1° C (34° F) of
evaporator target temperature
Low psi Control Input to PCM/ECM, discharge line
mounted - sets compressor to
A/C pressure transducer destroke/disengage below 200 kPa (29
psi), activates/engages compressor

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above 234 -262 kPa (34 - 38 psi)

A/C pressure transducer Input to PCM/ECM, discharge line
mounted - sets compressor to
High psi Control
destroke/disengage above 3130 kPa
(454 psi) and below 200 kPa (29 psi)
R-134a Refrigerant Charge Also see A/C Underhood Specification
0.51 kg (1.125 lbs.)
Capacity Label located in the engine compartment
A/C Clutch Coil Draw (2.2L
3.2 - 3.3 amps @ 12V ± 0.5V @ 21° C (70° F)
Diesel engine models)
A/C Clutch Coil Resistance When measured across coil lead
3.6 ± 0.2 ohms
(2.2L Diesel engine models) connector
A/C Clutch Air Gap (2.2L 0.35 - 0.60 mm (0.014 -
-
Diesel engine models) 0.024 in.)

FASTENER TORQUE

Description N.m Ft. Lbs. In. Lbs.

All Screws NOT Listed 2 - 17
Below
A/C Compressor to
25 18 -
Engine Bolts
A/C Receiver/Drier to
15 11 -
Frame Rail Bolts
A/C Expansion Valve to
11 - 97
Evaporator Bolts
A/C Liquid Lines to A/C
5 - 44
Receiver/Drier Nut/Bolt
A/C Suction Line
5 - 44
Junction Block Nut
Air Distribution Housing
1.2 - 10
Halves Screws
Air Distribution Housing
to HVAC Housing 1.2 - 10
Screws
Air Inlet Housing to
1.2 - 10
HVAC Housing Screws
Blend Door Lever Screw 0.6 - 5
Blower Motor Screws 1.2 - 10
Center Duct Screws 2.2 - 20
Defroster Duct Support
3 - 27
Screws
Defroster Duct Screws 2.2 - 20
Demister Duct Screws 2.2 - 20
Flange to HVAC
1.2 - 10
Housing Screw
Heat Shield to Dash
1 - 10
Panel Nuts

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HVAC Housing Halves

1.2 - 10
Screws
HVAC Housing to Dash
4.5 - 40
Panel Nut
Lower Condenser
Bracket to Radiator 4.5 - 40
Bolts
Mode Door Cam Screw 0.6 - 5
PTC Heater Unit to
1.2 - 10
Housing Screws
Rear Seat Floor Duct
2.2 - 20
Screw
Refrigerant Lines to A/C
25 18 -
Expansion Valve Bolt
Refrigerant Lines to A/C
20 15 -
Compressor Nuts
Refrigerant Lines to A/C
5 - 44
Condenser Nuts
Refrigerant Line Bracket
4.5 - 40
to Strut Tower Nut

SPECIAL TOOLS
SPECIAL TOOLS

Fig. 3: Trim Stick C-4755

Courtesy of CHRYSLER LLC

Fig. 4: Back Probe Tool 6801

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Courtesy of CHRYSLER LLC

Fig. 5: Pliers, A/C Snap Ring 9764

Courtesy of CHRYSLER LLC

CONTROLS
ACTUATOR, BLEND DOOR

Description

DESCRIPTION

Fig. 6: Mode Door Actuator

Courtesy of CHRYSLER LLC

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The blend door actuator (1) for the heating-A/C system is a reversible, 12-volt Direct Current (DC) servo
motor, which is mechanically connected to the blend-air door. The blend door actuator is located on the left
side of the HVAC air distribution housing.

The blend door actuator is contained within a black molded plastic housing with an integral wire connector
receptacle (2). An output shaft (3) with splines connect it to the blend door linkage and integral mounting
tabs (4) allow the actuator to be secured to the HVAC housing. The blend door actuator does not require
mechanical indexing to the blend-air door, as it is electronically calibrated by the A/C-heater control.

The A/C-heater control must be recalibrated each time an actuator motor is replaced. Refer to DTC-Based
Diagnostics/HVAC - Standard Procedure .

The blend door actuator is interchangeable with the actuator for the mode-air doors and the recirculation-air
door.

Operation

OPERATION

The blend door actuator is connected to the A/C-heater control through the vehicle electrical system by a
dedicated two-wire lead and connector of the instrument panel wire harness. The blend door actuator can
move the blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the
motor connection high and the other connection low, the blend-air door will move in one direction. When
the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the
opposite direction. Once the A/C-heater control makes the voltage to both connections high or both
connections low, the blend-air door stops and will not move.

The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position
of the blend door actuator and the blend-air door. The A/C-heater control learns the blend-air door stop
positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it
detects in the blend door actuator circuits. Refer to DTC-Based Diagnostics/HVAC - Diagnosis and
Testing .

The blend door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

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Fig. 7: Blend Door Actuator Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.

2. On RHD models, remove the two push-pins and silencer panel from the passenger side of the
instrument panel.
3. On RHD models, remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Removal .
4. Disconnect the wire harness connector (1) from the blend door actuator (2) located on the left side of
the HVAC air distribution housing (3).
5. Remove the two screws (4) that secure the blend door actuator to the air distribution housing and
remove the actuator.

Installation

INSTALLATION

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Fig. 8: Blend Door Actuator Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Position the blend door actuator (2) onto the left side of the HVAC air distribution housing (3). If
necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the
blend air door linkage.
2. Install the two screws (4) that secure the blend door actuator to the air distribution housing. Tighten
the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector (1) to the blend door actuator.
4. On RHD models, install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Installation .
5. On RHD models, install the silencer panel and two push-pins.
6. Reconnect the negative battery cable.
7. Initiate the Actuator Calibration function using a scan tool. Refer to DTC-Based Diagnostics/HVAC
- Standard Procedure .

ACTUATOR, MODE DOOR

Description

DESCRIPTION

Fig. 9: Mode Door Actuator

Courtesy of CHRYSLER LLC

The mode door actuator (1) for the heating-A/C system is a reversible, 12-volt Direct Current (DC) servo
motor, which is mechanically connected to the mode-air doors. The mode door actuator is located on the
right side of the HVAC air distribution housing.

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The mode door actuator is contained within a black molded plastic housing with an integral wire connector
receptacle (2). An output shaft with splines (3) connect it to mode door linkage and integral mounting tabs
(4) allow the actuator to be secured to the air distribution housing. The mode door actuator does not require
mechanical indexing to the mode-air doors, as it is electronically calibrated by the A/C-heater control.

The A/C-heater control must be recalibrated each time an actuator motor is replaced. Refer to DTC-Based
Diagnostics/HVAC - Standard Procedure .

The mode door actuator is interchangeable with the actuators for the recirculation and blend-air doors.

Operation

OPERATION

The mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a
dedicated two-wire lead and connector of the instrument panel wire harness. The mode door actuator can
move the mode-air door in two directions. When the A/C-heater control pulls the voltage on one side of the
motor connection high and the other connection low, the mode-air door will move in one direction. When
the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the
opposite direction. Once the A/C-heater control makes the voltage to both connections high or both
connections low, the mode-air door stops and will not move.

The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position
of the mode door actuator and the mode-air door. The A/C-heater control learns the mode-air door stop
positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it
detects in the mode door actuator circuits. Refer to DTC-Based Diagnostics/HVAC - Diagnosis and
Testing .

The mode door actuator cannot be adjusted or repaired and it must be replaced if inoperative or damaged.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

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Fig. 10: Identifying Mode Door Actuator, Wire Harness Connector, Bracket & Screws
Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.

2. On LHD models, remove the two push-pins and silencer panel from the passenger side of the
instrument panel.
3. On LHD models, remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Removal .
4. Remove the floor distribution duct from the right side of the HVAC air distribution housing. See
Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Removal.
5. Remove the three screws (1) that secure the mode door actuator (2) to the bracket (4) located on the
right side of the air distribution housing.
6. Disconnect the wire harness connector (3) from the mode door actuator and remove the actuator.

Installation

INSTALLATION

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Fig. 11: Identifying Mode Door Actuator, Wire Harness Connector, Bracket & Screws
Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Position the mode door actuator (2) onto the bracket (4) located on the right side of the HVAC air
distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator
output shaft with those in the mode air door linkage.
2. Install the three screws (1) that secure the mode door actuator to the air distribution housing. Tighten
the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector (3) to the mode door actuator.
4. Install the floor distribution duct onto the right side of the air distribution housing. See Heating and
Air Conditioning/Distribution/DUCT, Floor Distribution - Installation.
5. On LHD models, install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Installation .
6. On LHD models, install the silencer panel and two push-pins.
7. Reconnect the negative battery cable.
8. Initiate the Actuator Calibration function using a scan tool. Refer to DTC-Based Diagnostics/HVAC
- Standard Procedure .

ACTUATOR, RECIRCULATION DOOR

Description

DESCRIPTION

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Fig. 12: Recirculation Door Actuator Assembly

Courtesy of CHRYSLER LLC

The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is
connected directly to the pivot shaft lever of the recirculation-air door. The recirculation door actuator is
located on the right side of the HVAC air inlet housing.

The recirculation door actuator is contained within a black molded plastic housing with an integral wire
connector receptacle (2), an output shaft with splines (3) connect it to the recirculation door and three
integral mounting tabs (4) allow the actuator to be secured to the air inlet housing. The recirculation door
actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated
by the A/C-heater control.

The A/C-heater control must be recalibrated each time an actuator motor is replaced. Refer to DTC-Based
Diagnostics/HVAC - Standard Procedure .

The recirculation door actuator is interchangeable with the actuators for the blend and mode-air doors.

Operation

OPERATION

The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system
by a dedicated two-wire lead and connector of the instrument panel wire harness. The recirculation door
actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage
on one side of the motor connection high and the other connection low, the recirculation-air door will move
in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the
recirculation-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to
both connections high or both connections low, the recirculation-air door stops and will not move.

The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position
of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the

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recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code
(DTC) for any problems it detects in the recirculation door actuator circuits. Refer to DTC-Based
Diagnostics/HVAC - Diagnosis and Testing .

The recirculation door actuator cannot be adjusted or repaired and it must be replaced if inoperative or
damaged.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: Illustration shown with instrument panel removed for clarity.

NOTE: LHD model shown. RHD model similar.

Fig. 13: Identifying Recirculation Door Actuator & Air Inlet Housing
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the two push-pins and silencer panel from the passenger side of the instrument panel.
3. Remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel -
Removal .
4. Remove the two screws (1) that secure the recirculation door actuator (2) to the HVAC air inlet
housing (3).
5. Disconnect the wire harness connector (4) from the recirculation door actuator and remove the

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actuator.

Installation

INSTALLATION

NOTE: Illustrations shown with instrument panel removed for clarity.

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 14: Recirculation Door Actuator Alignment

Courtesy of CHRYSLER LLC

1. Install the recirculation door actuator (1) onto the HVAC air inlet housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator output shaft (3) with those on the recirculation
door pivot shaft adapter (4).

Fig. 15: Identifying Recirculation Door Actuator & Air Inlet Housing
Courtesy of CHRYSLER LLC

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2. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten
the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector (4) to the recirculation door actuator.
4. Install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel -
Installation .
5. Install the silencer panel and two push-pins.
6. Reconnect the negative battery cable.

CONTROL, A/C AND HEATER

Description

AUTOMATIC TEMPERATURE CONTROL (ATC) SYSTEM

Fig. 16: ATC A/C Heater Control

Courtesy of CHRYSLER LLC

The Automatic Temperature Control (ATC) single zone heating-A/C system uses electrically operated
controls. These controls provide the vehicle operator with a number of setting options to help control the
climate and comfort within the vehicle.

The A/C-heater control (1) for the ATC single zone system automatically maintains the interior comfort
level desired by the vehicle operator. The ATC system uses an infrared sensor located in the front overhead
console to measure the surface temperature of the driver and front seat passengers. Based on the sensor
input, the ATC system automatically adjusts air temperature, airflow volume, airflow distribution and
amount of inside air recirculation to maintain occupant comfort, even under changing outside weather
conditions. All controls are identified by International Standardization Organization (ISO) graphic symbols.

This ATC system offers several manual override features such as fan speed and airflow distribution. When
the outside air contains smoke, odors, high humidity, or if rapid cooling is desired, the interior conditioned
air can be recirculated within the vehicle.

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

a rotary control for manual and automatic blower motor speed selection and for turning the heating-

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A/C system on and off (2). This control also contains a push button function for recirculating the
conditioned air. The control contains an indicator lamp that illuminates when the heating-A/C system
is in recirculation mode.
a rotary control for temperature control of the discharged air (3). This control also contains a push
button function for manually turning the A/C system on and off. The control contains an indicator
lamp that illuminates when the A/C system is in operation.
a rotary control for manual and automatic mode control of the discharged air (4). This control also
contains a push button function for turning the rear window defogger system on and off. The control
contains an indicator lamp that illuminates when the rear window defogger system is in operation.

The ATC A/C-heater control obtains vehicle speed, engine speed, engine coolant temperature, ambient
temperature and refrigerant system head pressure data and is diagnosed using a scan tool. Refer to DTC-
Based Diagnostics/HVAC - Diagnosis and Testing .

Prior to replacing the A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the
heating-A/C system and run the Actuator Calibration function using a scan tool to verify that the concern is
not an air door calibration issue. Refer to DTC-Based Diagnostics/HVAC - Standard Procedure .

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

MANUAL TEMPERATURE CONTROL (MTC) SYSTEM

Fig. 17: A/C Heater Control

Courtesy of CHRYSLER LLC

The Manual Temperature Control (MTC) single zone heating-A/C system uses electrically operated
controls. These controls provide the vehicle operator with a number of setting options to help control the
climate and comfort within the vehicle.

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

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

a rotary control for fan speed selection and for turning the heating-A/C system on and off (2). This

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control also contains a push button function for recirculating the conditioned air. The control contains
an indicator lamp that illuminates when the heating-A/C system is in recirculation mode.
a rotary control for temperature control of the discharged air (3). This control also contains a push
button function for turning the A/C system on and off. The control contains an indicator lamp that
illuminates when the A/C system is in operation.
a rotary control for mode control of the discharged air (4). This control also contains a push button
function for turning the rear window defogger system on and off. The control contains an indicator
lamp that illuminates when the rear window defogger system is in operation.

The MTC A/C-heater control is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC -
Diagnosis and Testing .

Prior to replacing the A/C-heater control, check for any Diagnostic Trouble Codes (DTCs) related to the
heating-A/C system and run the Actuator Calibration function using a scan tool to verify that the concern is
not an air door calibration issue. Refer to DTC-Based Diagnostics/HVAC - Standard Procedure .

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

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: Take the proper precautions to protect the front face of the center bezel from
cosmetic damage while performing this procedure.

Fig. 18: A/C-Heater Control & Center Bezel With Four Screws

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Courtesy of CHRYSLER LLC

NOTE: MTC A/C-heater control shown. ATC A/C-heater contol similar.

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel center bezel (3) and place it on a workbench. Refer to Body/Instrument
Panel/BEZEL, Instrument Panel - Removal .
3. Remove the four screws (1 and 4) that secure the A/C-heater control (2) to the back of the center bezel
and remove the control.

Installation

INSTALLATION

NOTE: Take the proper precautions to protect the front face of the center bezel from
cosmetic damage while performing this procedure.

Fig. 19: A/C-Heater Control & Center Bezel With Four Screws
Courtesy of CHRYSLER LLC

NOTE: MTC A/C-heater control shown. ATC A/C-heater contol similar.

1. Position the A/C-heater control (2) onto the back of the center bezel (3).
2. Install the four screws (1 and 4) that secure the A/C-heater control to the bezel. Tighten the screws to
2 N.m (17 in. lbs.).
3. Install the center bezel. Refer to Body/Instrument Panel/BEZEL, Instrument Panel - Installation .
4. Reconnect the negative battery cable.

NOTE: When installing a new A/C-heater control, or reinstalling the original

control, the A/C-heater control will automatically run the Actuator
Calibration function when the ignition switch is initially turned to ON.
However, the Actuator Calibration function must be manually initiated
using a scan tool if the A/C-heater control was previously installed in

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another vehicle.

5. If required, initiate the Actuator Calibration function using a scan tool. Refer to DTC-Based
Diagnostics/HVAC - Standard Procedure .

MODULE, POWER, BLOWER MOTOR

Description

DESCRIPTION

Fig. 20: Blower Motor Power Module

Courtesy of CHRYSLER LLC

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

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

Operation

OPERATION

The blower motor power module is connected to the vehicle electrical system through a dedicated lead and
connector of the instrument panel wire harness. A second lead and connector of the instrument panel wire
harness is connected to the blower motor. The blower motor power module allows the microprocessor-based
automatic temperature control (ATC) A/C-heater control to calculate and provide infinitely variable blower
motor speeds based upon either manual blower switch input or the ATC programming using a pulse width
modulated (PWM) circuit strategy.

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The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower
motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear
output voltage to change or maintain the desired blower speed.

The blower motor power module is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC -
Diagnosis and Testing .

The blower motor power module cannot be adjusted or repaired must be replaced if inoperative or damaged.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

WARNING: The heat sink for the blower motor power module may get very hot
during normal operation. If the blower motor was turned on prior to
servicing the blower motor power module, wait five minutes to allow
the heat sink to cool before performing diagnosis or service. Failure to
follow these instructions may result in possible serious injury.

Fig. 21: Blower Motor Power Module

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.

2. If equipped, remove the two push-pins and silencer panel from the passenger side of the instrument

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panel.
3. Disconnect the wire harness connector (1) from the blower motor power module (2).
4. Remove the two screws (4) that secure the blower motor power module to the HVAC housing (3) and
remove the power module.

Installation

INSTALLATION

Fig. 22: Blower Motor Power Module

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Position the blower motor power module (2) into the bottom of the HVAC housing (3).
2. Install the two screws (4) that secure the blower motor power module to the HVAC housing. Tighten
the screws to 1.2 N.m (10 in. lbs.).
3. Connect the wire harness connector (1) to the blower motor power module.
4. If equipped, install the silencer panel and two push-pins.
5. Reconnect the negative battery cable.

RESISTOR, BLOWER MOTOR

Description

DESCRIPTION

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Fig. 23: BLOWER MOTOR RESISTOR

Courtesy of CHRYSLER LLC

A blower motor resistor is used on vehicles equipped with the manual temperature control (MTC) heating-
A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a
blower motor power module, instead of the blower motor resistor. See Heating and Air
Conditioning/Controls/MODULE, Power - Description.

The blower motor resistor is mounted to the bottom of the HVAC housing, on the passenger side of the
vehicle. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire
connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a two-piece
stamped steel base (4). The blower motor resistor is accessed for service from under the instrument panel.

Operation

OPERATION

The blower motor resistor is connected to the vehicle electrical system through a dedicated take out and
connector of the instrument panel wire harness. The blower motor resistor has three resistors, each of which
will reduce the current flow through the blower motor to change the blower motor speed.

The blower motor control for the heating-A/C system directs the ground path for the blower motor through
the correct resistor to obtain the selected speed. With the blower motor control in the lowest speed position,
the ground path for the blower motor is applied through all of the resistors. Each higher speed selected with
the blower motor control applies the blower motor ground path through fewer of the resistors, increasing the
blower motor speed. When the blower motor control is in the highest speed position, the blower motor
resistor is bypassed and the blower motor receives a direct path to ground.

The blower motor resistor cannot be adjusted or repaired and it must be replaced if found inoperative or
damaged.

