EPA 10 - US, Canada, Mexico

HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 - ProStar®+, LoneStar®

SERVICE MANUAL
SERVICE MANUAL

HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010

ProStar®+
LoneStar®

0000002221

Navistar, Inc.
June 2013
Revision 1

2701 Navistar Drive, Lisle, IL 60532 USA

© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Summary of Changes

Section / Change
Location

Section 5.3 Illustration and callouts for Figure 28 were changed to show new LPM.
Section 5.17 Illustration and callouts for Figure 54 were changed to show new LPM and wire routing.

LPM installation procedure was revised.

Section 5.24 EVAPORATOR removal and installation procedures were revised.
Section 5.25 Component names were changed to match those used in other sections.

Illustration and callouts for Figure 61 were changed to show new LPM.
Section 5.27 Illustration for Figure 68 was changed to show new LPM.
Section 6.3 Table 6 was updated with corrected values and two new columns containing metric
pressure measurements.
Section 6.5 This section was added to provide a procedure for recalibration of front HVAC system
actuators and doors.
Section 6.6 Existing NOTEs were revised and an additional NOTE was added in three subsections to
perform HVAC Control Head calibration under certain failure mode conditions.

Added HVAC Fault Codes Table.

New step was added to Tables 9, 10, and 11.

Corrected wording in Table 12.

Changed title of Table 13, added a column for Control Voltage to LPM, and changed voltage
values measured at Blower connector contacts A and B.
 TABLE OF CONTENTS

TABLE OF CONTENTS
1. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1. SYSTEM OPERATIONAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Distribution (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Air Distribution (Air Conditioning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Distribution (Heat and Ventilation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Distribution (Defrost). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A/C Refrigerant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear Air Distribution (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Air Distribution (Air Conditioning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear Air Distribution (Heat). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A/C Refrigerant Flow – Sleeper A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2. COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Freeze Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recirculation Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HVAC Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear HVAC Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear HVAC Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Heater Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Temperature Blend Air Door Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear HVAC Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear HVAC Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear HVAC Control Switches (Located in Instrument Panel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3. INTERNAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heater Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Evaporator Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HVAC Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4. UNDER HOOD COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor and Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A/C Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5. HVAC ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Operation Of The HVAC Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Operation of the Rear HVAC Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1. CONTROL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2. BLOWER FAN SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3. TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

i
TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)

3.4. MODE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MAX Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
NORM Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bi-Level Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Vent Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Floor Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mix Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5. DEHUMIDIFYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. SERVICE PROCEDURES FOR R-134A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.1. R-134A SERVICE PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2. RECOMMENDED SERVICE TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3. SEALANT DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4. REFRIGERANT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5. LEAK DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
RHS980C-NAV Leak Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
D440A-NAV and D400A Leak Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ultrasonic Leak Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Refrigerant Leak Testing with Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6. AUTOMATIC MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7. DISCHARGING THE SYSTEM (RECYCLE MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.8. EVACUATING THE SYSTEM (VACUUM MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.9. CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.10. FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Flushing Using the RHS980C-NAV (Recommended Method). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Alternate Method for Flushing (and Purging) the A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.11. OIL FILL GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Separation During Refrigerant Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Excessive Oil Loss Due to Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.12. CHECKING COMPRESSOR OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5. REMOVE AND INSTALL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1. PRESSURE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure Transducer – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure Transducer – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2. LOW PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Low Pressure Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Low Pressure Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.3. FREEZE PROBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Freeze Probe – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Freeze Probe – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.4. HVAC AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
HVAC Air Filter – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
HVAC Air Filter – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5. REFRIGERANT LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Refrigerant Line – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Refrigerant Line – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.6. FILTER-DRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Filter-Drier – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Filter-Drier – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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TABLE OF CONTENTS (CONT.)

5.7. THERMOSTATIC EXPANSION VALVE (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Thermostatic Expansion Valve (TXV) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Thermostatic Expansion Valve (TXV) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.8. FRESH AIR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fresh Air Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fresh Air Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.9. INTERIOR MODULE TRIM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Interior Module Trim Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Interior Module Trim Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.10. FRESH / RECIRCULATE DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fresh/Recirculate Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fresh/Recirculate Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.11. BLEND DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Blend Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Blend Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.12. MODE DOOR ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Mode Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Mode Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.13. FRESH/RECIRCULATE DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fresh/Recirculate Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fresh/Recirculate Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.14. BLEND DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Blend Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Blend Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.15. MODE DOOR GEAR TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Mode Door Gear Train – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Mode Door Gear Train – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.16. RECIRCULATION FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Recirculation Filters – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Recirculation Filters – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.17. LINEAR POWER MODULE (LPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Linear Power Module (LPM) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Linear Power Module (LPM) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.18. BLOWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Blower Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Blower Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.19. HEATER CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Heater Core – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Heater Core – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.20. HVAC CONTROL PANEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
HVAC Control Panel Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
HVAC Control Panel Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.21. COMPRESSOR/CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Compressor/Clutch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Compressor/Clutch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.22. A/C CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.23. HEATER HOSES/LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.24. EVAPORATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Evaporator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Evaporator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.25. BLOWER SCROLL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

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TABLE OF CONTENTS (CONT.)