Diagnosis and Testing

BLOWER MOTOR RESISTOR

WARNING: Disable the airbag system before attempting any steering wheel,

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steering column or instrument panel component diagnosis or service.

Disconnect and isolate the negative battery (ground) cable and wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: See appropriate Wiring Information for circuit descriptions and diagrams,
Wiring Information includes wiring diagrams, proper wire and connector
repair procedures, further details on wire harness routing and retention, as
well as pin-out and location views for the various wire harness connectors,
splices and grounds.

1. Disconnect and isolate the negative battery cable.

2. Disconnect the wire harness connector from the blower motor resistor. See Heating and Air
Conditioning/Controls/RESISTOR, Blower Motor - Removal.
3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each
case there should be continuity. If OK, repair the wire harness circuits between the blower motor
speed control and the blower motor resistor or blower motor as required. If not OK, replace the
inoperative blower motor resistor.

Removal

REMOVAL

WARNING: The blower motor resistor may get very hot during normal operation. If
the blower motor was turned on prior to servicing the blower motor
resistor, wait five minutes to allow the blower motor resistors to cool
before performing diagnosis or service. Failure to follow these
instructions may result in possible serious injury.

CAUTION: Do not operate the blower motor with the blower motor resistor
removed from the circuit. Failure to follow these instructions may result
in vehicle damage.

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Fig. 24: Blower Motor Resistor

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Disconnect and isolate the negative battery cable.

2. If equipped, remove the two push-pins and silencer panel from the passenger side of the instrument
panel.
3. Disconnect the wire harness connector (1) from the blower motor resistor (2).
4. Remove the two screws (4) that secure the blower motor resistor to the HVAC housing (3) and
remove the resistor.

Installation

INSTALLATION

Fig. 25: Blower Motor Resistor

Courtesy of CHRYSLER LLC

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NOTE: LHD model shown. RHD model similar.

1. Position the blower motor resistor (2) onto the bottom of the HVAC housing (3).
2. Install the two screws (4) that secure the blower motor resistor to the HVAC housing. Tighten the
screws to 1.2 N.m (10 in. lbs.).
3. Connect the wire harness connector (1) to the blower motor resistor.
4. If equipped, install the silencer panel and two push-pins.
5. Reconnect the negative battery cable.

SENSOR, AMBIENT TEMPERATURE

Description

DESCRIPTION

Fig. 26: Ambient Temperature Sensor

Courtesy of CHRYSLER LLC

The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the
vehicle. The ATC system uses the sensor data to maintain optimum passenger compartment temperature
levels. The ambient air temperature sensor is mounted to the front bumper beam.

Operation

OPERATION

The ambient air temperature sensor is a variable resistor that operates on a five volt reference signal sent by
the Totally Integrated Power Module (TIPM). The ambient air temperature sensor is connected to the TIPM
through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor
changes its internal resistance in response to changes in the outside air temperature, which either increases
or decreases the reference signal voltage read by the TIPM. The TIPM converts and broadcasts the sensor
data over the Controller Area Network (CAN) bus, where it is read by the Automatic Temperature Control
(ATC) A/C-heater control, Powertrain Control Module (PCM), Cabin Compartment Node (CCN) and other
vehicle control modules.

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The ambient air temperature sensor is diagnosed using a scan tool. Refer to DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Diagnosis and Testing .

The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or
damaged. Refer to Electrical/Message Center/SENSOR, Ambient Temperature - Removal .

SENSOR, EVAPORATOR TEMPERATURE

Description

DESCRIPTION

Fig. 27: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C
evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a
molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of
the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral
retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4)
with two terminals.

Operation

OPERATION

The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an
input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input
signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The
evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors
and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal
circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator
temperature sensor decreases.

The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The
A/C-heater control is programmed to respond to this input by requesting the powertrain control module

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(PCM) or the engine control module (ECM) (depending on engine application) to adjust the compressor
swash plate angle as necessary to optimize A/C system performance and to protect the A/C system from
evaporator freezing. See Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Operation.

The evaporator temperature sensor is diagnosed using a scan tool. Refer to DTC-Based
Diagnostics/NODE, Cabin Compartment (CCN) - Diagnosis and Testing .

The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if inoperative or
damaged.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

Fig. 28: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with air distribution housing removed for clarity.

NOTE: It is not necessary to remove and disassemble the HVAC housing to service
the evaporator temperature sensor. The evaporator temperature sensor can
be removed for service from underneath the instrument panel.

1. Disconnect and isolate the negative battery cable.

2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the
evaporator temperature sensor (1) from the instrument panel wire harness.

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3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature
sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC
housing.
4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the
heater core tubes and remove the sensor from the vehicle.

Installation

INSTALLATION

Fig. 29: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with air distribution housing removed for clarity.

1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater
core tubes located on the driver side of the HVAC housing (2).
2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the
retaining tabs (3) are fully engaged to the housing.
3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire
harness.
4. Reconnect the negative battery cable.

SENSOR, INFRARED TEMPERATURE

Description

DESCRIPTION

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Fig. 30: Infrared Sensor

Courtesy of CHRYSLER LLC

NOTE: Typical infrared temperature sensor shown.

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

The infrared sensor is used only on models equipped with the Automatic Temperature Control (ATC)
heating-A/C system.

Operation

OPERATION

The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and
surroundings and converts its data into a linear Pulse Width Modulated (PWM) output signal which is read
by the Automatic Temperature Control (ATC) A/C-heater control. The ATC A/C-heater control uses the
infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature
levels. By using thermal radiation (surface temperature) measurement, rather than an air temperature
measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the
occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels,
such as solar heat gain or evaporative heat loss.

The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow
temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature
of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store
Diagnostic Trouble Codes (DTCs) for any problem it detects.

The infrared sensor is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC - Diagnosis
and Testing .

The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Removal

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REMOVAL

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

Fig. 31: Infrared Sensor, Overhead Console & Retaining Tabs

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the overhead console (4) from the headliner and place it on a workbench.
3. Remove the screw (1) that secures the infrared sensor (3) to the back of the overhead console.
4. Disengage the infrared sensor from the retaining tabs (2) on the overhead console and remove the
sensor.

Installation

INSTALLATION

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

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Fig. 32: Infrared Sensor, Overhead Console & Retaining Tabs

Courtesy of CHRYSLER LLC

1. Position the infrared sensor (3) onto the back of the overhead console (4). Align the slot on the sensor
with the retaining tabs (2) on the console.
2. Install the screw (1) that secures the infrared sensor to the overhead console. Tighten the screw to 1.2
N.m (10 in. lbs).
3. Install the overhead console. Make sure the retaining tabs are fully engaged to the headliner.
4. Reconnect the negative battery cable.

TRANSDUCER, A/C PRESSURE

Description

DESCRIPTION

Fig. 33: A/C Pressure Transducer

Courtesy of CHRYSLER LLC

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

Operation

OPERATION

The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its
connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer
changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a
five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the
output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a
message to the Powertrain Control Module (PCM) or Engine Control Module (ECM) (depending on engine
application) over the Controller Area Network (CAN) C BUS. The PCM/ECM is programmed to respond to
this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and
the radiator cooling fan to help optimize A/C system performance and to protect the system components
from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor
displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a
greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi).
The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200
kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa
(34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi) the PCM will actuate the cooling
fan.

A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed
or installed without disturbing the refrigerant in the A/C system.

The A/C pressure transducer is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/MODULE,
Powertrain Control (PCM) - Diagnosis and Testing .

The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Removal

REMOVAL

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

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Fig. 34: Transducer-A/C Pressure Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: Typical A/C pressure transducer shown.

1. Disconnect and isolate the negative battery cable.

2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2). Refer to
Frame and Bumpers/Bumpers/FASCIA, Front - Removal .
3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the
wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3).
4. Remove the A/C pressure transducer from the A/C discharge line and remove and discard the O-ring
seal (4).

Installation

INSTALLATION

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

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Fig. 35: Transducer-A/C Pressure Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: Typical A/C pressure transducer shown.

1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C discharge
line (3).
2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure
transducer securely.
3. Connect the wire harness connector (1) to the A/C pressure transducer.
4. Reinstall the top of the front fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front -
Installation .
5. Reconnect the negative battery cable.

DISTRIBUTION
DUCT, DEFROSTER

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: LHD model shown in illustrations. RHD model similar.

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Fig. 36: Identifying Demister Hoses, Defroster Duct & Demister Ducts
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Removal .
3. Remove the instrument base panel. Refer to Body/Instrument Panel/PANEL, Instrument -
Removal .
4. Disconnect the demister hoses (1 and 3) from the demister ducts (4 and 5).
5. Remove the defroster duct (2) and demister hoses as an assembly from the instrument panel.

Fig. 37: Identifying Demister Hoses & Defroster Duct

Courtesy of CHRYSLER LLC

6. If required, remove the demister hoses (1 and 2) from the defroster duct (3).

Installation

INSTALLATION

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NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 38: Identifying Demister Hoses & Defroster Duct

Courtesy of CHRYSLER LLC

1. If required, install the demister hoses (1 and 2) onto the defroster duct (3).

Fig. 39: Identifying Demister Hoses, Defroster Duct & Demister Ducts
Courtesy of CHRYSLER LLC

2. Position the defroster duct (2) and demister hoses (1 and 3) as an assembly to the instrument panel.
3. Connect the demister hoses to the demister ducts (4 and 5).

NOTE: To prevent air leaks and excessive noise during A/C-heater operation,
make sure the defroster duct is properly positioned to the defroster
outlet foam seal, located on top of the HVAC housing.

4. Install the instrument base panel. Refer to Body/Instrument Panel/PANEL, Instrument -

Installation .

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5. Install the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Installation .
6. Reconnect the negative battery cable.

DUCT, FLOOR DISTRIBUTION

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable. Wait two
minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in possible serious or fatal injury.

NOTE: LHD model shown in illustrations. RHD model similar.

RIGHT FRONT FLOOR DUCT

Fig. 40: Right Floor Duct And HVAC Housing

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with instrument panel removed for clarity.

1. On LHD models, remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Removal .
2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct.

LEFT FRONT FLOOR DUCT

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Fig. 41: Duct-Left Front Floor

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with instrument panel removed for clarity.

1. On RHD models, remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Removal .
2. On LHD models, disconnect the shift interlock cable (3) from the left floor duct (1) and position the
cable out of the way.
3. Remove the screw (4) that secures the left floor duct to the left side of the HVAC housing (2).
4. Disconnect the left floor duct from the HVAC housing and remove the duct.

REAR FLOOR DISTRIBUTION DUCTS

Fig. 42: Rear Floor Distribution Ducts

Courtesy of CHRYSLER LLC

1. Remove the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .

2. Remove the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS).

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3. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as
required from the HVAC housing (3) and remove the duct(s).

REAR SEAT FLOOR DUCTS

Fig. 43: Rear Seat Floor Ducts

Courtesy of CHRYSLER LLC

NOTE: Right side rear floor duct shown. Left side duct similar.

1. Remove the center floor console. Refer to Body/Interior/HOUSING, Shifter - Removal .

2. Remove the front seat from the side of the vehicle being serviced. Refer to Body/Seats/SEAT -
Removal .
3. Pull the carpet back to gain access to the rear seat floor duct (2). Refer to Body/Interior/CARPET -
Removal .
4. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor
support (4).
5. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat
duct(s).

Installation

INSTALLATION

NOTE: LHD model shown in illustrations. RHD model similar.

RIGHT FRONT FLOOR DUCT

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Fig. 44: Right Floor Duct And HVAC Housing

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with instrument panel removed for clarity.

1. Connect the right floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully
engaged to the housing.
2. On LHD models, install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Installation .

LEFT FRONT FLOOR DUCT

Fig. 45: Duct-Left Front Floor

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with instrument panel removed for clarity.

1. Connect the left floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully
engaged to the housing.

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2. Install the screw (4) that secures the left floor duct to the HVAC housing. Tighten the screw to 2 N.m
(17 in. lbs.).
3. On LHD models, connect the shift interlock cable (3) to the left floor duct.
4. On RHD models, install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX,
Instrument Panel - Installation .

REAR FLOOR DISTRIBUTION DUCTS

Fig. 46: Rear Floor Distribution Ducts

Courtesy of CHRYSLER LLC

1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required
to the HVAC housing (3). Make sure the ducts are fully engaged to the housing.
2. Install the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS).
3. Install the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Installation .

REAR SEAT FLOOR DUCTS

Fig. 47: Rear Seat Floor Ducts

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Courtesy of CHRYSLER LLC

NOTE: Right side rear floor duct shown. Left side duct similar.

1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully
engaged to each other.
2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining
screw (1). Tighten the screw to 2.2 N.m (20 in. lbs.).
3. Reinstall the carpet. Refer to Body/Interior/CARPET - Installation .
4. Install the front seat to the side of the vehicle being serviced. Refer to Body/Seats/SEAT -
Installation .
5. Install the center floor console. Refer to Body/Interior/HOUSING, Shifter - Installation .

DUCT, INSTRUMENT PANEL

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: LHD model shown in illustrations. RHD model similar.

DRIVER SIDE DUCT ASSEMBLY

NOTE: The driver side instrument panel duct is serviced only as an assembly with
the driver side demister duct.

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Fig. 48: Identifying Screws, Driver Side Demister Hose & Drivers Side Duct Assembly
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Removal .
3. Remove the base panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .
4. Disconnect the driver side demister hose (2) from the driver side duct assembly (3).
5. Remove the two screws (1) that secure the driver side duct assembly to the instrument panel support.
6. Remove the driver side duct assembly from the instrument panel.

CENTER AND PASSENGER SIDE DUCT

Fig. 49: Identifying Screws & Passenger Side Instrument Panel Duct
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the driver side duct assembly (refer to DRIVER SIDE DUCT ASSEMBLY).

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3. Remove the two screws (1) that secure the center and passenger side instrument panel duct (2) to the
instrument panel support.
4. Remove the center and passenger side instrument panel duct from the instrument panel.

Installation

INSTALLATION

NOTE: LHD model shown in illustrations. RHD model similar.

DRIVER SIDE DUCT ASSEMBLY

NOTE: The driver side instrument panel duct is serviced only as an assembly with
the driver side demister duct.

Fig. 50: Identifying Screws, Driver Side Demister Hose & Drivers Side Duct Assembly
Courtesy of CHRYSLER LLC

1. Position the driver side duct assembly (3) to the instrument panel.
2. Install the two screws (1) that secure the driver side duct assembly to the instrument panel support.
Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Connect the driver side demister hose (2) to the driver side duct assembly.
4. Install the instrument base panel. Refer to Body/Instrument Panel/PANEL, Instrument -
Installation .
5. Install the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Installation .
6. Reconnect the negative battery cable.

CENTER AND PASSENGER SIDE DUCT

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Fig. 51: Identifying Screws & Passenger Side Instrument Panel Duct
Courtesy of CHRYSLER LLC

1. Position the center and passenger side instrument panel duct to the instrument panel.
2. Install the two screws (1) that secure the center and passenger side instrument panel duct (2) to the
instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Install the driver side duct assembly (refer to DRIVER SIDE DUCT ASSEMBLY).
4. Reconnect the negative battery cable.

DUCT, INSTRUMENT PANEL DEMISTER

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: LHD model shown in illustrations. RHD model similar.

DRIVER SIDE DUCT ASSEMBLY

NOTE: The driver side demister duct is serviced only as an assembly with the driver
side instrument panel duct.

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Fig. 52: Identifying Screws, Driver Side Demister Hose & Drivers Side Duct Assembly
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Removal .
3. Remove the base panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .
4. Disconnect the driver side demister hose (2) from the driver side duct assembly (3).
5. Remove the two screws (1) that secure the driver side duct assembly to the instrument panel support.
6. Remove the driver side duct assembly from the instrument panel.

PASSENGER SIDE DUCT

Fig. 53: Identifying Passenger Side Demister Hose, Screws & Passenger Side Demister Duct
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Removal .

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3. Remove the base panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .

4. Disconnect the passenger side demister hose (1) from the passenger side demister duct (3).
5. Remove the two screws (2) that secure the passenger side demister duct to the instrument panel
support.
6. Remove the passenger side demister duct from the instrument panel.

Installation

INSTALLATION

NOTE: LHD model shown in illustrations. RHD model similar.

DRIVER SIDE DUCT ASSEMBLY

NOTE: The driver side demister duct is serviced only as an assembly with the driver
side instrument panel duct.

Fig. 54: Identifying Screws, Driver Side Demister Hose & Drivers Side Duct Assembly
Courtesy of CHRYSLER LLC

1. Position the driver side duct assembly (3) to the instrument panel.
2. Install the two screws (1) that secure the driver side duct assembly to the instrument panel support.
Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Connect the driver side demister hose (2) to the driver side duct assembly.
4. Install the instrument base panel. Refer to Body/Instrument Panel/PANEL, Instrument -
Installation .
5. Install the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Installation .
6. Reconnect the negative battery cable.

PASSENGER SIDE DUCT

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Fig. 55: Identifying Passenger Side Demister Hose, Screws & Passenger Side Demister Duct
Courtesy of CHRYSLER LLC

1. Position the passenger side demister duct (3) to the instrument panel.
2. Install the two screws (2) that secure the passenger side demister duct to the instrument panel support.
Tighten the screws to 2.2 N.m (20 in. lbs.).
3. Connect the passenger side demister hose (1) to the passenger side demister duct.
4. Install the instrument base panel. Refer to Body/Instrument Panel/PANEL, Instrument -
Installation .
5. Install the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Installation .
6. Reconnect the negative battery cable.

FILTER, PARTICULATE AIR

Description

DESCRIPTION

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 56: Particulate Air Filter

Courtesy of CHRYSLER LLC

Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the
HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin.

The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-
A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to
indicate the direction of air flow through the filter.

Removal

REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

WARNING: Always make sure the A/C-heater system is turned off and that the
ignition switch is in the OFF position prior to servicing the particulate
air filter. Never place fingers or other objects into the filter opening of
the HVAC housing. Failure to follow this warning may result in serious
injury.

NOTE: LHD model shown in illustrations. RHD model similar.

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Fig. 57: Particulate Filter Cover

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with instrument panel removed for clarity.

1. Remove the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel -
Removal .
2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side
of the HVAC housing (3) and remove the cover.

Fig. 58: Particulate Filter

Courtesy of CHRYSLER LLC

3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight
out of the housing.

Installation

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INSTALLATION

NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction
through the filter. Make sure to properly install the particulate air filter.
Failure to properly install the filter will result in the need to replace the filter
sooner than required by design.

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 59: Particulate Filter

Courtesy of CHRYSLER LLC

1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the
particulate air filter directly into the housing with the arrow on the filter pointing to the floor.

Fig. 60: Particulate Filter Cover

Courtesy of CHRYSLER LLC

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2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs
(1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged.
3. Install the glove box bin. Refer to Body/Instrument Panel/GLOVE BOX, Instrument Panel -
Installation .

HOUSING, HVAC

Description

DESCRIPTION

NOTE: LHD model shown RHD model similar.

Fig. 61: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

All models use a common HVAC housing assembly. The HVAC housing assembly is mounted within the
passenger compartment and consists of three separate housings:

HVAC housing - The HVAC housing (1) is mounted to the dash panel behind the instrument panel
and contains the A/C evaporator, when equipped with A/C. The HVAC housing consists of an upper
and a lower housing that are attached together and has mounting provisions for the air inlet housing,
air distribution housing, blower motor and blower motor resistor or power module (depending on
application).
Air distribution housing - The air distribution housing (2) is mounted to the rear of the HVAC
housing and contains the heater core, blend-air and mode-air doors and door linkage.
Air inlet housing - The air inlet housing (3) is mounted to the passenger side end of the HVAC
housing. When equipped with A/C, the air inlet housing contains the recirculation-air door and
recirculation door actuator.