Blower Scroll Housing – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Blower Scroll Housing – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.26. SPLITTING/SEPARATING BLOWER SCROLL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Splitting/Separating Blower Scroll Housing – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Splitting/Separating Blower Scroll Housing – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.27. INTERIOR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Interior Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Interior Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.28. SPLITTING/SEPARATING INTERIOR MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Splitting/Separating Interior Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Splitting/Separating Interior Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.29. FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.30. HVAC CONTROLS (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
HVAC Controls – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Digital Controls – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Analog Controls – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.31. HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Heater Hose Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Heater Hose Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.32. A/C HOSE ASSEMBLY – TO REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
A/C Hose Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
A/C Hose Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.33. THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Thermostatic Expansion Valve – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Thermostatic Expansion Valve – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.34. BLOWER – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Blower – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Blower – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.35. FILTER ELEMENT – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Filter Element – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Filter Element – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.36. OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Outlet Duct Temperature Sensor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Outlet Duct Temperature Sensor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.37. LINEAR POWER MODULE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Linear Power Module – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Linear Power Module – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.38. BLEND DOOR ACTUATOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Blend Door Actuator – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Blend Door Actuator – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.39. SLEEPER HVAC CONTROLLER – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Sleeper HVAC Controller – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Sleeper HVAC Controller – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.40. HEATER CORE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Heater Core – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Heater Core – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.41. TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Temperature Blend Air Door – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Temperature Blend Air Door – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.42. EVAPORATOR CORE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Evaporator Core – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

iv
 TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)

Evaporator Core – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.43. REAR HVAC UNIT, COMPLETE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Rear HVAC Unit – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Rear HVAC Unit – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

6. DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

6.1. PRELIMINARY CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Check for Obvious Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Refrigerant Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Check for Noncondensable Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.2. PHYSICAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Physical Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Refrigerant Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Low Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Line Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.3. A/C SYSTEM TEST MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.4. ABNORMAL GAUGE READINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Diagnosis of Abnormal Gauge Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.5. FRONT ACTUATOR / DOOR POSITION RECALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Recalibrate Front Actuator / Door Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.6. TROUBLESHOOTING TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
HVAC Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
HVAC Control Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Mode Door Actuator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Blend Door Actuator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fresh/Recirculate Door Actuator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Linear Power Module/Blower Motor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
A/C Compressor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Pressure Transducer (IBB engine) Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Pressure Transducer (I6, V8 engine) Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Freeze Thermistor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Low Pressure Switch Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Auxiliary HVAC Controller Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Auxiliary HVAC (Analog) Control Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Sleeper HVAC (LED) Control Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Rear HVAC Blend Door Actuator Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Rear HVAC Blower Motor/LPM Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Rear HVAC Temperature Sensor Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

7. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.1. TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.2. AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

8. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

8.1. INTERNATIONAL® SERVICING SYSTEM (RHS980C-NAV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.2. RHS980C-NAV TEMPERATURE PROBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

v
TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)

8.3. REFRIGERANT IDENTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

8.4. D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.5. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.6. FLUSH/PURGE FITTING ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.7. TOOLS OBTAINED LOCALLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.8. ELECTRONIC SERVICE TOOL (EST), EZ-TECH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

vi
 1. SAFETY PRECAUTIONS
Refrigerant R-134a is a nonflammable, nonexplosive, and noncorrosive hydrofluorocarbon refrigerant. R-134a
is heavier than air and has a slight ether-type odor. Although R-134a is classified as a safe refrigerant, the
following precautions must be observed to protect the A/C system components and the person working on
the system.

WARNING

Carbon monoxide is a colorless, odorless, and dangerous gas that is present in vehicle
exhaust. To prevent personal injury or death, when it is necessary to operate the engine
during vehicle service in a confined area, always use the proper equipment to vent the
exhaust gasses outside of the work area.