The heating-A/C system is a blend-air type system. The blend-air door controls the amount of conditioned
air that is allowed to flow through, or around, the heater core.

The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to
cool and dehumidify the incoming air prior to blending it with the heated air. The discharge air temperature

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is controlled by an electric blend door actuator, which moves the blend-air door. This allows an almost
immediate control of the output air temperature of the system. The electric mode door actuator operates the
mode-air doors, which direct the flow of the conditioned air out the various air outlets, depending on the
mode selected. The blower motor controls the velocity of air flowing through the HVAC housing assembly
by spinning the blower wheel within the HVAC housing at the selected speed by use of a blower motor
resistor or power module (depending on application). When equipped with A/C, an electric recirculation
door actuator operates the recirculation-air door, which closes off the fresh air intake and recirculates the air
already inside the vehicle. The electric door actuators, blower motor resistor or power module (depending on
application) and the blower motor are connected to the vehicle electrical system by the instrument panel
wire harness.

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

Removal

HOUSING-AIR DISTRIBUTION

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

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

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

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Fig. 62: Air Distribution Housing-Removal/Installation

Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the floor distribution ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Removal.
3. Remove the heater core. See Heating and Air Conditioning/Plumbing/CORE, Heater - Removal.
4. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the
HVAC housing (4).
5. Remove the six screws (1) that secure the air distribution housing to the rear of the HVAC housing.
6. Carefully disengage the one plastic retaining clip that secures the right side of the air distribution
housing to the HVAC housing.
7. Remove the air distribution housing from the rear of the HVAC housing.
8. If required, disassemble the air distribution housing. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Disassembly.

HOUSING-AIR INLET

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

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NOTE: The air inlet housing must be removed from HVAC housing and
disassembled for service of the recirculation-air door.

NOTE: LHD model shown. RHD model similar.

Fig. 63: Air Inlet Housing-Removal/Installation

Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. If equipped, remove the particulate air filter. See Heating and Air
Conditioning/Distribution/FILTER, Particulate Air - Removal.
3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3).
4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and
remove the inlet housing from the HVAC housing.
5. If required, disassemble the air inlet housing. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Disassembly.

HOUSING-HVAC

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable. Wait two
minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in possible serious or fatal injury.

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

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

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 64: Heat Shield

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Partially drain the engine cooling system. Refer to Cooling - Standard Procedure .
4. Remove the nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the
engine compartment and remove the heat shield.

Fig. 65: Refrigerant Lines To Evaporator Bolt

Courtesy of CHRYSLER LLC

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5. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C expansion
valve (3).
6. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and
discard the O-ring seals.
7. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports.
8. Disconnect the heater hoses (4) from the heater core tubes.
9. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing
removal.

Fig. 66: HVAC Housing To Dash Panel Nut

Courtesy of CHRYSLER LLC

NOTE: Make sure to remove the five bolts that secure the HVAC housing to the
instrument panel support prior to removing the instrument panel from
the vehicle.

10. Remove the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .
11. Remove the rear floor ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Removal.
12. Remove the condensation drain tube. See Heating and Air Conditioning/Plumbing/TUBE,
Condensation Drain - Removal.
13. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3).

NOTE: Use care to ensure that the interior is covered in case of loss of
residual fluids from the heater and evaporator cores.

14. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger
compartment.

SCREEN-AIR INLET

NOTE: LHD model shown. RHD model similar.

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Fig. 67: HVAC Housing Air Inlet Screen

Courtesy of CHRYSLER LLC

1. Remove the cowl grille screen. Refer to Body/Exterior/COVER, Cowl Panel - Removal .
2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl
panel (3) and remove the screen.

Disassembly

HOUSING-AIR DISTRIBUTION

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

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

Fig. 68: HVAC Housing, Air Inlet Housing & Air Distribution Housing

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Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the air distribution housing (2) from the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
3. If equipped with the 2.2L diesel engine, remove the electric Positive Temperature Coefficient (PTC)
heater unit from the air distribution housing. See Heating and Air Conditioning/Cabin
Heater/UNIT, Heater - Removal.
4. Remove the heater core from the air distribution housing. See Heating and Air
Conditioning/Plumbing/CORE, Heater - Removal.

Fig. 69: Blend Door Actuator

Courtesy of CHRYSLER LLC

5. Remove the screws (1) that secure the blend door actuator (2) to the left side of the air distribution
housing (3) and remove the actuator.
6. If equipped with dual zone system, remove the screws that secure the other blend door actuator to the
right side of the air distribution housing and remove the actuator. See Heating and Air
Conditioning/Controls/ACTUATOR, Blend Door - Removal.

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Fig. 70: Blend Door Levers

Courtesy of CHRYSLER LLC

7. Remove the blend door lever (1) from the left side of the air distribution housing (2).

NOTE: To remove the blend door pivot lever, disengage the retaining tab on
the lever and pull the lever straight off the pivot shaft.

8. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4).

Fig. 71: Mode Door Actuator & Bracket

Courtesy of CHRYSLER LLC

NOTE: It is not necessary to remove the mode door actuator from the bracket
when servicing the air distribution housing.

9. Remove the three screws (1) that secure the mode door actuator (2) and bracket (3) to the right side of
the air distribution housing (4) and remove the actuator and bracket as an assembly.

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Fig. 72: Mode Door Cam

Courtesy of CHRYSLER LLC

10. Remove the mode door cam (1) from the right side of the air distribution housing (2).

Fig. 73: Parting Line And Retainers

Courtesy of CHRYSLER LLC

NOTE: If any foam seal on the air distribution housing outlets is deformed or
damaged, the seal must be replaced.

11. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution
housing (3). If either seal is deformed or damaged, it must be replaced.
12. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution
housing together.
13. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing
together and carefully separate the housing.

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Fig. 74: Air Doors-Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: If a seal on an air door is deformed or damaged, the air door must be
replaced.

14. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the
air distribution housing (5).

Fig. 75: Mode Door Levers-Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: To remove the mode door levers, disengage the retaining tabs on the
inside of the air distribution housing and pull the levers straight out of
the housing.

15. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing
(5).

HOUSING-AIR INLET

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NOTE: The air inlet housing must be removed from HVAC housing and
disassembled for service of the recirculation-air door.

NOTE: LHD model with A/C shown in illustrations. RHD models similar.

Fig. 76: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the air inlet housing (3) from the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.

Fig. 77: Identifying Recirculation Door Actuator & Air Inlet Housing
Courtesy of CHRYSLER LLC

3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air
inlet housing (3) and remove the actuator.

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Fig. 78: Recirculation Air Screen & Air Inlet Housing

Courtesy of CHRYSLER LLC

4. Carefully disengage the retaining tab (1) at each corner of the recirc air screen (2) and remove the
screen from the air inlet housing (3).

Fig. 79: Recirculation-Air Door, Air Inlet Housing & Recirculation Door Pivot Shaft Adapter
Courtesy of CHRYSLER LLC

5. To remove the recirculation door pivot shaft adapter (3) from the right end of the recirculation-air
door(1), first carefully push down on the tab of the door lever pivot shaft adapter located inside of the
air inlet housing (2), then pull the pivot shaft adapter straight out of the end of the recirculation-air
door pivot shaft.

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

NOTE: If a rubber seal on the recirculation air-door is deformed or damaged,

the air-door must be replaced.

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6. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the
air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be
replaced.

HOUSING-HVAC

NOTE: The HVAC housing must be removed from the vehicle and disassembled for
service of the A/C evaporator.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

Fig. 80: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the air distribution housing (2) from the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
3. Remove the air inlet housing (3) from the HVAC housing. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.

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Fig. 81: Blower Motor & Resistor

Courtesy of CHRYSLER LLC

4. Remove the three screws (1) that secure the blower motor (3) and the wire lead bracket (2), if
equipped, to the bottom of the HVAC housing (4) and remove the blower motor.
5. Remove the two screws (5) that secure the blower motor resistor or power module (6), depending on
application, to the bottom of the HVAC housing and remove the resistor or module.

Fig. 82: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator
temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.

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Fig. 83: HVAC Housing

Courtesy of CHRYSLER LLC

NOTE: If the foam seal or plastic flange is deformed or damaged, it must be

replaced.

7. Remove the two bolts that secure the A/C expansion valve (6) to the A/C evaporator and remove the
valve. See Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Removal.
8. Remove and discard the O-ring seals and install plugs in, or tape over the opened expansion valve and
evaporator tube ports.
9. Remove the foam seal and plastic flange (2) from the front of the two halves of the HVAC housing
(4). Carefully release the four retaining tabs located at the back of the flange and pull the flange off of
the evaporator tubes. If the seal or flange is deformed or damaged, it must be replaced.
10. Remove any residual sealer from the flange area at the front of the two halves of the HVAC housing.
11. Remove the six screws (3) and three metal clips (5) that secure the two halves of the HVAC housing
together.
12. Disengage the eight plastic retaining tabs (1) that secure the two halves of the HVAC housing together
and separate the housing.

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Fig. 84: Evaporator Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: If the foam insulator around the A/C evaporator is deformed or

damaged, the insulator must be replaced.

13. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC
housing (3).

Assembly

HOUSING-AIR DISTRIBUTION

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

Fig. 85: Mode Door Levers-Removal/Installation

Courtesy of CHRYSLER LLC

1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5)
Make sure the lever retaining tabs are fully engaged to the housing.

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Fig. 86: Air Doors-Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: Properly position the air doors within the air distribution housing by
first aligning the four mode door levers to the scribe lines located on
the right outer side of the air distribution housing. Then, install the air
doors onto the mode door levers with the UP mark on each air door
facing toward the top of the housing.

NOTE: If a seal on an air door is deformed or damaged, the air door must be
replaced.

2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution
housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on
each air door facing toward the top of the housing.

Fig. 87: Parting Line And Retainers

Courtesy of CHRYSLER LLC

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3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two
halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged.
4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution
housing together. Tighten the screws to 2.2 N.m (20 in lbs.). Make sure the metal clip is fully engaged
to the housing halves.

NOTE: If any foam seal on the air distribution housing outlets is deformed or
damaged, the seal must be replaced.

5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it
must be replaced.

Fig. 88: Mode Door Cam

Courtesy of CHRYSLER LLC

NOTE: Align the pins on the mode door levers with the grooves in the back of
the mode door cam prior to installation of the cam.

6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam
(1) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam.

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Fig. 89: Mode Door Actuator & Bracket

Courtesy of CHRYSLER LLC

7. Position the mode door actuator (2) and bracket (3) onto the right side of the HVAC air distribution
housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft
with those in the mode door cam.
8. Install the screws (1) that secure the mode door actuator bracket to the air distribution housing.
Tighten the screws to 2 N.m (17 in. lbs.).

Fig. 90: Blend Door Levers

Courtesy of CHRYSLER LLC

9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left
side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot
shaft.

NOTE: Align the pin on the blend door lever with the groove in the pivot lever
prior to installation of the blend door lever.

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10. Install the blend door lever (1) onto the air distribution housing. Make sure the levers are correctly
aligned to each other.

Fig. 91: Blend Door Actuator

Courtesy of CHRYSLER LLC

11. Position the blend door actuator (2) onto the left side of the air distribution housing (3). If necessary,
rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend door
lever.
12. Install the screws (1) that secure the blend door actuator to the air distribution housing. Tighten the
screws to 2 N.m (17 in. lbs.).
13. If equipped with dual zone system, position the blend door actuator onto the right side of the air
distribution housing and install the retaining screws. If necessary, rotate the actuator slightly to align
the splines on the actuator output shaft with those in the blend door. Tighten the screws to 2 N.m (17
in. lbs.).

Fig. 92: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

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14. If equipped with the 2.2L diesel engine, install the electric Positive Temperature Coefficient (PTC)
heater unit into the air distribution housing. See Heating and Air Conditioning/Cabin
Heater/UNIT, Heater - Installation.
15. Install the heater core into the air distribution housing (2). See Heating and Air
Conditioning/Plumbing/CORE, Heater - Installation.
16. Install the air distribution housing onto the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Installation.
17. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

HOUSING-AIR INLET

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

Fig. 93: Recirculation-Air Door, Air Inlet Housing & Recirculation Door Pivot Shaft Adapter
Courtesy of CHRYSLER LLC

1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of
the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet
housing.

NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it
straight into the end of the recirculation door pivot shaft.

2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation
air-door. Make sure the adapter is fully engaged to the pivot shaft.

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Fig. 94: Recirculation Air Screen & Air Inlet Housing

Courtesy of CHRYSLER LLC

3. Position the recirc air screen (2) to the air inlet housing (3) and engage the retaining tab (1) at each
corner of the screen. Make sure the retaining tabs are fully engaged to the housing.

Fig. 95: Recirculation Door Actuator Alignment

Courtesy of CHRYSLER LLC

4. Position the recirculation door actuator (1) to the right side of the HVAC air inlet housing (2).
5. Install the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output shaft (3) with those on the recirculation door pivot
shaft adapter (4).

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Fig. 96: Identifying Recirculation Door Actuator & Air Inlet Housing
Courtesy of CHRYSLER LLC

6. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten
the screws to 2 N.m (17 in. lbs.).

Fig. 97: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

7. Install the air inlet housing (3) onto the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Installation.
8. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

HOUSING-HVAC

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

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Fig. 98: Evaporator Removal/Installation

Courtesy of CHRYSLER LLC

NOTE: Make sure that the foam insulator is properly positioned around the A/C
evaporator and in the HVAC housing.

1. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC
housing (3).

Fig. 99: HVAC Housing

Courtesy of CHRYSLER LLC

2. Install the two halves of the HVAC housing (4) together and engage the eight plastic retaining tabs
(1). Make sure the retaining tabs are fully engaged.
3. Install the six screws (3) and three metal clips (5) that secure the two halves of the HVAC housing
together. Tighten the screws to 1.2 N.m (10 in lbs.). Make sure the metal clips are fully engaged to the
housing halves.
4. Install a bead of silicone sealer around the flange area at the front of the HVAC housing.

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NOTE: If the foam seal or plastic flange is deformed or damaged, it must be

replaced.

5. Install the plastic flange and foam seal (2) over the evaporator tubes and onto the front of the HVAC
housing. Make sure the four flange retaining tabs are fully engaged to the housing.
6. Remove the tape or plugs from the expansion valve and evaporator ports.
7. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings.
Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use
only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Install the A/C expansion valve (6) and the two retaining bolts. Tighten the bolts to 11 N.m (97 in.
lbs.). See Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Installation.

Fig. 100: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

9. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure
the retaining tabs (3) are fully engaged to the housing.

Fig. 101: Blower Motor & Resistor

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Courtesy of CHRYSLER LLC

10. Position the blower motor (3) into the bottom of the HVAC housing (4).
11. Install the wire lead bracket (2), if equipped, and the three screws (1) that secure the blower motor to
the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
12. Position the blower motor resistor or power module (6), depending on application, into the HVAC
housing.
13. Install the two screws (5) that secure the blower motor resistor or power module to the HVAC
housing. Tighten the screws to 1.2 N.m (10 in. lbs.).

Fig. 102: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

14. Install the air inlet housing (3) onto the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Installation.
15. Install the air distribution housing (2) onto the HVAC housing. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Installation.

NOTE: If the heater core is being replaced, flush the cooling system. Refer to
Cooling - Standard Procedure .

16. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

Installation

HOUSING-AIR DISTRIBUTION

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models
similar.

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Fig. 103: Air Distribution Housing-Removal/Installation

Courtesy of CHRYSLER LLC

1. Position the air distribution housing (2) onto the rear of the HVAC housing (4) and engage the one
plastic retaining clip.
2. Install the six screws (1) that secure the air distribution housing to the HVAC housing. Tighten the
screws to 1.2 N.m (10 in. lbs.).
3. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the
HVAC housing.
4. Install the heater core. See Heating and Air Conditioning/Plumbing/CORE, Heater - Installation.
5. Install the floor distribution ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Installation.

NOTE: If the heater core is being replaced, flush the cooling system. Refer to
Cooling - Standard Procedure .

6. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

HOUSING-AIR INLET

NOTE: LHD model shown. RHD model similar.

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Fig. 104: Air Inlet Housing-Removal/Installation

Courtesy of CHRYSLER LLC

1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic
retaining tabs (4). Make sure the retaining tabs are fully engaged.
2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws
to 1.2 N.m (10 in. lbs.).
3. If equipped, install the particulate air filter. See Heating and Air
Conditioning/Distribution/FILTER, Particulate Air - Installation.
4. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

HOUSING - HVAC

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 105: HVAC Housing To Dash Panel Nut

Courtesy of CHRYSLER LLC

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1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of
the HVAC housing is correctly located over the dash panel mounting stud.
2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel.
Tighten the nut to 4.5 N.m (40 in. lbs.).
3. Install the condensation drain tube. See Heating and Air Conditioning/Plumbing/TUBE,
Condensation Drain - Installation.
4. Install the rear floor ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Installation.
5. Install the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Installation .

Fig. 106: Refrigerant Lines To Evaporator Bolt

Courtesy of CHRYSLER LLC

6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core
tubes.
7. Remove the tape or plugs from the refrigerant line fittings and the expansion valve ports.
8. Lubricate new rubber O-rings seals with clean refrigerant oil and them onto the liquid and suction line
fittings. Use only the specified O-ring seals as they are made of special materials compatible to the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
9. Connect the A/C liquid and suction line assembly (2) to the A/C expansion valve (3).
10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C expansion valve.
Tighten the nut to 25 N.m (18 ft. lbs.).

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Fig. 107: Heat Shield

Courtesy of CHRYSLER LLC

11. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
12. Install the nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in. lbs.).
13. Reconnect the negative battery cable.
14. If the heater core is being replaced, flush the cooling system. Refer to Cooling - Standard
Procedure .
15. Refill the engine cooling system. Refer to Cooling - Standard Procedure .
16. Evacuate and charge the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.

SCREEN-AIR INLET

NOTE: LHD model shown. RHD model similar.

Fig. 108: HVAC Housing Air Inlet Screen

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Courtesy of CHRYSLER LLC

1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-
in retainers (1) that secure the screen to the panel.
2. Install the cowl grille screen. Refer to Body/Exterior/COVER, Cowl Panel - Installation .

MOTOR, BLOWER

Description

DESCRIPTION

Fig. 109: Blower Motor

Courtesy of CHRYSLER LLC

The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning
the blower wheel (2) within the HVAC air inlet housing at the selected speed.

The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral
wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower wheel is secured to
the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC
housing.

Operation

OPERATION

The blower motor controls the velocity of air moving through the HVAC housing by spinning the blower
wheel within the HVAC air inlet housing at the selected speed.

On the Manual Temperature Control (MTC) heating-A/C system, blower motor speed is controlled by
regulating the path to ground through the blower control switch and the blower motor resistor. With the
Automatic Temperature Control (ATC) heating-A/C system, blower motor speed is controlled by an
electronic blower motor power module, that uses a Pulse Width Modulated (PWM) input from the A/C-
heater control and a feedback signal from the blower motor to regulate the blower motor ground path. On
both systems, the blower motor receives battery current through the Totally Integrated Power Module

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(TIPM) whenever the ignition switch is in the Run position, and the blower motor control is in any position
except Off.

The blower motor can be accessed for service from underneath the instrument panel.