WARNING

To prevent personal injury or death, safety goggles or other adequate eye protection
must be worn when working with refrigerant. The temperature of liquid refrigerant is
-20 degrees F (-29 degrees C). Serious injury or blindness will result from refrigerant
contacting the eyes.

WARNING

To prevent personal injury or death, if the refrigerant should contact the eyes, DO NOT
rub them. Splash the eyes with cold water for at least 15 minutes to gradually get the
temperature above the freezing point. See a doctor immediately.

WARNING

To prevent personal injury or death, wear nonporous gloves. Should liquid refrigerant
come into contact with the skin, remove any contaminated clothing, including shoes;
then treat the injury as though the skin had been frostbitten or frozen. See a doctor
immediately.

WARNING

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

are not exposed to open flame or temperatures above 125 degrees F (51 degrees C). Do
not discard empty refrigerant containers where they are likely to be subjected to the heat
of trash burners, etc.; they may explode, resulting in personal injury or possible death.
Containers must be stored, installed, and disposed of in accordance with all state and
local ordinances.
 WARNING

To prevent personal injury or death, never weld, solder, steam clean or use excessive
heat on any of the air conditioning lines or equipment while the system is charged. Heat
applied to any part will cause the pressure within the system to become excessive, which
may result in an explosion and possible personal injury.

WARNING

To prevent personal injury or death, do not smoke or allow any type of fire or flame
in the immediate area while servicing the air conditioning system. Refrigerant is not
combustible; however, in the presence of heat it changes to a poisonous gas. Inhalation
can cause death or serious injury.

WARNING

To prevent personal injury or death, R-134a must not be mixed with air and then
pressurized. When mixed with large quantities of air and pressurized, R-134a becomes
combustible.

WARNING

To prevent personal injury or death, refrigerant must be recovered from the air
conditioning system before any components of the system are removed or replaced.
Removing components while pressure is in the system will cause personal injury or
death.

WARNING

To prevent personal injury or death, do not remove the compressor oil fill plug to
check the oil level in the refrigerant compressor while the A/C system is charged with
refrigerant. The crankcase side of the compressor is under pressure and personal
injury or death may result. It is not possible to check the oil level in the compressor on
an A/C system that is under system pressure.

WARNING

To prevent personal injury or death, do not install or remove A/C testing or charging
equipment while the engine is running. Serious injury or death may result from doing
so.
 WARNING

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

equipment when working with R-134a to prevent accidental discharge. If released into
the atmosphere, the refrigerant evaporates very quickly and may displace the oxygen
surrounding the work area, especially in small or enclosed areas. This situation creates
the hazard of suffocation or brain damage for anyone in the work area. If a leak should
occur, avoid breathing the refrigerant and lubricant vapor. Thoroughly ventilate the
area before continuing with service. Federal and state laws require that refrigerant be
recovered and recycled to help protect the environment.

WARNING

To prevent personal injury or death, while the manifold gauge set is connected to both the
air conditioning system and refrigerant supply cylinder, never open the high side hand
valve of the manifold gauge set while the A/C system is operating. If hot, high pressure
refrigerant is forced through the gauge to the refrigerant supply cylinder, it could cause
the cylinder to rupture and cause personal injury or death.

WARNING

To prevent personal injury or death, always use correct replacement refrigerant hoses.
Do not use hoses other than those specified for the system being serviced. The use of
improper hoses may cause a hose rupture, which may result in personal injury or death.

WARNING

To prevent personal injury or death, during system diagnostic tests, DO NOT turn either
hand valve on the manifold gauge set for any reason; equipment can be damaged and
personal injury or death can result. When connected to the A/C system the gauges will
indicate the system pressures with the valves closed (fully CW). These valves are used
only while servicing the A/C refrigerant system.

WARNING

To prevent personal injury or death, when installing and removing any service hose or
fitting, a small amount of refrigerant may escape. Always follow all safety precautions
to avoid injury.

CAUTION

To prevent damage to HVAC components, use only new or recycled R-134a refrigerant;
not any of the so called “direct replacement” refrigerants. Use of a recovery machine
dedicated for R-134a is necessary to reduce the possibility of oil and refrigerant
incompatibility concerns.
 CAUTION

To prevent damage to HVAC components, use only the specified PAG lubricant in the
refrigerant system (see SPECIFICATIONS). PAG oils absorb atmospheric moisture very
quickly. Never leave PAG oil exposed to air for a prolonged time. Wear nonporous gloves
while handling PAG oil, and tightly reseal the oil container immediately after each use.