NOTE: The blower motor is supplied with a 12 volt feed from the TIPM whenever the
ignition switch is in the Run position. Due to an open circuit condition within
the blower motor control switch, the TIPM is unable to detect an open circuit
for the blower motor.

The blower motor control system is diagnosed using a scan tool. Refer to DTC-Based Diagnostics/HVAC -
Diagnosis and Testing .

The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or
repaired and must be replaced if inoperative or damaged.

Diagnosis and Testing

BLOWER MOTOR

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable and wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the
blower motor resistor, whenever the ignition switch is in the RUN position.
Due to an open circuit condition within the blower motor control switch the
TIPM is UNABLE to detect an OPEN circuit for the blower motor.

To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect
the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. See
appropriate Wiring Information for circuit descriptions and diagrams.

OPERATION

Possible causes of an inoperative blower motor include:

Open fuse
Inoperative blower motor resistor or power module (depending on application)
Inoperative A/C-heater control
Inoperative blower motor
Inoperative blower motor circuit wiring or wire harness connectors

NOISE

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To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On.
To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector
and operate the heater-A/C system. If the noise goes away, possible causes include:

Foreign material on fresh air inlet screen

Foreign material in blower wheel
Foreign material in HVAC housing
Improper blower motor mounting
Deformed or damaged blower wheel
Worn blower motor bearings or brushes

VIBRATION

Possible causes of a blower motor vibration include:

Improper blower motor mounting

Foreign material in blower wheel
Deformed or damaged blower wheel
Worn blower motor bearings

Removal

REMOVAL

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

Fig. 110: Blower Motor

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

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1. Disconnect and isolate the negative battery cable.

2. If equipped, remove the silencer from below the passenger side of the instrument panel.
3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument
panel wire harness connector (1) from the blower motor (2).
4. Remove the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped)
to the bottom of the HVAC housing (5) and remove the blower motor.

Installation

INSTALLATION

Fig. 111: Blower Motor

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

1. Position the blower motor (2) into the bottom of the HVAC housing (5).
2. Install the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to
the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
3. Connect the instrument panel wire harness connector (1) to the blower motor and engage the
connector lock.
4. If equipped, install the silencer below the passenger side of the instrument panel.
5. Reconnect the negative battery cable.

OUTLET, AIR

Removal

BEVERAGE COOLER

The beverage cooler air control valve and lever are serviced as an assembly with the instrument base panel.
Refer to Body/Instrument Panel/PANEL, Instrument - Removal .

INSTRUMENT PANEL

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NOTE: Take the proper precautions to protect the face of the instrument panel cover
from cosmetic damage while performing this procedure.

NOTE: Driver side air outlet shown. Passenger side similar.

Fig. 112: Air Outlet

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Removal .

NOTE: If the foam seal on the air outlet is deformed or damaged, it must be
replaced.

3. Remove the three screws (1) that secure the air outlet (2) to the cover (3) and remove the outlet.

Installation

BEVERAGE COOLER

The beverage cooler air control valve and lever are serviced as an assembly with the instrument base panel.
Refer to Body/Instrument Panel/PANEL, Instrument - Installation .

INSTRUMENT PANEL

NOTE: Take the proper precautions to protect the face of the instrument panel cover
from cosmetic damage while performing this procedure.

NOTE: Driver side air outlet shown. Passenger side similar.

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Fig. 113: Air Outlet

Courtesy of CHRYSLER LLC

NOTE: If the foam seal on the air outlet is deformed or damaged, it must be
replaced.

1. Position the air outlet (2) onto the cover (3).

2. Install the three screws (1) that secure the air outlet. Tighten the screws to 2 N.m (17 in. lbs.).

NOTE: To prevent air leaks and excessive noise during A/C-heater operation,
make sure the foam seal on the air outlet is properly positioned into the
duct.

3. Install the instrument panel covers. Refer to Body/Instrument Panel/COVER, Instrument Panel -
Installation .
4. Reconnect the negative battery cable.

PLUMBING
WARNING

WARNING

WARNING: The A/C system contains refrigerant under high pressure. Repairs
should only be performed by qualified service personnel. Serious or
fatal injury may result from improper service procedures.

WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist.
Exposure may irritate the eyes, nose, and/or throat. Wear eye
protection when servicing the A/C refrigerant system. Serious eye
injury can result from direct contact with the refrigerant. If eye contact
occurs, seek medical attention immediately.

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WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created
when refrigerant is burned. An electronic leak detector is
recommended. Serious or fatal injury may result from improper service
procedures.

WARNING: If accidental A/C system discharge occurs, ventilate the work area
before resuming service. Large amounts of refrigerant released in a
closed work area will displace the oxygen and cause suffocation and
serious or fatal injury.

WARNING: The evaporation rate of R-134a refrigerant at average temperature and

altitude is extremely high. As a result, anything that comes in contact
with the refrigerant will freeze. Always protect the skin or delicate
objects from direct contact with the refrigerant.

WARNING: The R-134a service equipment or the vehicle refrigerant system should
not be pressure tested or leak tested with compressed air. Some
mixtures of air and R-134a have been shown to be combustible at
elevated pressures. These mixtures are potentially dangerous, and
may result in fire or explosion causing property damage and serious or
fatal injury.

WARNING: The engine cooling system is designed to develop internal pressures

up to 145 kPa (21 psi). Do not remove or loosen the coolant pressure
cap, cylinder block drain plugs, radiator drain, radiator hoses, heater
hoses, or hose clamps while the engine cooling system is hot and
under pressure. Allow the vehicle to cool for a minimum of 15 minutes
before opening the cooling system for service. Failure to observe this
warning can result in serious burns from the heated engine coolant.

CAUTION

CAUTION

CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not
use R-12 equipment or parts on an R-134a A/C system. These
refrigerants are not compatible and damage to the A/C system will
result.

CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a
refrigerant oil. These refrigerant oils are not compatible and damage to
the A/C system will result.

CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or A/C system. Many
federal, state/provincial and local regulations prohibit the recharge of
A/C systems with known leaks. Chrysler LLC recommends the
detection of A/C system leaks through the use of approved leak
detectors and fluorescent leak detection dyes. Vehicles found with A/C

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system sealers should be treated as contaminated and replacement of

the entire A/C refrigerant system is recommended. A/C systems found
to be contaminated with A/C system sealers, A/C stop-leak products or
seal conditioners voids the warranty for the A/C system.

CAUTION: Recover the refrigerant before opening any fitting or connection. Open
the fittings with caution, even after the system has been discharged.
Never open or loosen a connection before recovering the refrigerant.

CAUTION: The internal parts of the A/C system will remain stable as long as
moisture-free refrigerant and refrigerant oil is used. Abnormal amounts
of dirt, moisture or air can upset the chemical stability. This may cause
operational troubles or even serious damage if present in more than
very small quantities. Before disconnecting a component, clean the
outside of the fittings thoroughly to prevent contamination from
entering the refrigerant system. Keep service tools and the work area
clean. Do not open the refrigerant system or uncap a replacement
component until you are ready to service the system. Immediately after
disconnecting a component from the refrigerant system, seal the open
fittings with a cap or plug. This will prevent contamination from
entering the A/C system.

CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left
uncapped. Do not open a container of refrigerant oil until you are ready
to use it. Replace the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and moisture-free
container.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this caution
will result in serious A/C compressor damage.

CAUTION: Do not overcharge the refrigerant system. Overcharging will cause

excessive compressor head pressure and can cause compressor noise
and A/C system failure.

DIAGNOSIS AND TESTING

REFRIGERANT SYSTEM LEAKS

WARNING: R-134a service equipment or vehicle A/C system should not be

pressure tested or leak tested with compressed air. Mixture of air and
R-134a can be combustible at elevated pressures. These mixtures are
potentially dangerous and may result in fire or explosion causing
property damage and possible serious or fatal injury.

Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure

may irritate eyes, nose and throat. Use only approved service
equipment meeting SAE requirements to discharge an R-134a system.

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If accidental system discharge occurs, ventilate work area before

resuming service.

NOTE: If the A/C system refrigerant charge is empty or low, a leak in the A/C system
is likely. Visually inspect all A/C lines, fittings and components for an oily
residue. Oil residue can be an indicator of an A/C system leak location.

NOTE: The only way to correctly determine if the A/C system is fully charged with
refrigerant to conduct the A/C Performance Test. See Heating and Air
Conditioning - Diagnosis and Testing.

Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345
kPa (50 psi). See Heating and Air Conditioning/Plumbing - Standard Procedure. If less than 345 kPa
(50 psi), proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW.

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (-26
in. Hg) or greater vacuum). See Heating and Air Conditioning/Plumbing - Standard Procedure.
Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not
present. If system will not maintain vacuum level, proceed to 2.
2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant
system. See Heating and Air Conditioning/Plumbing - Standard Procedure and proceed to 1 of
the System Low procedure.

SYSTEM LOW

1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
2. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5
minutes.
Doors or windows open
Transaxle in Park or Neutral with the parking brake set (depending on application)
A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C
compressor engaged

CAUTION: A leak detector only designed for R-12 refrigerant will not detect
leaks in an R-134a refrigerant system.

3. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to
detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily
usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector
probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak
detection. Use only Chrysler LLC approved refrigerant dye.

STANDARD PROCEDURE

REFRIGERANT SYSTEM RECOVERY

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WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow the warnings and
cautions may result in serious or fatal injury.

CAUTION: Various aftermarket manufacturers produce A/C system sealants that

are designed to stop A/C refrigerant system leaks. The use of A/C
system sealants may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or the vehicle A/C
system and are not recommended for use by Chrysler LLC.

Fig. 114: Identifying R-134A Refrigerant Recovery/Recycling/Charging Station

Courtesy of CHRYSLER LLC

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

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

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

REFRIGERANT SYSTEM EVACUATE

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this caution

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will result in serious A/C compressor damage.

NOTE: Special effort must be used to prevent moisture from entering the A/C
system oil. Moisture in the oil is very difficult to remove and will cause a
reliability problem with the A/C compressor.

If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended
period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C
compressor be used. This will eliminate the possibility of contaminating the refrigerant system.

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be
filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable
operating levels. This will reduce the performance of the A/C system and damage the A/C compressor.
Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system:

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

1. Recover the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold
gauge set with vacuum pump and refrigerant recovery equipment. See Heating and Air
Conditioning/Plumbing - Standard Procedure. Do not operate the engine with a vacuum on the
A/C system.
3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a
minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge
reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30
minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the
refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains
specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge
valves. Then allow the system to evacuate an additional 10 minutes.
4. Close all valves. Turn off and disconnect the vacuum pump.
5. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.

REFRIGERANT SYSTEM CHARGE

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

NOTE: The Underhood HVAC Specification Label contains the refrigerant fill
specification of the vehicle being serviced.

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Fig. 115: Refrigerant Recovery/Recycling Station - Typical

Courtesy of CHRYSLER LLC

After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a
refrigerant charge can be injected into the system.

Use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE Standard J2788 to charge
the refrigerant system with R-134a refrigerant. See the operating instructions supplied by the equipment
manufacturer for proper care and use of this equipment.

CHARGING PROCEDURE

CAUTION: A small amount of refrigerant oil is removed from the A/C system each
time the refrigerant system is recovered and evacuated. Before
charging the A/C system, you MUST replenish any oil lost during the
recovery process. See the equipment manufacturer instructions for
more information.

1. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE
standard J2788 should be connected to the refrigerant system.
3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See
Heating and Air Conditioning/Plumbing/REFRIGERANT - Specifications. See the operating
instructions supplied by the equipment manufacturer for proper use of this equipment.
4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant
to flow into the system.
5. When the transfer of refrigerant has stopped, close both the suction and discharge valves.
6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in
the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the
blower motor is running at its lowest speed setting. Run the engine at a steady high idle (about 1400
rpm).
7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system.

WARNING: Take care not to open the discharge (high pressure) valve at this

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time. Failure to follow this warning may result in possible serious

or fatal injury.

8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
9. Reinstall the caps onto the refrigerant system service ports.

COMPRESSOR, A/C

Description

COMPRESSOR, A/C - FIXED DISPLACEMENT

Fig. 116: A/C Compressor -Typical

Courtesy of CHRYSLER LLC

2.2L Diesel models are equipped with a clutch operated Denso 10SRE18 A/C compressor (1) with a fixed
displacement of 180 cubic centimeters (11 cubic inches). This A/C compressor is a reciprocating, swash
plate-type compressor with five double-acting pistons. The A/C compressor has the suction and discharge
ports (2) and the high pressure relief valve (3) located near the rear of the compressor.

The A/C compressor is secured to the engine with three bolts.

A label identifying the use of R-134a refrigerant and ND-8 PAG oil is located on the A/C compressor.

COMPRESSOR, A/C - VARIABLE DISPLACEMENT

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Fig. 117: Denso 6SEU16 Compressor 09 JC

Courtesy of CHRYSLER LLC

All gasoline engine models use a Denso 6SEU16 clutchless, variable displacement, swashplate type A/C
compressor (1). This A/C compressor has a total displacement of 160 cubic centimeters (9.7 cubic inches)
and has a control valve (2) and high pressure relief valve (3) located on the back cover.

The A/C compressor is secured to the engine with three bolts.

A label identifying the use of R-134a refrigerant and ND-8 PAG oil is located on the A/C compressor.

CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

Fig. 118: A/C Compressor Clutch Components

Courtesy of CHRYSLER LLC

NOTE: Typical A/C clutch assembly shown.

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On 2.2L diesel engine equipped models, the clutch assembly for the Denso fixed displacement A/C
compressor consists of a stationary electromagnetic A/C clutch coil (4), pulley bearing and pulley assembly
(3), clutch plate (2) and shims (7). These components provide the means to engage and disengage the A/C
compressor from the engine accessory drive belt.

The A/C clutch coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C
compressor with snap rings (5 and 6). The clutch plate is splined to the compressor shaft and secured with a
bolt (1).

HUB AND PULLEY - VARIABLE DISPLACEMENT A/C COMPRESSOR

Fig. 119: A/C Compressor Hub And Pulley Assembly

Courtesy of CHRYSLER LLC

NOTE: Typical clutchless A/C compressor pulley and drive hub shown.

On all gasoline engine equipped models, the non-servicable hub and pulley assembly for the Denso 6SEU16
variable displacement A/C compressor provides the means to drive the A/C compressor using the engine
accessory drive belt. The hub and pulley assembly consists of an aluminum drive hub (1) with composite
tabs (2) that are positioned between rubber dampeners (3), which are located inside of a composite pulley
(4).

The A/C pulley has a bearing (5) that is retained to the nose of the A/C compressor with a snap ring (6). The
drive hub and shim (7) are retained to the compressor shaft by use of left handed threads.

HIGH PRESSURE RELIEF VALVE

A high pressure relief valve is located on the compressor cylinder head at the rear of each A/C compressor.
See Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Description. This mechanical
valve is designed to vent refrigerant from the A/C system to protect against damage to the A/C compressor
and other A/C system components caused by condenser air flow restriction or an overcharge of refrigerant.

Operation

COMPRESSOR, A/C - FIXED DISPLACEMENT

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On 2.2L diesel engine equipped models, the Denso fixed displacement A/C compressor is driven by the
engine through an electric clutch, drive pulley and belt arrangement. This A/C compressor is lubricated by
refrigerant oil that is circulated throughout the refrigerant system with the refrigerant.

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

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level can prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

The Denso fixed displacement A/C compressor cannot be repaired and must be replaced if inoperative or
damaged. The compressor clutch, pulley and bearing assembly, and clutch coil are available for service if
inoperative or damaged. If an internal failure of the A/C compressor has occurred, the A/C
condenser/receiver/drier assembly must also be replaced. See Heating and Air
Conditioning/Plumbing/CONDENSER, A/C - Removal.

COMPRESSOR, A/C - VARIABLE DISPLACEMENT

Fig. 120: 5SE12C Compressor-Operation

Courtesy of CHRYSLER LLC

NOTE: Typical variable displacement A/C compressor shown.

The Denso 6SEU16 A/C compressor used on all gasoline engine equipped models, is a variable
displacement compressor (VDC) that is driven by the engine through a drive hub (1) and pulley (2). This
A/C compressor does not require the use of an electromagnetic clutch, as the compressor uses an integral
control solenoid (3) to reduce or increase the stroke of the five pistons (4) within the compressor by
automatically adjusting the angle of the swashplate (5).

The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction

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port. It then compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is
then pumped to the A/C condenser through the compressor discharge port. The A/C compressor is lubricated
by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant.

The A/C compressor is controlled by the Powertrain Control Module (PCM). The PCM calculates
compressor displacement required by A/C system load and demand by monitoring vehicle speed, A/C high
side pressure, engine speed, evaporator temperature, accelerator pedal position, ambient temperature and
A/C-heater request signals. The PCM then sends a Pulse Width Modulated (PWM) signal to the A/C
compressor control solenoid to increase or decrease refrigerant flow through an orifice located within the
compressor housing. The amount of refrigerant allowed to pass through the orifice in the compressor
determines the head pressure which controls the angle of the swashplate, which in turn, determines the
amount of compressor displacement. When there is no demand for A/C, the swashplate is adjusted to nearly
a zero degree angle, which removes compressor torque drag from the engine.

This A/C compressor will reduce the displacement of the compressor based on ambient air temperature. For
example; as the outside temperature falls from 27° C (80° F) to 19° C (66° F), the amount of refrigerant flow
required through the A/C orifice valve to keep the A/C evaporator cool becomes less, and the swashplate is
adjusted to a lower angle, which reduces compressor displacement. However, due to the lower outside air
temperature, panel air outlet temperature will not noticeably change.

The A/C compressor control system is diagnosed using a scan tool. Refer to DTC-Based
Diagnostics/HVAC - Diagnosis and Testing .

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system when equipped with a variable
displacement A/C compressor. Failure to follow this caution will result
in serious A/C compressor damage.

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level can prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

NOTE: The compressor drive hub and the pulley and bearing assembly can not be
serviced separately from the A/C compressor. In the event of drive hub or
pulley and bearing assembly damage or failure, the A/C compressor, drive
hub and pulley and bearing must be replaced as an assembly.

The A/C compressor cannot be adjusted or repaired and must be replaced if inoperative or damaged. If an
internal failure of the A/C compressor has occurred, the A/C condenser/receiver/drier assembly must also be
replaced. See Heating and Air Conditioning/Plumbing/CONDENSER, A/C - Removal.

CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

On 2.2L diesel engine equipped models, the clutch components for the Denso fixed displacement A/C
compressor provide the means to engage and disengage the compressor from the engine accessory drive
belt. When the electromagnetic A/C clutch coil is energized, it magnetically draws the clutch plate into
contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley
freewheels on the clutch hub bearing, which is part of the pulley assembly.

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

The A/C clutch control system is diagnosed using a scan tool.

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

HUB AND PULLEY - VARIABLE DISPLACEMENT A/C COMPRESSOR

Fig. 121: A/C Compressor Hub

Courtesy of CHRYSLER LLC

NOTE: Typical clutchless compressor pulley drive hub shown.

The design of the Denso 6SEU16 variable displacement A/C compressor used on all gasoline engine
equipped models, does not require the use of an electromagnetic clutch, as the compressor is controlled by
an integral control valve that allows refrigerant to bypass within the compressor. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Description.

The three bridges (1) located on compressor drive hub (2) are designed to break away in the event of
compressor seizure. This action prevents damage to the serpentine accessory drive belt. See Heating and
Air Conditioning/Plumbing/COMPRESSOR, A/C - Inspection.

NOTE: The compressor drive hub and the pulley and bearing assembly can not be
serviced separately from the A/C compressor. In the event of drive hub or
pulley and bearing assembly damage or failure, the A/C compressor, drive
hub and pulley and bearing must be replaced as an assembly.

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The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C
compressor. The A/C compressor must be replaced if the drive hub or pulley and bearing assembly is worn
or damaged.

HIGH PRESSURE RELIEF VALVE

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

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

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

Diagnosis and Testing

CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

The compressor clutch coil electrical circuit for the Denso fixed displacement A/C compressor used on 2.2L
diesel engine equipped models, is controlled by the Engine Control Module (ECM) through the Totally
Integrated Power Module (TIPM) (see appropriate Wiring Information for complete HVAC wiring
diagrams). Begin testing of a suspected compressor clutch coil problem by performing the preliminary
checks.

PRELIMINARY CHECKS

1. Using a scan tool, check for Diagnostic Trouble Codes (DTCs) in the A/C-heater control, TIPM and
ECM. If no DTCs are found, go to 2. If any DTCs are found, repair as required.
2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level. See Heating
and Air Conditioning - Diagnosis and Testing. If the refrigerant charge level is OK, go to COIL
RESISTANCE TEST and/or COIL CURRENT DRAW TEST. If the refrigerant charge level is not
OK, adjust the refrigerant charge as required.

COIL RESISTANCE TEST

1. Disconnect and isolate the negative battery cable.

2. Disconnect the wire harness connector from the A/C clutch coil connector.
3. Use an ohm meter and Back Probe Tool 6801 and measure the resistance of the clutch coil at the coil
connector terminals.
4. See the A/C Clutch Coil Specifications chart below for the acceptable A/C clutch coil resistance.
Specifications apply for a work area temperature of 21° C (70° F).
a. If the A/C clutch coil reading is below specifications, the coil is shorted and must be replaced.
b. If the A/C clutch coil reading is above specifications, the coil is open and must be replaced.

COIL CURRENT DRAW TEST

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1. Verify the battery state of charge. Refer to Electrical/Battery System/BATTERY - Diagnosis and
Testing .
2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal using
Back Probe Tool 6801. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the
battery and the clutch coil.
3. With the heater-A/C control in the A/C mode and the blower at low speed, start the engine and allow
it to run at a normal idle speed.
4. The compressor clutch should engage immediately, and the clutch coil supply voltage should be
within two volts of the battery voltage. If the coil supply voltage is OK, go to 5. If the coil supply
voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage
drop and repair as necessary.
5. See the A/C Clutch Coil Specifications chart below for the acceptable A/C clutch coil current draw.
Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts,
add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.
a. If the compressor clutch coil current reading is zero, the coil is open and must be replaced.
b. If the compressor clutch coil current reading is above specifications, the coil is shorted and must
be replaced.

A/C CLUTCH COIL SPECIFICATIONS

Coil Resistance Current Draw
3.6 ± 0.2 ohms 3.2 - 3.3 amps @ 11.5 - 12.5 volts

A/C SYSTEM NOISE TESTING

When investigating an A/C system related noise, you must first know the conditions under which the noise
occurs. These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed,
engine temperature and any other special conditions. Noises that develop during A/C operation can often be
misleading. For example: what sounds like a failed bearing, may be caused by loose bolts, nuts, mounting
brackets or a loose A/C compressor.

NOTE: The A/C compressor must be replaced if any unusual noise is heard from the
compressor itself.

1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Turn the A/C
system On and Off several times to clearly identify any compressor noise. On variable displacement
compressors, listen to the A/C compressor while it is operating at maximum and minimum
displacement. On fixed displacement compressors, listen to the compressor while the A/C clutch
cycles on and off. Probe the A/C compressor with an engine stethoscope or a long screwdriver with
the handle held to your ear to better localize the source of the noise. To duplicate high-ambient
temperature conditions (high head pressure), restrict the air flow through the A/C condenser. Install a
manifold gauge set or a scan tool to be certain that the discharge pressure does not exceed 2600 kPa
(377 psi).

NOTE: Drive belts are speed sensitive. At different engine speeds and
depending upon drive belt tension, drive belts can develop noises that
are mistaken for an A/C compressor noise. Improper drive belt tension
can cause a misleading noise when a variable displacement A/C
compressor is operating at maximum displacement, which may not
occur when the compressor is at minimum displacement, or when a

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fixed displacement compressor clutch is engaged.

2. Check the condition of the accessory drive belt. Refer to Cooling/Accessory Drive/BELT,
Serpentine - Diagnosis and Testing .

NOTE: On variable displacement A/C compressors, the compressor must be

replaced if the drive hub is broken or if the compressor shaft does not
rotate smoothly.

3. When equipped with a variable displacement A/C compressor, check the compressor hub and pulley
and bearing assembly. Be certain that the hub and pulley are properly aligned and that the pulley
bearing is mounted securely to the A/C compressor. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Inspection.
4. When equipped with a fixed displacement A/C compressor, check the compressor clutch retainer. Be
certain that the clutch coil is mounted securely to the compressor, and that the clutch plate and pulley
are properly aligned and have the correct air gap. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Installation.

NOTE: The A/C compressor must be replaced if any debris or unusually

discolored oil is found on the A/C compressor manifold.

5. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause
unusual noises. Also check the refrigerant lines and hoses for kinks or sharp bends that will restrict
refrigerant flow, which can cause noises.
6. Loosen all of the compressor mounting hardware and retighten. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Removal.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system when equipped with the
Denso 6SEU16 variable displacement compressor. Failure to
follow this caution will result in serious A/C compressor damage.

7. If the noise is from opening and closing of the high pressure relief valve, recover, evacuate and
recharge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure. If the high pressure relief valve still does not seat properly, replace the A/C compressor.
See Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal.
8. If the noise is from liquid refrigerant slugging in the A/C suction line, check the refrigerant system
charge. See Heating and Air Conditioning - Diagnosis and Testing. If the refrigeant charge is ok,
replace the A/C receiver/drier. See Heating and Air Conditioning/Plumbing/DRIER, A/C Receiver
- Removal and check the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure.
9. If a slugging condition still exists after replacing the A/C receiver/drier, then replace the A/C
compressor. See Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal.

Removal

CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

WARNING: Refer to the applicable warnings and cautions for this system before

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performing the following operation. See Heating and Air

Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

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

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

Fig. 122: A/C Compressor Shaft Bolt

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Remove the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
3. Disconnect the engine wire harness from the compressor clutch coil connector (1) located on the top
of the A/C compressor (5).

NOTE: Some models (depending on application) may require the A/C

compressor to be removed from its installed location and repositioned
to gain access to the compressor shaft bolt and/or pulley and field coil
snap rings. However, the refrigerant system can still remain fully
charged.

4. If necessary, remove the bolts that secure the A/C compressor to the engine and reposition the
compressor to gain access to the shaft bolt and/or pulley and clutch coil snap rings. See Heating and
Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal.
5. Carefully remove the compressor clutch coil connector and wire lead from the connector bracket (2).
6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to

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hold the clutch plate (4) from rotating during bolt removal.

Fig. 123: Identifying Compressor Shaft, Clutch Plate & Shim(s)

Courtesy of CHRYSLER LLC

CAUTION: Do not pry between the clutch plate and the pulley and bearing
assembly to remove the clutch plate from the compressor shaft as
this may damage the clutch plate.

NOTE: Use care not to lose any clutch shim(s) during removal of the clutch
plate, as they may be reused during the clutch plate installation
process.

7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor
shaft (1) and remove the clutch plate and shim(s) (3).

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Fig. 124: Clutch Pulley & Snap Ring

Courtesy of CHRYSLER LLC

8. Using A/C Snap Ring Pliers 9764 (1) or equivalent, remove the snap ring (2) that secures the pulley
and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing
assembly.

Fig. 125: Clutch Coil & Snap Ring

Courtesy of CHRYSLER LLC

9. Using A/C Snap Ring Pliers 9764 (1) or equivalent, remove the snap ring (4) that secures the
compressor clutch coil (2) to the front of the A/C compressor (3) and remove the coil.

COMPRESSOR, A/C

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air

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Conditioning/Plumbing - Warning and see Heating and Air

Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

Fig. 126: A/C Compressor-Refrigerant Lines

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. On gasoline engine models;
a. raise and support the vehicle.
b. remove the right front wheel. Refer to Tires and Wheels - Removal .
c. position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
d. remove the drive belt splash shield.
4. Remove the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
5. Disconnect the compressor control valve wire lead (2) or clutch coil lead, depending on engine
application, from the engine wire harness.
6. Remove the nuts (1) that secure the A/C discharge line (3) and the A/C suction line (4) to the A/C
compressor (5).
7. Disconnect the A/C discharge and suction lines from the A/C compressor and remove and discard the
O-ring seals and gaskets.

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Fig. 127: A/C Compressor Removal/Installation

Courtesy of CHRYSLER LLC

8. Support the A/C compressor (1) and remove the three bolts (2) that secure the compressor to the
engine and remove the compressor.
9. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.

Inspection

CLUTCH INSPECTION - FIXED DISPLACEMENT A/C COMPRESSOR

Fig. 128: Identifying Compressor Shaft, Clutch Plate & Shim(s)

Courtesy of CHRYSLER LLC

Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate
should be replaced if there is excessive wear or scoring.

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If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil.
If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced.

Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and clutch plate if
required.

HUB AND PULLEY INSPECTION - VARIABLE DISPLACEMENT A/C COMPRESSOR

NOTE: The compressor drive hub and the pulley and bearing assembly can not be
serviced separately from the A/C compressor. In the event of drive hub or
pulley and bearing assembly damage or failure, the A/C compressor, drive
hub and pulley and bearing must be replaced as an assembly.

Fig. 129: Compressor Hub And Pulley Inspection

Courtesy of CHRYSLER LLC

NOTE: Typical clutchless compressor drive hub and pulley and bearing assembly
shown.

The bridges (1) located on the non-servicable compressor hub (2) are designed to break away in the event of
compressor seizure. Examine the bridges for separation or cracks (3). Damage to the bridges are an
indication of excessive compressor torque, which is most likely caused by compressor failure.

Check the non-servicable pulley bearing (4) for roughness or excessive noise. Check the pulley dampeners
(5) for excessive play which can be caused by deterioration or damage. Inspect the belt surfaces of the non-
servicable pulley (4) for wear. If the pulley surfaces are oily, inspect the shaft and nose area of the A/C
compressor for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C
compressor must be replaced.

Replace the A/C compressor if wear or damage is found to the drive hub or pulley and bearing assembly.
See Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal.

Installation

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CLUTCH - FIXED DISPLACEMENT A/C COMPRESSOR

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

Fig. 130: Clutch Coil & Snap Ring

Courtesy of CHRYSLER LLC

1. Align the dowel pin on the back of the compressor clutch coil (2) with the hole in the front of the A/C
compressor (3) and position the coil onto the compressor. Be certain that the compressor clutch coil
wire lead is properly routed so that it is not pinched between the A/C compressor and the coil.

CAUTION: The snap ring must be fully and properly seated in the groove or it
will vibrate out, resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure the compressor clutch coil to
the A/C compressor. The bevel side of the snap ring must face outward
and both snap ring eyelets must be oriented to the right or to the left of
the coil dowel pin location on the A/C compressor.

2. Using A/C Snap Ring Pliers 9764 (1) or equivalent, install the snap ring (4) that secures the
compressor clutch coil to the front of the A/C compressor. Be certain that the snap ring is fully and
properly seated in the groove and oriented correctly.

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Fig. 131: Identifying Pulley & Bearing Assembly

Courtesy of CHRYSLER LLC

CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not
damaged during A/C compressor pulley and bearing installation.

CAUTION: When installing the pulley and bearing assembly, DO NOT mar the
friction surfaces of the pulley or premature failure of the A/C
clutch will result.

3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the
pulley gently with a block of wood (2) placed on the pulley friction surface.

Fig. 132: Clutch Pulley & Snap Ring

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Courtesy of CHRYSLER LLC

CAUTION: The snap ring must be fully and properly seated in the groove or it
will vibrate out, resulting in a clutch failure and severe damage to
the A/C compressor.

NOTE: A new snap ring must be used to secure the pulley and bearing
assembly to the A/C compressor. The bevel side of the snap ring must
face outward.

4. Using A/C Snap Ring Pliers 9764 (1) or equivalent, install the snap ring (2) that secures the pulley
and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and
properly seated in the groove.

Fig. 133: Identifying Compressor Shaft, Clutch Plate & Shim(s)

Courtesy of CHRYSLER LLC

5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original
shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are
being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft.

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Fig. 134: A/C Compressor Shaft Bolt

Courtesy of CHRYSLER LLC

6. Install the clutch plate (4) onto the front of the A/C compressor (5).
7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 in. lbs.).

NOTE: The shims may compress after tightening the shaft bolt. Check the air
gap in four or more places to verify the air gap is correct. Spin the
pulley before performing a final check of the air gap.

NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire
gap gauge to measure the clutch air gap. On other models, use a blade
type feeler gauge to measure the air gap.

8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate
and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024
in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air
gap is obtained.

CAUTION: Be certain that the compressor clutch coil wire lead is routed so
that it is not pinched between the A/C compressor and the coil
connector bracket.

9. Carefully route the compressor clutch coil wire lead behind the connector bracket (2).
10. Install the compressor clutch coil connector (1) onto the connector bracket.
11. Reinstall the A/C compressor onto the engine if removed for A/C clutch service. See Heating and
Air Conditioning/Plumbing/COMPRESSOR, A/C - Installation.
12. Connect the engine wire harness to the compressor clutch coil connector.
13. Install the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .

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14. Reconnect the negative battery cable.

COMPRESSOR, A/C

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level can prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C
compressor has occurred. See Heating and Air
Conditioning/Plumbing/DRIER, A/C Receiver - Removal. Failure to
replace the A/C receiver drier can cause serious damage to the
replacement A/C compressor.

CAUTION: On late model year gasoline engine equipped vehicles with automatic
transaxle, the A/C condenser/receiver/drier assembly must be replaced
if an internal failure of the A/C compressor has occurred. Failure to
replace the A/C condenser/receiver/drier assembly can cause serious
damage to the replacement A/C compressor.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be removed from the new
A/C compressor. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure.

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

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

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Fig. 135: A/C Compressor Removal/Installation

Courtesy of CHRYSLER LLC

1. If the A/C compressor (1) is being replaced, refrigerant oil must first be drained from the new A/C
compressor. When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant system. See Heating
and Air Conditioning/Plumbing/OIL, Refrigerant - Standard Procedure. Use only refrigerant oil
of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor into the engine compartment.
3. Install the three bolts (2) that secure the A/C compressor to the engine. Tighten the bolts to 25 N.m
(18 ft. lbs.).

Fig. 136: A/C Compressor-Refrigerant Lines

Courtesy of CHRYSLER LLC

4. Remove the tape or plugs from the compressor ports and the refrigerant line fittings.
5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the
refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the
R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
6. Connect the A/C discharge line (3) and the A/C suction line (4) to the A/C compressor (5).
7. Install the nuts (1) that secure the A/C suction and discharge lines to the A/C compressor. Tighten the
nuts to 20 N.m (15 ft. lbs.).
8. Connect the compressor control valve wire lead (2) or clutch coil lead, depending on application, to
the engine wire harness.
9. Install the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
10. On gasoline engine models;
a. install the drive belt splash shield.
b. reposition the front portion of the right front wheelhouse splash shield. Refer to
Body/Exterior/SHIELD, Splash - Installation .
c. install the right front wheel. Refer to Tires and Wheels - Installation .
11. Reconnect the negative battery cable.

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CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system when equipped with the
Denso 6SEU16 variable displacement compressor. Failure to
follow this caution will result in serious A/C compressor damage.

12. Evacuate and charge the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.

CONDENSER, A/C

Description

DESCRIPTION

NOTE: A/C condenser for late model year gasoline engine with automatic transaxle
shown. Other models similar.

Fig. 137: A/C Condenser

Courtesy of CHRYSLER LLC

The A/C condenser (1) is a heat exchanger that allows the high-pressure refrigerant gas being discharged
from A/C compressor to give up its heat to the air passing over the condenser fins, which causes the
refrigerant flowing through the condenser to cool and change to a liquid state. The A/C condenser is located
at the front of the engine compartment, behind the grille.

The A/C condenser has tapping blocks for the A/C refrigerant lines (2) and the integral automatic
transmission cooler (4), when equipped.

Early model year gasoline engine equipped vehicles with automatic transaxle have the A/C receiver/drier
mounted to the right front frame rail. See Heating and Air Conditioning/Plumbing/DRIER, A/C
Receiver - Description. Late model year gasoline engine equipped vehicles with automatic transaxle have
the A/C receiver/drier (3) mounted to the left end of the A/C condenser.

CAUTION: On late model year gasoline engine equipped vehicles with automatic

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transaxle, the A/C condenser/receiver/drier assembly must be replaced

if an internal failure of the A/C compressor has occurred. Failure to
replace the A/C condenser/receiver/drier assembly can cause serious
damage to the replacement A/C compressor. See Heating and Air
Conditioning/Plumbing/CONDENSER, A/C - Removal.

Operation

OPERATION

When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C
condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a
high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling
performance of the A/C system. Therefore, it is important that there are no objects placed in front of the
radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might
obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled
following radiator or A/C condenser service.

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

The A/C condenser has no serviceable parts. The O-ring seals used on the connections are made from a
special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced
whenever a refrigerant line is disconnected from the A/C condenser.

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

Removal

REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

CAUTION: On late model year gasoline engine equipped vehicles with automatic
transaxle, the A/C condenser/receiver/drier assembly must be replaced
if an internal failure of the A/C compressor has occurred. Failure to
replace the A/C condenser/receiver/drier assembly can cause serious
damage to the replacement A/C compressor.

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

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Fig. 138: Discharge Line To Condenser

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. If equipped with the 2.2L diesel engine, remove the front fascia. Refer to Frame and
Bumpers/Bumpers/FASCIA, Front - Removal .
4. If equipped with a gasoline engine, remove the upper radiator support and position it out of the way.
Refer to Body/Exterior/PANEL, Closure - Removal .
5. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access
to the A/C condenser (2).
6. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser and
remove and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port.

Fig. 139: Liquid Line To Condenser

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Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

8. Raise and support the vehicle.

NOTE: On gasoline engine equipped models, reach up through the opening in

the bottom of the front fascia located in the right front corner of the
vehicle to gain access to the A/C liquid line.

9. Remove the nut (1) that secures the A/C liquid line (2) to the right side of the A/C condenser (3).
10. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and
gasket.
11. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.

Fig. 140: Identifying A/C Condenser, Radiator & Upper Condenser Brackets
Courtesy of CHRYSLER LLC

NOTE: A/C condenser for late model year gasoline engine with automatic
transaxle shown. Other models similar.

NOTE: Illustration shown with front fascia and diesel engine charge air cooler
(CAC) (when equipped) removed for clarity.

12. Remove the two bolts (3) that secure the lower condenser brackets to the radiator (5).
13. Lower the vehicle.
14. If equipped, disconnect the automatic transmission cooler lines (2) from the left side of the A/C
condenser (1). Refer to Cooling/Transmission/TUBES AND HOSES, Transmission Oil Cooler -
Standard Procedure .
15. If equipped with the 2.2L diesel engine, remove the charge air cooler (CAC).
16. Carefully lift the A/C condenser straight up and disengage the two upper condenser brackets (4) from
the radiator and remove the condenser from the engine compartment.