CAUTION

To prevent damage to HVAC components, use only MINERAL BASED refrigerant oil (see
SPECIFICATIONS) to lubricate O-rings and fittings.

CAUTION

Disconnect battery ground cable during service to prevent damage to the vehicle
electrical system. If the battery must remain connected for a specific test, use extreme
caution when taking measurements.

CAUTION

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

verify that the pulley alignment and belt tension are correct.

CAUTION

To prevent damage to HVAC components, when charging the A/C system, the refrigerant
tank must be kept upright. If the tank is not in the upright position, liquid refrigerant may
enter the system and cause compressor damage.

CAUTION

To prevent damage to the test equipment, make sure test equipment is clear of all moving
parts in the engine compartment.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant recovered intended for recovery.
Detection devices are readily available to check for the presence of these chemicals
and are highly recommended to protect the RHS980C-NAV.

NOTE – When servicing the A/C system, ensure that the inner gaskets are present in both service port
caps; and verify that the caps are installed when service is completed. The service port caps, with
functioning gaskets, are an important part of maintaining a leak free A/C system.
NOTE – Although your service equipment may appear physically different from the equipment shown
here, the function of the equipment used to perform each service procedure is basically the same. If
you are performing these service procedures using service equipment different from that shown, refer
to the manufacturer's instructions supplied with that equipment.
GENERAL DESCRIPTION

2. GENERAL DESCRIPTION

1. INTERIOR MODULE 6. CONDENSER

2. FRESH AIR MODULE 7. CONDENSER TO EVAPORATOR
3. SUCTION LINE LINE
4. COMPRESSOR 8. FILTER-DRIER
5. COMPRESSOR TO 9. LOW PRESSURE SWITCH
CONDENSER LINE
Figure 1 The Heater/Ventilation/Air Conditioning (HVAC) System

The Blend-Air air conditioning and heating system is a system of components designed to provide conditioned
air to the occupants of the vehicle. The term "Blend-Air" refers to the mixing or blending of air from the
cooling and heating systems to produce a desired air temperature for the vehicle occupants. The two main
modules (the fresh air module and interior module) are mounted on opposite sides of the dash panel on the
passenger side of the vehicle. The evaporator core, freeze probe, fresh/recirculate air door, air door actuator,
and recirculation air filter(s) are located on, or near, the dash mounted interior module on the interior side
of the dash panel. The expansion valve, filter-drier, and low pressure switch are part of the interior module,
however, these components are located on the under-hood side of the dash assembly. The condenser,
compressor, heater hoses, and A/C lines are located under the hood. The fresh air module houses the HVAC
filter only, and has two drain tubes located on the bottom of the module. The HVAC filter can be accessed from
the HVAC filter access cover located on front of the fresh air module.

NOTE – A heater-only version of the system is also available. The heater components and operation are
identical to those described for the air conditioning and heating system.

1
 GENERAL DESCRIPTION

1. HVAC CONTROL PANEL 3. FUSE PANEL COVER

2. CENTER IP TRIM PANEL 4. HVAC TRIM COVER
(BEZEL)
Figure 2 In-Cab HVAC Components

The HVAC control panel is located in the center section of the instrument panel. The heater core, blower
motor, linear power module, evaporator, blower air scroll housing, passenger floor duct, and air door actuators
are located in (or on) the interior module and may be serviced without removing the interior module. The
interior module is located behind the HVAC trim cover.

2
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

2.1. SYSTEM OPERATIONAL DESCRIPTION

Air Distribution (General)

1. HVAC AIR INLET 9. TEMPERATURE BLEND DOOR

2. FLOOR DUCT OUTLET 10. INTERIOR MODULE
3. DEFROST OUTLET 11. BLOWER ASSEMBLY
4. DEFROST/FLOOR DOOR 12. RECIRCULATE AIR INLET
(MODE DOOR) (OPEN TO CAB INTERIOR)
5. VENT OUTLET FOR 13. EVAPORATOR
INSTRUMENT PANEL 14. FRESH/RECIRCULATION AIR
6. IP VENTS/FLOOR DOOR (MODE DOOR
DOOR) 15. FRESH AIR MODULE
7. HEATER SCRUB DOOR 16. HVAC FILTER ELEMENT
8. HEATER CORE
Figure 3 Cross-Section of Front HVAC Air Handling Components

The electrically actuated fresh/recirculate air door is located in the interior module, and is controlled by the
mode control (right knob) on the HVAC control panel. When the door is in the recirculate position, outside
air is blocked by the door. Recirculation air, from the cab, enters the interior module through recirculation
filters located on each side of the interior module. With the fresh/recirculate air door in the fresh air position,
fresh outside air enters the top of the fresh air module via an air duct which is part of the cowl drain tray.
(The recirculate air is blocked by the fresh/recirculate air door.) The air entering from the fresh air module
enters the evaporator, flows through the dual inlet, dual scroll blower assembly and then, is pushed through
the interior module.