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Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

CAUTION: On late model year gasoline engine equipped vehicles with automatic
transaxle, the A/C condenser/receiver/drier assembly must be replaced
if an internal failure of the A/C compressor has occurred. Failure to
replace the A/C condenser/receiver/drier assembly can cause serious
damage to the replacement A/C compressor.

NOTE: If the A/C condenser is being replaced, add 10 milliliters (0.3 fluid ounce) of
refrigerant oil to the refrigerant system. If the A/C condenser is equipped
with an A/C receiver/drier, be sure to add an addition 30 milliliters (1.0 fluid
ounce) of refrigerant oil. When replacing multiple A/C system components,
see REFRIGERANT OIL CAPACITIES to determine how much oil should be
added to the refrigerant system. See Heating and Air
Conditioning/Plumbing/OIL, Refrigerant - Standard Procedure. Use only
refrigerant oil of the type recommended for the A/C compressor in the
vehicle.

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

Fig. 141: Identifying A/C Condenser, Radiator & Upper Condenser Brackets
Courtesy of CHRYSLER LLC

NOTE: A/C condenser for late model year gasoline engine with automatic transaxle

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shown. Other models similar.

NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC)
(when equipped) removed for clarity.

1. Carefully lower the A/C condenser (1) straight down in front of the radiator (5) and engage the upper
condenser brackets (4) to the radiator.
2. If equipped with the 2.2L diesel engine, install the charge air cooler (CAC).
3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C condenser.
Refer to Cooling/Transmission/TUBES AND HOSES, Transmission Oil Cooler - Standard
Procedure .
4. Raise and support the vehicle.
5. Install the two bolts (3) that secure the lower condenser brackets to the radiator. Tighten the bolts to
4.5 N.m (40 in. lbs.).

Fig. 142: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

NOTE: On gasoline engine equipped models, reach up through the opening in

the bottom of the front fascia located in the right front corner of the
vehicle to gain access to the A/C liquid line.

6. Remove the tape or plug from the liquid line fitting and the condenser outlet port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the
liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten the
nut to 5 N.m (44 in. lbs.).

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Fig. 143: Discharge Line To Condenser

Courtesy of CHRYSLER LLC

9. Lower the vehicle.

10. Remove the tape or plug from the discharge line fitting and the condenser inlet port.
11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the
discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
12. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access
to the A/C condenser (2).
13. Connect the A/C discharge line (4) to the A/C condenser and install the retaining nut (3). Tighten the
nut to 5 N.m (44 in. lbs.).
14. If equipped with a gasoline engine, reposition and install the upper radiator support. Refer to
Body/Exterior/PANEL, Closure - Installation .
15. If equipped with the 2.2L diesel engine, install the front fascia. Refer to Frame and
Bumpers/Bumpers/FASCIA, Front - Installation .
16. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this
caution will result in serious A/C compressor damage.

17. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure
18. If the A/C condenser is being replaced, add 10 milliliters (0.3 fluid ounce) of refrigerant oil to the
refrigerant system. If the A/C condenser is equipped with an A/C receiver/drier, be sure to add an
addition 30 milliliters (1.0 fluid ounce) of refrigerant oil. When replacing multiple A/C system
components, see REFRIGERANT OIL CAPACITIESthe Refrigerant Oil Capacities chart to
determine how much oil should be added to the refrigerant system. See Heating and Air
Conditioning/Plumbing/OIL, Refrigerant - Standard Procedure. Use only refrigerant oil of the
type recommended for the A/C compressor in the vehicle.
19. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard

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Procedure.

CORE, HEATER

Description

DESCRIPTION

NOTE: LHD model shown. RHD model similar.

Fig. 144: Heater Core

Courtesy of CHRYSLER LLC

The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which
is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins
and is positioned within the air distribution housing so that only the selected amount of air entering the
housing passes through the heater core before it is distributed through the heating-A/C system ducts and
outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes
(3).

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

Operation

OPERATION

Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows
through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins.
Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows
control of the heater output air temperature by regulating the amount of air flowing through the heater core.
The blower motor speed controls the volume of air flowing through the HVAC housing.

The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged.

Removal

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REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

NOTE: The HVAC housing assembly must be removed from vehicle for service of
the heater core.

NOTE: LHD model with A/C shown. RHD and heater-only models similar.

Fig. 145: Heater Core Removal/Installation

Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the left side front floor duct. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Removal.

NOTE: If the foam seal for the flange is deformed or damaged, it must be
replaced.

3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (5).
4. Remove the screw (6) that secures the flange to the front of the HVAC housing and remove the
flange.
5. On RHD models, remove the air distribution housing from the HVAC housing. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal
6. Carefully pull the heater core (4) out of the driver side of the air distribution housing (3).

Installation

INSTALLATION

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NOTE: LHD model with A/C shown. RHD and heater-only models similar.

Fig. 146: Heater Core Removal/Installation

Courtesy of CHRYSLER LLC

1. Carefully install the heater core (4) into the side of the air distribution housing (3).
2. On RHD models, install the air distribution housing onto the HVAC housing (5). See Heating and
Air Conditioning/Distribution/HOUSING, HVAC - Installation.
3. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing.
4. Install the screw (6) that secures the flange to the HVAC housing. Tighten the screw to 1.2 N.m (10
in. lbs.).

NOTE: If the foam seal for the flange is deformed or damaged, it must be
replaced.

5. Install the foam seal (1) onto the flange.

6. Install the left side front floor duct. See Heating and Air Conditioning/Distribution/DUCT, Floor
Distribution - Installation.

NOTE: If the heater core is being replaced, flush the cooling system. Refer to
Cooling - Standard Procedure .

7. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING,
HVAC - Installation.

CORE, SERVICE PORT VALVE

Description

DESCRIPTION

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Fig. 147: High Side Service Port

Courtesy of CHRYSLER LLC

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

The high side service port (1) is located on the A/C discharge line (2) in front of the engine, below the upper
radiator hose (3).

Fig. 148: Low Side Service Port

Courtesy of CHRYSLER LLC

The low side service port (1) is located on the A/C liquid line (2) near the right front strut tower (3). Both
the high side and low side A/C service port valve cores are serviceable.

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

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

Removal

REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in serious or fatal injury.

Fig. 149: Identifying A/C Service Port Components

Courtesy of CHRYSLER LLC

NOTE: Typical A/C service port shown.

1. Remove the protective cap (1) from the service port (2).
2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port.
4. Install a plug in, or tape over the opened service port(s).

Installation

INSTALLATION

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Fig. 150: Identifying A/C Service Port Components

Courtesy of CHRYSLER LLC

NOTE: Typical A/C service port shown.

1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of
the type recommended for the A/C compressor in the vehicle.
2. Remove the tape or plug from the service port (2).

CAUTION: A valve core that is not fully seated in the A/C service port can
result in damage to the valve during refrigerant system evacuation
and charge. Such damage may result in a loss of system
refrigerant while uncoupling the charge adapters.

3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s).

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this
caution will result in serious A/C compressor damage.

4. Evacuate and charge the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.

NOTE: The protective cap helps aid in service port sealing and helps protect
the refrigerant system from contamination. Remember to always
reinstall the protective cap onto the service port when refrigerant
system service is complete.

5. Install the protective cap (1) onto the service port.

DRIER, A/C RECEIVER

Description

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DESCRIPTION

The A/C receiver/drier is part of the high-side of the A/C system. The A/C receiver/drier stores any unused
refrigerant, filters and helps remove moisture from the refrigerant, and retains any refrigerant vapor that may
leave the A/C condenser, until it becomes a liquid. The A/C receiver/drier is located on the right front frame
rail or on the A/C condenser, depending on engine and transaxle application.

Fig. 151: Identifying A/C Receiver/Drier, A/C Liquid Line & Right Front Frame Rail
Courtesy of CHRYSLER LLC

On all early model vehicles, the A/C receiver/drier (1) is mounted to the right front frame rail (4). On late
model vehicles, only the gasoline and diesel engine models with manual or Constant Velocity Transaxle
(CVT) have the A/C receiver/drier mounted to the frame rail. Late model gasoline engine equipped vehicles
with automatic transaxle have the A/C receiver/drier mounted to the A/C condenser.

CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C
compressor has occurred. See Heating and Air
Conditioning/Plumbing/DRIER, A/C Receiver - Removal. Failure to
replace the A/C receiver drier can cause serious damage to the
replacement A/C compressor.

The A/C liquid line (2) and jumper line (3) are attached to the A/C receiver/drier and the connections are
sealed by use of metal gaskets with rubber O-ring seals.

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Fig. 152: A/C Condenser

Courtesy of CHRYSLER LLC

On late model gasoline engine equipped vehicles with automatic transaxle, the A/C receiver/drier (1) is
mounted to the left end of the A/C condenser (2) and must be replaced with the condenser as an assembly.

CAUTION: On late model year gasoline engine equipped vehicles with automatic
transaxle, the A/C condenser/receiver/drier assembly must be replaced
if an internal failure of the A/C compressor has occurred. Failure to
replace the A/C condenser/receiver/drier assembly can cause serious
damage to the replacement A/C compressor. See Heating and Air
Conditioning/Plumbing/CONDENSER, A/C - Removal.

Operation

OPERATION

The A/C receiver/drier performs a filtering action to prevent foreign material in the refrigerant from
contaminating the A/C expansion valve. Refrigerant enters the A/C receiver/drier as a high-pressure, low
temperature liquid. Desiccant inside the A/C receiver/drier absorbs any moisture which may have entered
and become trapped within the refrigerant system. In addition, during periods of high demand operation of
the A/C system, the A/C receiver/drier acts as a reservoir to store surplus refrigerant.

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

The A/C receiver/drier has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals
used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-
ring seals and gaskets must be replaced whenever the A/C receiver/drier is disconnected.

The A/C receiver/drier cannot be repaired and must be replaced if leaking or damaged, or if an internal
failure of the A/C compressor has occurred.

Removal

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REMOVAL

WARNING: Review safety precautions and warnings in this service information

before performing this procedure. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in serious or fatal injury.

NOTE: LHD model shown. RHD model similar.

Fig. 153: Identifying A/C Receiver/Drier, Right Front Frame Rail & Retaining Bolts
Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Raise and support the vehicle.
4. Remove the right front wheel. Refer to Tires and Wheels - Removal .
5. Position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
6. Remove the nut (2) that secures the A/C refrigerant line (1) to the A/C receiver/drier (5).
7. Disconnect the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring seal
and gasket.
8. Remove the bolt (3) that secures the liquid jumper line (4) to the A/C receiver/drier.
9. Disconnect the jumper line from the A/C receiver/drier and remove and discard the O-ring seal and
gasket.
10. Remove the A/C suction line from the plastic bracket located on the A/C receiver/drier.
11. Remove the two bolts (6) that secure the A/C receiver/drier to the right front frame rail (7) and
remove the receiver/drier.
12. Install plugs in, or tape over the opened refrigerant line fittings and receiver/drier ports.

Installation

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INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

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

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

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

NOTE: LHD model shown. RHD model similar.

Fig. 154: Identifying A/C Receiver/Drier, Right Front Frame Rail & Retaining Bolts
Courtesy of CHRYSLER LLC

1. Position the A/C receiver/drier (5) to the right front frame rail (7) and install the retaining bolts (6).
Tighten the bolts to 15 N.m (11 ft. lbs.).
2. Install the A/C suction line into the plastic bracket on the A/C receiver/drier.
3. Remove the tape or plugs from the refrigerant line fittings and the receiver/drier ports.
4. Lubricate new O-ring seals and gaskets with clean refrigerant oil and install them onto the refrigerant
line fittings. Use only the specified O-ring seals and gaskets as they are made of a special material for
the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the

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vehicle.
5. Connect the A/C liquid line (1) to the A/C receiver/drier and install the retaining nut (2). Tighten the
nut to 5 N.m (44 in. lbs.).
6. Connect the liquid jumper line (4) to the A/C receiver/drier and install the retaining bolt (3). Tighten
the bolt to 5 N.m (44 in. lbs.).
7. Reposition the right front wheel house splash shield to the body. Refer to Body/Exterior/SHIELD,
Splash - Installation .
8. Install the right front wheel. Refer to Tires and Wheels - Installation .
9. Lower the vehicle.
10. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system when equipped with the
Denso 6SEU16 variable displacement compressor. Failure to
follow this caution will result in serious A/C compressor damage.

11. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure
12. If the A/C receiver drier is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the
refrigerant system. When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant system. See Heating
and Air Conditioning/Plumbing/OIL, Refrigerant - Standard Procedure. Use only refrigerant oil
of the type recommended for the A/C compressor in the vehicle.
13. Charge the A/C system. See Heating and Air Conditioning/Plumbing - Standard Procedure.

EVAPORATOR, A/C

Description

DESCRIPTION

Fig. 155: Evaporator Components

Courtesy of CHRYSLER LLC

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NOTE: LHD model shown. RHD model similar.

The A/C evaporator (1) for the heating-A/C system is mounted in the HVAC housing, which is located
behind the instrument panel. The A/C evaporator and its insulator (2) are positioned within the HVAC
housing so that all air entering the housing must pass over the evaporator fins before it is distributed through
the heating-A/C system ducts and outlets.

A tapping block (3) and O-ring seals (4) are used to connect and seal the A/C evaporator tubes (5) to the
A/C expansion valve.

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

Operation

OPERATION

Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses
on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to
boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.

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

The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the
connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals
must be replaced whenever the A/C expansion valve is removed from the A/C evaporator.

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

Removal

REMOVAL

NOTE: The HVAC housing assembly must be removed from the vehicle and the air
distribution housing removed for service of the A/C evaporator.

NOTE: LHD model shown in illustrations. RHD model similar.

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Fig. 156: HVAC Housing

Courtesy of CHRYSLER LLC

1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.
2. Remove the two bolts that secure the A/C expansion valve (1) to the A/C evaporator and remove the
valve. See Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Removal.
3. Remove and discard the O-ring seals and install plugs in, or tape over the opened expansion valve and
evaporator tube ports.

NOTE: If the foam seal or plastic flange is deformed or damaged, it must be

replaced.

4. Remove the foam seal and plastic flange (2) from the front of the two halves of the HVAC housing
(3). Carefully release the four retaining tabs located at the back of the flange and pull the flange off of
the evaporator tubes. If the seal or flange is deformed or damaged, it must be replaced.
5. Remove any residual sealer from the flange area at the front of the two halves of the HVAC housing.

Fig. 157: HVAC Housing, Air Inlet Housing & Air Distribution Housing

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Courtesy of CHRYSLER LLC

6. Remove the air distribution housing (2) from the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Removal.

Fig. 158: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

7. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator
temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.

Fig. 159: A/C Evaporator & HVAC Housing

Courtesy of CHRYSLER LLC

NOTE: If the foam insulator around the A/C evaporator is deformed or

damaged, the insulator must be replaced.

8. Carefully tip the top of the A/C evaporator (1) rearward and remove the evaporator from the back of
the HVAC housing (2).

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Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

NOTE: If only the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid
ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of
the type recommended for the A/C compressor in the vehicle.

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

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 160: A/C Evaporator & HVAC Housing

Courtesy of CHRYSLER LLC

NOTE: Make sure that the foam insulator is properly positioned around the A/C
evaporator and in the HVAC housing.

1. Carefully install the A/C evaporator (1) into the HVAC housing (2).

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Fig. 161: Evaporator Temperature Sensor

Courtesy of CHRYSLER LLC

2. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure
the retaining tabs (3) are fully engaged to the housing.

Fig. 162: HVAC Housing, Air Inlet Housing & Air Distribution Housing
Courtesy of CHRYSLER LLC

3. Install the air distribution housing (2) onto the HVAC housing (1). See Heating and Air
Conditioning/Distribution/HOUSING, HVAC - Installation.

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Fig. 163: HVAC Housing

Courtesy of CHRYSLER LLC

4. Install a bead of silicone sealer around the flange area at the front of the HVAC housing (3).

NOTE: If the foam seal or plastic flange is deformed or damaged, it must be

replaced.

5. Install the plastic flange and foam seal (2) over the evaporator tubes and onto the front of the HVAC
housing. Make sure the four flange retaining tabs are fully engaged to the housing.
6. Remove the tape or plugs from the expansion valve and evaporator ports.
7. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings.
Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use
only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Install the A/C expansion valve (1) and the two retaining bolts. Tighten the bolts to 11 N.m (97 in.
lbs.). See Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Installation.
9. Install the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC -
Installation.
10. If the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the
refrigerant system. When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant system. See Heating
and Air Conditioning/Plumbing/OIL, Refrigerant - Standard Procedure. Use only refrigerant oil
of the type recommended for the A/C compressor in the vehicle.

LINE, A/C DISCHARGE

Removal

REMOVAL

WARNING: Review safety precautions and warnings in this service information

before performing this procedure. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions

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may result in possible serious or fatal injury.

CAUTION: If replacing the A/C discharge line, be sure to use the discharge line
designed for the A/C compressor in the vehicle. Failure to use the
correct A/C discharge line may result in possible discharge line or
compressor damage.

NOTE: It is not necessary to remove the front fascia for A/C discharge line service.

Fig. 164: A/C Discharge Line-Compressor

Courtesy of CHRYSLER LLC

NOTE: Typical engine shown.

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. On gasoline engine equipped models, raise and support the vehicle.
4. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3).
5. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal
and gasket.
6. Install plugs in, or tape over the opened discharge line fitting and the compressor port.

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Fig. 165: A/C Discharge Line-Condenser

Courtesy of CHRYSLER LLC

7. On gasoline engine equipped models, partially lower the vehicle.

8. On all models remove the upper radiator closure panel and carefully pull the top of the fascia forward
to gain access to the A/C discharge line (3). Refer to Body/Exterior/PANEL, Closure - Removal .
9. Reach down through the opening between the radiator and the front fascia and disconnect the wire
harness connector (1) from the A/C pressure transducer (2).
10. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4).
11. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal
and gasket.
12. Install plugs in, or tape over the discharge line fitting and the condenser port.
13. If necessary, remove the A/C pressure transducer from the A/C discharge line.

Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

CAUTION: If replacing the A/C discharge line, be sure to use the discharge line
designed for the A/C compressor in the vehicle. Failure to use the
correct A/C discharge line may result in possible discharge line or
compressor damage.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

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

Fig. 166: A/C Discharge Line-Condenser

Courtesy of CHRYSLER LLC

1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C
pressure transducer securely.
2. Position the A/C discharge line into the engine compartment.
3. Remove the tape or plugs from the discharge line fitting and the condenser port.
4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the
discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Reach down through the opening between the radiator and the front fascia and connect the A/C
discharge line to the A/C condenser (4).
6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 N.m
(44 in. lbs.).
7. Connect the wire harness connector (1) to the A/C pressure transducer.
8. Install the upper radiator closure panel. Refer to Body/Exterior/PANEL, Closure - Installation .

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Fig. 167: A/C Discharge Line-Compressor

Courtesy of CHRYSLER LLC

NOTE: Typical engine shown.

9. On gasoline engine equipped models, raise and support the vehicle.

10. Remove the tape or plugs from the discharge line fitting and the compressor port.
11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the
discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
12. Connect the A/C discharge line (2) to the A/C compressor (3).
13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20
N.m (15 ft. lbs.).
14. On gasoline engine equipped models, lower the vehicle.
15. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system when equipped with the
Denso 6SEU16 variable displacement compressor. Failure to
follow this caution will result in serious A/C compressor damage.

16. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
17. Adjust the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.
18. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.

LINE, A/C LIQUID

Removal

REMOVAL

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

WARNING: Review safety precautions and warnings in this service information

before performing this procedure. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

NOTE: LHD model shown in illustrations. RHD model similar.

FRONT JUMPER LINE

Fig. 168: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Raise and support the vehicle.
4. Remove the right front wheel. Refer to Tires and Wheels - Removal .
5. Position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
6. Remove the bolt (1) that secures the liquid jumper line (2) to the A/C receiver/drier (3).
7. Disconnect the jumper line from the A/C receiver/drier and remove and discard the O-ring seal and
gasket.

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 169: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

8. Remove the nut (1) that secures the liquid jumper line (2) to the A/C condenser (3)
9. Disconnect the jumper line from the A/C condenser and remove and discard the O-ring seal and
gasket.
10. Install plugs in, or tape over the opened jumper line fittings and the receiver/drier and condenser ports.

LIQUID AND SUCTION LINE ASSEMBLY

NOTE: The A/C liquid line is serviced as an assembly with the rear portion of the
A/C suction line.

Fig. 170: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Raise and support the vehicle.
4. Remove the right front wheel. Refer to Tires and Wheels - Removal .
5. Position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
6. Remove the nut (3) that secures the front portion of the A/C suction line (4) to the rear portion of the
A/C suction line (2).
7. Disconnect the A/C suction lines and remove and discard the O-ring seal and gasket.
8. On all models, except late model year vehicles equipped with a gasoline engine and four speed
automatic transaxle;
a. disconnect the A/C suction line from the plastic bracket located on the A/C receiver/drier (6).
b. remove the nut (5) that secures the A/C liquid line (1) to the A/C receiver/drier.
c. disconnect the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring
seal and gasket.

Fig. 171: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

9. On late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the A/C suction line bracket from the frame rail.
b. remove the nut (1) that secures the A/C liquid line (2) to the A/C condenser (3).
c. disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal
and gasket.

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 172: Heat Shield

Courtesy of CHRYSLER LLC

10. On all models, partially lower the vehicle.

11. Remove the nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the
engine compartment and remove the heat shield.

Fig. 173: A/C Liquid & Suction Line Assembly

Courtesy of CHRYSLER LLC

NOTE: It is only necessary to position the windshield washer reservoir, power

steering fluid reservoir and engine coolant reservoir out of the way.
Draining of the washer fluid, power steering fluid and engine coolant is
not required.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

12. Position the windshield washer reservoir, power steering reservoir and the engine coolant reservoir
out of the way.
13. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower
(5).
14. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to
the dash panel and position the vacuum line out of the way.
15. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C expansion
valve (6).
16. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and
discard the O-ring seals.
17. Remove the A/C liquid and suction line assembly from the engine compartment.
18. Install plugs in, or tape over all the opened refrigerant line fittings, expansion valve and receiver/drier
or condenser ports, as required.

Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

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

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

NOTE: LHD model shown in illustrations. RHD model similar.

FRONT JUMPER LINE

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 174: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

1. Remove the tape or plugs from the jumper line fitting and the condenser port.
2. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the
jumper line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Connect the liquid jumper line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten
the nut to 5 N.m (44 in. lbs.).

Fig. 175: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

4. Remove the tape or plug from the jumper line fitting and receiver/drier port.
5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the
jumper line fitting. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

6. Connect the liquid jumper line (2) to the A/C receiver/drier (3) and install the retaining bolt (3).
Tighten the bolt to 5 N.m (44 in. lbs.).
7. Reposition the right front wheel house splash shield to the body. Refer to Body/Exterior/SHIELD,
Splash - Installation .
8. install the right front wheel. Refer to Tires and Wheels - Installation .
9. Lower the vehicle.
10. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this
caution will result in serious A/C compressor damage.

11. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
12. Adjust the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.
13. Charge the A/C system. See Heating and Air Conditioning/Plumbing - Standard Procedure.

LIQUID AND SUCTION LINE ASSEMBLY

NOTE: The A/C liquid line is serviced as an assembly with the rear portion of the
A/C suction line.

Fig. 176: A/C Liquid & Suction Line Assembly

Courtesy of CHRYSLER LLC

1. Position the A/C liquid and suction line assembly (4) into the engine compartment.

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

2. Remove the tape or plugs from the refrigerant line fittings and the expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the liquid and
suction line fittings. Use only the specified O-ring seals as they are made of special materials
compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
4. Connect the A/C liquid and suction line assembly to the A/C expansion valve (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C expansion valve.
Tighten the bolt to 20 N.m (15 ft. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the
dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten
the nut to 4.5 N.m (40 in. lbs.).
8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant
reservoir.

Fig. 177: Heat Shield

Courtesy of CHRYSLER LLC

9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in.
lbs.).
11. On all models, raise and support the vehicle.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 178: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

12. On late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the condenser port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto
the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
c. connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1).
Tighten the nut to 5 N.m (44 in. lbs.).

Fig. 179: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

13. Remove the tape or plugs from the suction line fittings.
14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

suction line fittings. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
15. Connect the front portion of the A/C suction line (4) to the rear portion of the A/C suction line (2) and
install the retaining nut (3). Tighten the nut to 5 N.m (44 in. lbs.).
16. Install the A/C suction line into the plastic bracket on the A/C receiver/drier (6), or install the suction
line retaining bracket to the right front frame rail, depending on engine and transaxle application.
17. On all models, except late model year vehicles equipped with a gasoline engine and four speed
automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the receiver/drier port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto
the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
c. connect the A/C liquid line (1) to the A/C receiver/drier (6) and install the retaining nut (5).
Tighten the nut to 5 N.m (44 in. lbs.).
18. On all models;
a. reposition the right front wheel house splash shield to the body. Refer to
Body/Exterior/SHIELD, Splash - Installation .
b. install the right front wheel. Refer to Tires and Wheels - Installation .
c. Lower the vehicle.
19. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this
caution will result in serious A/C compressor damage.

20. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
21. Adjust the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.
22. Charge the A/C system. See Heating and Air Conditioning/Plumbing - Standard Procedure.

LINE, A/C SUCTION

Removal

REMOVAL

WARNING: Review safety precautions and warnings in this service information

before performing this procedure. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in possible serious or fatal injury.

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

NOTE: LHD model shown in illustrations. RHD model similar.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

FRONT SUCTION LINE

Fig. 180: Lower Suction Line-Compressor

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. On diesel engine models, remove the bolt that secures the right front impact sensor to the radiator
support and position the sensor out of the way for clearance. Refer to Restraints/SENSOR, Impact -
Removal .
4. On gasoline engine models;
a. raise and support the vehicle.
b. remove the right front wheel. Refer to Tires and Wheels - Removal .
c. position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
d. remove the drive belt splash shield to gain access to the A/C suction line (2).
5. Remove the nut (1) that secures the A/C suction line to the A/C compressor (3).
6. Disconnect the A/C suction line from the A/C compressor.

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2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 181: Identifying A/C Suction Line & Retaining Nut

Courtesy of CHRYSLER LLC

7. On diesel engine models;

a. raise and support the vehicle.
b. remove the right front wheel. Refer to Tires and Wheels - Removal .
c. position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
8. Remove the nut (2) that secures the front portion of the A/C suction line (3) to the rear portion of the
A/C suction line (1) and disconnect the lines.
9. Remove the front portion of the A/C suction line from the engine compartment and remove and
discard the O-ring seals and gaskets.
10. Install plugs in, or tape over the opened suction line fittings and compressor port.

SUCTION AND LIQUID LINE ASSEMBLY

NOTE: The rear portion of the A/C suction line is serviced as an assembly with the
A/C liquid line.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 182: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Raise and support the vehicle.
4. Remove the right front wheel. Refer to Tires and Wheels - Removal .
5. Position the front portion of the right front wheelhouse splash shield out of the way. Refer to
Body/Exterior/SHIELD, Splash - Removal .
6. Remove the nut (3) that secures the front portion of the A/C suction line (4) to the rear portion of the
A/C suction line (2).
7. Disconnect the A/C suction lines and remove and discard the O-ring seal and gasket.
8. On all models, except late model year vehicles equipped with a gasoline engine and four speed
automatic transaxle;
a. disconnect the A/C suction line from the plastic bracket located on the A/C receiver/drier (6).
b. remove the nut (5) that secures the A/C liquid line (1) to the A/C receiver/drier.
c. disconnect the A/C liquid line from the A/C receiver/drier and remove and discard the O-ring
seal and gasket.

Fig. 183: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

9. On late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the A/C suction line bracket from the frame rail.
b. remove the nut (1) that secures the A/C liquid line (2) to the A/C condenser (3).
c. disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal
and gasket.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 184: Heat Shield

Courtesy of CHRYSLER LLC

10. On all models, partially lower the vehicle.

11. Remove the nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the
engine compartment and remove the heat shield.

Fig. 185: A/C Liquid & Suction Line Assembly

Courtesy of CHRYSLER LLC

NOTE: It is only necessary to position the windshield washer reservoir, power

steering fluid reservoir and engine coolant reservoir out of the way.
Draining of the washer fluid, power steering fluid and engine coolant is
not required.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

12. Position the windshield washer reservoir, power steering reservoir and the engine coolant reservoir
out of the way.
13. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower
(5).
14. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to
the dash panel and position the vacuum line out of the way.
15. Remove the bolt (3) that secures the A/C suction and liquid line assembly (4) to the A/C expansion
valve (6).
16. Disconnect the A/C suction and liquid line assembly from the A/C expansion valve and remove and
discard the O-ring seals.
17. Remove the A/C suction and liquid line assembly from the engine compartment.
18. Install plugs in, or tape over all the opened refrigerant line fittings, expansion valve and receiver/drier
or condenser ports, as required.

Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

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

NOTE: Gasoline engine model shown in illustrations. Diesel engine model similar.

NOTE: LHD model shown in illustrations. RHD model similar.

FRONT SUCTION LINE

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 186: Identifying A/C Suction Line & Retaining Nut

Courtesy of CHRYSLER LLC

1. Remove the tape or plugs from the suction line fittings and compressor port.
2. Lubricate a new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto
the suction line fittings. Use only the specified O-ring as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
3. Position the front portion of the A/C suction line (3) into the engine compartment.
4. Connect the front portion of the A/C suction line to the rear portion of the A/C suction line (1) and
install the retaining nut (2). Tighten the nut to 5 N.m (44 in. lbs.).
5. On diesel engine models;
a. reposition the right front wheel house splash shield to the body. Refer to
Body/Exterior/SHIELD, Splash - Installation .
b. install the right front wheel. Refer to Tires and Wheels - Installation .
c. Lower the vehicle.

Fig. 187: Lower Suction Line-Compressor

Courtesy of CHRYSLER LLC

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

6. Connect the A/C suction line (2) to the A/C compressor (3).
7. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 N.m
(15 ft. lbs.).
8. On gasoline engine models;
a. install the drive belt splash shield.
b. reposition the right front wheel house splash shield to the body. Refer to
Body/Exterior/SHIELD, Splash - Installation .
c. install the right front wheel. Refer to Tires and Wheels - Installation .
d. Lower the vehicle.
9. On diesel engine models, install the right front impact sensor onto the radiator support. Refer to
Restraints/SENSOR, Impact - Installation .
10. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this
caution will result in serious A/C compressor damage.

11. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
12. Adjust the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.
13. Charge the A/C system. See Heating and Air Conditioning/Plumbing - Standard Procedure.

SUCTION AND LIQUID LINE ASSEMBLY

NOTE: The rear portion of the A/C suction line is serviced as an assembly with the
A/C liquid line.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 188: A/C Liquid & Suction Line Assembly

Courtesy of CHRYSLER LLC

1. Position the A/C suction and liquid line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the expansion valve ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the liquid and
suction line fittings. Use only the specified O-ring seals as they are made of special materials
compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
4. Connect the A/C suction and liquid line assembly to the A/C expansion valve (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C expansion valve.
Tighten the bolt to 20 N.m (15 ft. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the
dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten
the nut to 4.5 N.m (40 in. lbs.).
8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant
reservoir.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

Fig. 189: Heat Shield

Courtesy of CHRYSLER LLC

9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in.
lbs.).
11. On all models, raise and support the vehicle.

Fig. 190: Liquid Line To Condenser

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with front fascia removed for clarity.

12. On late model year vehicles equipped with a gasoline engine and four speed automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the condenser port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto
the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

c. connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1).
Tighten the nut to 5 N.m (44 in. lbs.).

Fig. 191: Identifying A/C Receiver/Drier

Courtesy of CHRYSLER LLC

13. Remove the tape or plugs from the suction line fittings.
14. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the
suction line fittings. Use only the specified O-ring as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
15. Connect the front portion of the A/C suction line (4) to the rear portion of the A/C suction line (2) and
install the retaining nut (3). Tighten the nut to 5 N.m (44 in. lbs.).
16. Install the A/C suction line into the plastic bracket on the A/C receiver/drier (6), or install the suction
line retaining bracket to the right front frame rail, depending on engine and transaxle application.
17. On all models, except late model year vehicles equipped with a gasoline engine and four speed
automatic transaxle;
a. remove the tape or plugs from the liquid line fitting and the receiver/drier port.
b. lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto
the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-
134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
c. connect the A/C liquid line (1) to the A/C receiver/drier (6) and install the retaining nut (5).
Tighten the nut to 5 N.m (44 in. lbs.).
18. On all models;
a. reposition the right front wheel house splash shield to the body. Refer to
Body/Exterior/SHIELD, Splash - Installation .
b. install the right front wheel. Refer to Tires and Wheels - Installation .
c. Lower the vehicle.
19. Reconnect the negative battery cable.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a
vacuum present within the A/C system. Failure to follow this

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caution will result in serious A/C compressor damage.

20. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
21. Adjust the refrigerant oil level. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.
22. Charge the A/C system. See Heating and Air Conditioning/Plumbing - Standard Procedure.

OIL, REFRIGERANT

Standard Procedure

REFRIGERANT OIL LEVEL

When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant
oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C
compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator, A/C
condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil.

It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper
lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too
much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air
temperatures.

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. Drain the refrigerant oil from the A/C compressor
using the procedures described below. Failure to properly drain the
refrigerant oil from the A/C compressor can prevent the A/C system
from operating as designed and cause serious compressor damage.

CAUTION: ND-8 PAG refrigerant oil is used in the A/C system. Only refrigerant oil
of the same type should be used to service this R-134a A/C system. Do
not use any other refrigerant oil. The refrigerant oil container should be
kept tightly capped until it is ready for use and then tightly capped after
use to prevent contamination from moisture and dirt. Refrigerant oil will
quickly absorb any moisture it comes in contact with, therefore, special
effort must be used to keep all R-134a system components moisture-
free. Moisture in the refrigerant oil is very difficult to remove and will
cause a reliability problem with the A/C compressor.

NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil
being removed during the recovery process. This amount of refrigerant oil
should always be added back into the refrigerant system. Refer to the
reclaim/recycling equipment manufacturers instructions.

It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has
been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a
refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1
fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak.

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Refrigerant oil must be added when an A/C condenser, A/C receiver/drier or A/C evaporator is replaced. See
REFRIGERANT OIL CAPACITIES.

The refrigerant oil level in a new A/C compressor must first be adjusted to the proper amount prior to
compressor installation. See the COMPRESSOR OIL DRAIN PROCEDURES.

REFRIGERANT OIL CAPACITIES

Component ml. oz.
Total System Fill 100 3.4
A/C Receiver/Drier 30 1.0
A/C Condenser 10 0.3
A/C Evaporator 10 0.3
50 1.7
A/C Compressor - Denso 6SEU16
Variable Displacement (See COMPRESSOR OIL DRAIN PROCEDURE -
VARIABLE DISPLACEMENT)
Drain and measure the oil from the old compressor (See
A/C Compressor - Denso 10SRE18
COMPRESSOR OIL DRAIN PROCEDURE - FIXED
Fixed Displacement
DISPLACEMENT).

COMPRESSOR OIL DRAIN PROCEDURE - VARIABLE DISPLACEMENT

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. The refrigerant oil in the Denso 6SEU16 A/C
compressor can only be drained using the procedure described below.
Failure to properly drain the refrigerant oil from the A/C compressor
can prevent the A/C system from operating as designed and cause
serious compressor damage.

If the Denso 6SEU16 A/C compressor is being replaced, some refrigerant oil must first be drained from the
replacement A/C compressor. The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the
factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from the replacement 6SEU16 compressor. Use the
following procedure to drain and measure refrigerant oil from the 6SEU16 A/C compressor.

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Fig. 192: 6SEU16 Compressor Drain Plug

Courtesy of CHRYSLER LLC

1. Place the replacement A/C compressor (2) on a workbench and remove the drain plug (1).

CAUTION: The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.)
from the factory. Drain 50 milliliters (1.7 oz.) of refrigerant oil from
the new 6SEU16 compressor when replacing only the compressor.

NOTE: When replacing multiple A/C system components, see REFRIGERANT

OIL CAPACITIES to determine how much oil should be removed from

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the replacement A/C compressor (example: new 6SEU16 compressor

and receiver/drier requires 80 ml. (2.7 oz.) of oil to be added to the
system. 100 ml. (3.4 oz.) of oil is in replacement compressor. 100 ml.
(3.4 oz.) minus 80 ml. (2.7 oz.) equals 20 ml. (0.7 oz.) of oil to be drained
from replacement compressor).

2. Position the replacement A/C compressor so that the refrigerant oil can drain out of the drain port into
a suitable clean measured container. Hold the replacement A/C compressor in this position until the
required amount of refrigerant oil is drained from the compressor.

CAUTION: Failure to properly adjust the refrigerant oil level prior to

installation of a replacement compressor can prevent the A/C
system from operating as designed and cause serious
compressor damage.

3. Reinstall the drain plug. Tighten the drain plug securely.

4. Install the replacement A/C compressor onto the engine. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Installation.

COMPRESSOR OIL DRAIN PROCEDURE - FIXED DISPLACEMENT

CAUTION: Be certain to adjust the refrigerant system oil level when replacing an
A/C compressor. Failure to properly drain and measure the refrigerant
oil from the A/C compressor can prevent the A/C system from operating
as designed and cause serious compressor damage.

The Denso 10SRE18 A/C compressor is filled with refrigerant oil from the factory. Use the following
procedure to drain and measure refrigerant oil from the 10SRE18 A/C compressor.

1. Position the original A/C compressor so that the refrigerant oil can drain out of the suction and
discharge ports into a suitable clean measured container. Hold the original A/C compressor in this
position until all of the refrigerant oil is drained from the compressor.
2. Drain all of the refrigerant oil from the replacement A/C compressor into a clean measured container.
3. Refill the replacement A/C compressor with the same amount of refrigerant oil that was drained out of
the original compressor. Use only clean refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

CAUTION: Failure to properly adjust the refrigerant oil level prior to

installation of a replacement compressor can prevent the A/C
system from operating as designed and cause serious
compressor damage.

4. Install the replacement A/C compressor onto the engine. See Heating and Air
Conditioning/Plumbing/COMPRESSOR, A/C - Installation.

REFRIGERANT

Specifications

REFRIGERANT CHARGE CAPACITY

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REFRIGERANT CHARGE CAPACITY

Application Capacity
All models 0.51 kg (1.125 lbs.)

TUBE, CONDENSATION DRAIN

Removal

REMOVAL

Fig. 193: Condensation Drain Tube

Courtesy of CHRYSLER LLC

1. Pull back the floor carpet to gain access to the condensation drain tube (2) located on the left side of
the vehicle at the front right of the foot well. Refer to Body/Interior/CARPET - Removal .
2. Disconnect the condensation drain tube from the bottom of the HVAC housing (1).
3. Remove the condensate drain tube from the rubber grommet (3) in the front floor panel (4).
4. If required, remove the rubber grommet from the floor panel.

Installation

INSTALLATION

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Fig. 194: Condensation Drain Tube

Courtesy of CHRYSLER LLC

1. If removed, install the rubber grommet (3) onto the driver side front floor panel (4). Make sure the
grommet is fully engaged to the floor panel.
2. Connect the condensation drain tube (2) onto the drain port located on the bottom of the HVAC
housing (1).
3. Install the condensation drain tube into the rubber grommet.
4. Reinstall the floor carpet. Refer to Body/Interior/CARPET - Installation .

VALVE, A/C EXPANSION

Description

DESCRIPTION

Fig. 195: A/C Expansion Valve

Courtesy of CHRYSLER LLC

The A/C expansion valve controls the amount of refrigerant entering the A/C evaporator. The A/C

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expansion valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve
type body (1) with an inlet port (2), outlet port (3) and an integral thermal sensor (4).

The A/C expansion valve is located in the engine compartment at the dash panel, between the A/C
refrigerant lines and the A/C evaporator.

Operation

OPERATION

The A/C expansion valve controls the high-pressure, low temperature liquid refrigerant from the A/C liquid
line and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the A/C
evaporator. A mechanical sensor in the A/C expansion valve monitors the temperature and pressure of the
refrigerant leaving the A/C evaporator through the A/C suction line, and adjusts the orifice size at the liquid
line port to let the proper amount of refrigerant into the evaporator to meet the vehicle A/C cooling
requirements. Controlling the refrigerant flow through the A/C evaporator ensures that none of the
refrigerant leaving the A/C evaporator is still in a liquid state, which could damage the A/C compressor.

NOTE: Replacement of the refrigerant line O-ring seals is required anytime a

refrigerant line is disconnected from the expansion valve, or if the expansion
valve is removed. Failure to replace the rubber O-ring seals may result in a
refrigerant system leak.

The A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if
inoperative or damaged.

Diagnosis and Testing

A/C EXPANSION VALVE

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in serious or fatal injury.

NOTE: The A/C expansion valve should only be tested following testing of the A/C
compressor.

NOTE: Liquid CO2 is required to test the A/C expansion valve. This material is
available from most welding supply facilities. Liquid CO2 is also available
from companies which service and sell fire extinguishers.

When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27°C (70°
to 85°F). To test the expansion valve:

1. Connect a charging station or manifold gauge set to the refrigerant system service ports. See Heating
and Air Conditioning/Plumbing - Standard Procedure.
2. Verify the refrigerant system charge level by conducting the A/C Performance Test. See Heating and
Air Conditioning - Diagnosis and Testing.

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3. Close all doors, windows and vents to the passenger compartment.

4. Set the A/C-heater controls so that the A/C compressor is operating, the temperature control is in the
highest temperature position, the mode-air doors is directing air output to the floor and the blower
motor operating is operating at the highest speed.
5. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow
the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the
A/C evaporator.
6. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 827 kPa to 1655
kPa (120 psi to 240 psi). The suction (low pressure) gauge should read 207 kPa to 345 kPa (30 psi to
50 psi). If OK, go to 7. If not OK, replace the inoperative A/C expansion valve.

WARNING: Protect the skin and eyes from exposure to liquid CO2 or
personal injury can result.

7. If the suction (low pressure) gauge reads within the specified range, freeze the A/C expansion valve
for 30 seconds using liquid CO2 or another suitable super-cold material. Do not spray R-134a or R-
12 refrigerant on the A/C expansion valve for this test. The suction (low pressure) gauge reading
should drop by 69 kPa (10 psi). If OK, go to 8. If not OK, replace the inoperative A/C expansion
valve. See Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Removal.
8. Allow the A/C expansion valve to thaw. The suction (low pressure) gauge reading should stabilize at
207 kPa to 345 kPa (30 psi to 50 psi). If not OK, replace the inoperative A/C expansion valve. See
Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Removal.

Removal

REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow these instructions
may result in serious or fatal injury.

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Fig. 196: Heat Shield

Courtesy of CHRYSLER LLC

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing -
Standard Procedure.
3. Remove the nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the
engine compartment and remove the heat shield.

Fig. 197: Refrigerant Lines To Evaporator Bolt

Courtesy of CHRYSLER LLC

4. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C expansion
valve (3).
5. Disconnect the A/C liquid and suction line assembly from the A/C expansion valve and remove and
discard the O-ring seals.

Fig. 198: Front Expansion Valve

Courtesy of CHRYSLER LLC

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6. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block
(3).
7. Remove the A/C expansion valve from the tapping block and remove and discard the O-ring seals
8. Install plugs in, or tape over the opened refrigerant fittings and all expansion valve and evaporator
tube ports.

Installation

INSTALLATION

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C
refrigerant system. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure. Failure to properly adjust the
refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant
system. See Heating and Air Conditioning/Plumbing/OIL, Refrigerant -
Standard Procedure.

NOTE: Replacement of the refrigerant line O-ring seals is required anytime a

refrigerant line is disconnected from the expansion valve, or if the expansion
valve is removed. Failure to replace the rubber O-ring seals may result in a
refrigerant system leak.

NOTE: LHD model shown in illustrations. RHD model similar.

Fig. 199: Front Expansion Valve

Courtesy of CHRYSLER LLC

1. Remove the tape or plugs from the opened refrigerant line fittings and all expansion valve and
evaporator ports.

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2. Lubricate new O-ring seals with clean refrigerant oil and install them onto the refrigerant line and
evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for
the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3)
4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block.
Tighten the bolts to 11 N.m (97 in. lbs.).

Fig. 200: Refrigerant Lines To Evaporator Bolt

Courtesy of CHRYSLER LLC

5. Connect the A/C liquid and suction line assembly (2) to the A/C expansion valve (3).
6. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C expansion valve.
Tighten the bolt to 25 N.m (18 ft. lbs.).

Fig. 201: Heat Shield

Courtesy of CHRYSLER LLC

7. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.

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8. Install the nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in. lbs.).
9. Reconnect the negative battery cable.
10. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.
11. Adjust the refrigerant oil level, if required. See Heating and Air Conditioning/Plumbing/OIL,
Refrigerant - Standard Procedure.
12. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard
Procedure.

CABIN HEATER
RELAY, HEATER UNIT

Description

DESCRIPTION

Fig. 202: Standard ISO-Type Relay

Courtesy of CHRYSLER LLC

Two relays (1) are used for the electric Positive Temperature Coefficient (PTC) heater system when
equipped with the 2.2L diesel engine. The relays are International Standards Organization (ISO)-type relays.
Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal
functions and patterns (2). The PTC relays are electromechanical devices that switch fused battery current
directly to the heating elements of the PTC heater unit. The PTC relays are energized by control circuits of
the Totally Integrated Power Module (TIPM).

The two PTC relays are located below the left front fender in the diesel accessory fuse/relay block.

Removal

REMOVAL

NOTE: LHD model shown. RHD model similar.

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Fig. 203: Diesel Accessory Fuse/Relay Block

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with left front fender removed for clarity.

1. Disconnect and isolate the negative battery cable.

2. Remove the left front wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash -
Removal .
3. Open the cover (1) of the diesel accessory fuse/relay block (2) located on the left front frame rail (3).
4. Remove the positive temperature coefficient (PTC) relays as necessary from the fuse/relay block.

Installation

INSTALLATION

NOTE: LHD model shown. RHD model similar.

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Fig. 204: Diesel Accessory Fuse/Relay Block

Courtesy of CHRYSLER LLC

NOTE: Illustration shown with left front fender removed for clarity.

1. Position the positive temperature coefficient (PTC) relays as necessary into the proper receptacle of
the diesel accessory fuse/relay block (2) located on the left front frame rail (3).
2. Align the PTC relay terminals with the terminal cavities in the fuse/relay block and push down firmly
on each relay until the terminals are fully seated.
3. Close the cover (1) of the diesel accessory fuse/relay block.
4. Install the left front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash -
Installation .
5. Reconnect the negative battery cable.

UNIT, HEATER

Description

DESCRIPTION

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Fig. 205: POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

An electric Positive Temperature Coefficient (PTC) heater unit (1) is used on vehicles when equipped with
the 2.2L diesel engine. The PTC heater unit aids in passenger compartment heating by compensating for the
lower engine coolant temperatures produced by the diesel engine. The PTC heater unit is mounted in the
HVAC air distribution housing, downstream of the heater core and is controlled by the diesel Engine
Control Module (ECM) and the Totally Integrated Power Module (TIPM) through two relays in diesel
accessory fuse/relay block located below the left front fender.

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

The PTC heater unit is accessed for service by removing the instrument panel.

Operation

OPERATION

The Positive Temperature Coefficient (PTC) heater unit dissipates 1 kW of electrical power through four
heating bars. The Engine Control Module (ECM) and the Totally Integrated Power module (TIPM) operate
the two relays for the PTC heater unit. The PTC heater unit is split into two "banks". Each bank is driven
separately based on alternator load. This allows for lower in-rush current and optimum battery charging.
After a bank has been turned on, another bank can only be turned on 10 seconds after the previous. On
average, the PTC banks are not switched more than 25 times for each vehicle start. The electrical power
output is between 900-1050 W.

The control system for the PTC heater unit is diagnosed using a scan tool. Prior to replacing a PTC heater

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unit, check for any Diagnostic Trouble Codes (DTCs) related to the ECM, TIPM and heating-A/C system.
See the appropriate Diagnostic Information.

The PTC heater unit cannot be adjusted or repaired and must be replaced if inoperative or damaged.

Diagnosis and Testing

POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER UNIT

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

NOTE: See appropriate Wiring Information for circuit descriptions and diagrams.
Wiring Information includes wiring diagrams, proper wire and connector
repair procedures, further details on wire harness routing and retention, as
well as pin-out and location views for the various wire harness connectors,
splices and grounds.

Prior to replacing the Positive Temperature Coefficient (PTC) heater unit, check for any Diagnostic Trouble
Codes (DTCs) related to the Engine Control Module (ECM), Totally Integrated Power Module (TIPM) and
the heating-A/C system and repair as necessary. See appropriate DTC Based Diagnostics service
information.

1. Disconnect and isolate the negative battery cable.

2. Disconnect the wire harness connector from the PTC heater unit. See Heating and Air
Conditioning/Cabin Heater/UNIT, Heater - Removal.
3. Using an ohmmeter, check for continuity between all of the PTC heater unit terminals. In each case
there should be continuity. If OK, repair the wire harness circuits between the PTC heater unit, PTC
relays and the TIPM. If NOT OK, replace the PTC heater unit.

Removal

REMOVAL

WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. See Heating and Air
Conditioning/Plumbing - Warning and see Heating and Air
Conditioning/Plumbing - Caution. Failure to follow the warnings and
cautions may result in possible serious or fatal injury.

WARNING: Disable the airbag system before attempting any steering wheel,
steering column or instrument panel component diagnosis or service.
Disconnect and isolate the negative battery (ground) cable, then wait
two minutes for the airbag system capacitor to discharge before

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performing further diagnosis or service. This is the only sure way to

disable the airbag system. Failure to follow these instructions may
result in accidental airbag deployment and possible serious or fatal
injury.

Fig. 206: Identifying PTC Heater Connector

Courtesy of CHRYSLER LLC

NOTE: PTC heater shown removed from distribution housing for clarity.

1. Disconnect and isolate the negative battery cable.

2. Remove the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .

NOTE: To disconnect the wire harness connector from the heater unit, pull
downward on the connector lock while pulling the connector away from
the heater unit.

3. Disengage the wire connector lock (2) that secures the wire harness connector (1) to the positive
temperature coefficient (PTC) heater unit (3) located on the left side of the HVAC air distribution
housing and disconnect the connector from the heater.

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Fig. 207: PTC HEATER UNIT

Courtesy of CHRYSLER LLC

NOTE: LHD model shown. RHD model similar.

4. Remove the two screws (1) that secure the PTC heater unit (2) to the left side of the HVAC air
distribution housing (3).
5. Carefully remove the PTC heater unit from the air distribution housing by pulling it straight out of the
housing.

Installation

INSTALLATION

Fig. 208: PTC HEATER UNIT

Courtesy of CHRYSLER LLC

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

NOTE: LHD model shown. RHD model similar.

1. Carefully install the positive temperature coefficient (PTC) heater unit (2) into the left side of the
HVAC air distribution housing (3). Make sure to position the two locator tabs on the end of the heater
unit into the molded locator indentations on the right side of the air distribution housing.
2. Install the two screws (1) that secure the PTC heater unit to the air distribution housing. Tighten the
screws to 1.2 N.m (10 in. lbs.).

Fig. 209: Identifying PTC Heater Connector

Courtesy of CHRYSLER LLC

NOTE: PTC heater shown removed from distribution housing for clarity.

3. Connect the wire harness connector (1) to the PTC heater unit (3) while pushing upward on the
connector lock (2). Make sure the wire harness connector and lock are fully engaged.
4. Install the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Installation .
5. Reconnect the negative battery cable.

A/C PERFORMANCE TEMPERATURE AND PRESSURE

Ambient 21° C (70° 27° C (80° 32° C (90° 38° C (100° 43° C (110°
Temperature F) F) F) F) F)
(Apparent)
Air 6 -15° C (42 7 -18° C (45 9 - 21° C 11 - 22° C 13 - 24° C
Temperature - 59° F) - 64° F) (48 - 69° F) (52 - 72° F) (56 - 75° F)
at Center
Panel Outlet
A/C High Side 1034 - 1896 1207 - 2068 1379 - 2241 1551 - 2413 1724 - 2241
Pressure kPa (150 - kPa (175 - kPa (200 - kPa (225 - kPa (250 -
275 psi) 300 psi) 325 psi) 350 psi) 375 psi)
A/C Low Side 214 - 365 248 - 407 283 - 476 317 - 483 359 - 496 kPa
Pressure kPa (31 - 53 kPa (36 - 59 kPa (41 - 69 kPa (46 - 70 (52 - 72 psi)
psi) psi) psi) psi)

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

A/C SYSTEM DIAGNOSIS

Condition Possible Causes Correction
Equal refrigerant pressures 1. No refrigerant in the 1. See REFRIGERANT SYSTEM
refrigerant system LEAKS. Test the refrigerant system for
leaks. Repair, evacuate and charge the
refrigerant system if required.
2. Inoperative A/C 2. See COMPRESSOR, A/C. Test the
compressor or clutch compressor and/or clutch and replace if
(depending on compressor required.
application)
3. Improperly installed or 3. See TRANSDUCER, A/C Pressure. Test
inoperative A/C pressure the transducer and replace if required.
transducer
4. Inoperative A/C-heater 4. See appropriate DTC Based Diagnostics
control, PCM/ECM service information. Test the A/C-heater
(depending on engine control, PCM/ECM (depending on engine
application), Gateway application), Gateway Module and TIPM and
Module or TIPM replace if required.
Normal refrigerant 1. Excessive refrigerant oil 1. See REFRIGERANT OIL LEVEL.
pressures, but A/C in system Recover the refrigerant from the refrigerant
Performance Test air system and inspect the refrigerant oil
temperatures at center content. Restore the refrigerant oil to the
panel outlet are too high proper level if required.
2. Blend door actuator 2. See ACTUATOR, Blend Door. Inspect
improperly installed or the actuator for proper operation. Replace the
inoperative actuator as required.
3. Blend door inoperative or 3. See HOUSING, HVAC. Inspect the blend
sealing improperly door for proper operation and sealing. Repair
if required.
The low side pressure is 1. Low refrigerant system 1. See REFRIGERANT SYSTEM
normal or slightly low, and charge LEAKS. Test the refrigerant system for
the high side pressure is leaks. Repair, evacuate and charge the
too low refrigerant system if required.
2. Refrigerant flow through 2. See EVAPORATOR, A/C. Replace the
A/C evaporator is restricted restricted A/C evaporator if required.
3. Refrigerant flow through 3. See Plumbing. Inspect the refrigerant
refrigerant lines is restricted lines for kinks, tight bends or improper
routing. Correct the routing or replace the
refrigerant line if required.
4. Inoperative A/C 4. See COMPRESSOR, A/C. Replace the
compressor compressor if required.
The low side pressure is 1. Inoperative radiator 1. See appropriate Cooling system
normal or slightly high, cooling fan information. Test the radiator cooling fan
and the high side pressure and replace if required.
is too high 2. A/C condenser air flow 2. See CONDENSER, A/C. Check the A/C
restricted condenser for damaged fins, foreign objects
obstructing air flow through the condenser
fins and missing or improperly installed air
seals. Clean, repair or replace components as

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required.
3. Refrigerant flow through 3. See DRIER, A/C Receiver. Replace the
the A/C receiver/drier is restricted receiver/drier if required.
restricted
4. Refrigerant flow through 4. See Plumbing. Inspect the refrigerant
refrigerant lines is restricted lines for kinks, tight bends or improper
routing. Correct the routing or replace the
refrigerant line if required.
5. Refrigerant system 5. See REFRIGERANT SYSTEM
overcharged CHARGE. Recover the refrigerant from the
refrigerant system. Charge the refrigerant
system to the proper level if required.
6. Air in the refrigerant 6. See REFRIGERANT SYSTEM
system LEAKS. Test the refrigerant system for
leaks. Repair, evacuate and charge the
refrigerant system if required.
7. Engine overheating 7. See appropriate Cooling system service
information. Test the engine cooling system
and repair if required.
The low side pressure is 1. Accessory drive belt 1. See appropriate Cooling system service
too high, and the high side slipping information. Inspect the accessory drive belt
pressure is too low condition and tension. Replace the accessory
drive belt or tensioner if required.
2. Inoperative A/C 2. See VALVE, A/C Expansion. Test the
expansion valve expansion valve and replace if required.
3. Inoperative A/C 3. See COMPRESSOR, A/C. Replace the
compressor compressor if required.
The low side pressure is 1. Restricted refrigerant 1. See Plumbing. Inspect the refrigerant
too low, and the high side flow through the refrigerant lines for kinks, tight bends or improper
pressure is too high lines routing. Correct the routing or replace the
refrigerant line if required.
2. Restricted refrigerant 2. See VALVE, A/C Expansion. Test the
flow through the A/C expansion valve and replace if required.
expansion valve
3. Restricted refrigerant 3. See CONDENSER, A/C. Replace the
flow through the A/C restricted condenser if required.
condenser

HEATER TEMPERATURE REFERENCE

Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahrenheit Celsius Fahrenheit
16° 60° 54° 130°
21° 70° 56° 132°
27° 80° 57° 134°
32° 90° 58° 136°

A/C CLUTCH COIL SPECIFICATIONS

Coil Resistance Current Draw

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 2010 Dodge Caliber R/T
2010 HVAC Heating & Air Conditioning - Service Information - Caliber

3.6 ± 0.2 ohms 3.2 - 3.3 amps @ 11.5 - 12.5 volts

REFRIGERANT OIL CAPACITIES

Component ml. oz.
Total System Fill 100 3.4
A/C Receiver/Drier 30 1.0
A/C Condenser 10 0.3
A/C Evaporator 10 0.3
50 1.7
A/C Compressor - Denso 6SEU16
Variable Displacement (See COMPRESSOR OIL DRAIN PROCEDURE -
VARIABLE DISPLACEMENT)
Drain and measure the oil from the old compressor (See
A/C Compressor - Denso 10SRE18
COMPRESSOR OIL DRAIN PROCEDURE - FIXED
Fixed Displacement
DISPLACEMENT).

REFRIGERANT CHARGE CAPACITY

Application Capacity
All models 0.51 kg (1.125 lbs.)

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