3
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

The temperature blend door is controlled by the temperature control (center knob) on the HVAC control panel.
The electrically actuated temperature blend door diverts air from the blower assembly, either through the heater
core or around it, depending on the temperature selected for the outlet air. Engine coolant flows through the
heater core at all times. The air proceeds to the mode doors. In addition to the temperature blend door there is
the heater scrub door, which is controlled via a linkage driven from the temperature blend door. The purpose of
the heater scrub door is to close off the air pathway from picking up hot air while operating in A/C mode.

The two mode doors, defrost/floor and IP vent/floor, are controlled by the mode control (right knob) on the
HVAC control panel. The doors are located at the top of the interior module and are controlled together
via a gear assembly and an electrical actuator. These mode doors direct air to the air outlets (floor ducts,
instrument panel vents, and/or defrost vents) based on the mode selected by the operator. The ductwork
for the instrument panel vents and the defrost vents is integrated into the instrument panel structure. The
upper surfaces of the interior module interface with ductwork through two large openings in the bottom of the
Instrument Panel. Left-hand drive (LHD) vehicles have a passenger floor duct attached to the right side of the
interior module and a driver side floor duct attached to the left side of the module.

The speed of the system blower motor, which controls the volume of air moved through the system, is selected
by the fan speed control (left knob) on the HVAC control panel.

4
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

Air Distribution (Air Conditioning)

Figure 4 System Airflow by Mode

Item A (Figure 4) illustrates the system airflow when operating in the NORM A/C mode. In the NORM A/C
mode, the fresh/recirculate air door is in the fresh air position. Fresh outside air enters the top of the fresh
air module via an air duct, which is part of the cowl drain tray. The remainder of NORM A/C operation is
identical to MAX A/C operation.

5
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

Item B (Figure 4) illustrates the system airflow when operating in the MAX A/C mode. In the MAX A/C mode,
the fresh/recirculate air door is in the recirculate position; outside air is blocked by the door. Recirculation
air (REC), from the cab, enters the interior module through the recirculation filters, located on each side of
the interior module. The air is pulled by the blower assembly through the evaporator core and is pushed
through the interior module. The temperature blend air door diverts air either through the heater core or past
it depending on the temperature selected for the outlet air. Although the temperature control is operational
while in the A/C modes, the temperature control is generally set to divert all air around the heater core. The air
proceeds to the mode doors where all of the air is directed to the instrument panel vents.

Item C (Figure 4)illustrates the system airflow when operating in the Bi-Level A/C mode. The Bi-Level A/C
mode operation is identical to NORM A/C operation; except, the mode doors direct the output air to both the
floor ducts, and the instrument panel vents.
Air Distribution (Heat and Ventilation)

Item A (Figure 4) illustrates the system airflow when operating in the Heat and Ventilation Vent mode. In the
Heat and Ventilation Vent mode, the fresh/recirculate air door is in the fresh air position. Fresh outside air
enters the top of the fresh air module via an air duct, which is part of the cowl drain tray. The air is pulled into
the interior module, through the evaporator core, by the dual scroll blower assembly. The blower then pushes
the air through the remainder of the interior module. The temperature blend air door diverts air either through
the heater core or past it depending on the temperature selected for the outlet air. The temperature blended air
proceeds to the mode doors where all of the air is directed to the instrument panel vents. Item A (Figure 4A)
shows all air bypassing the heater core (temperature control set to cool, full CCW).

Item D (Figure 4) illustrates the system airflow when operating in the Heat and Ventilation Floor mode. The
Heat and Ventilation Floor mode is identical to the Heat and Ventilation Vent mode; except, the mode doors
direct all of the output air to the floor ducts. Item D (Figure 4) shows all air diverted through heater core
(temperature control set to hot, full cw).
Air Distribution (Defrost)

Item E (Figure 4) illustrates the system airflow when operating in the Bi-Level Defrost/Heat mode. In the
Bi-Level Defrost/Heat mode the fresh/recirculate air door is in the fresh air position. Fresh outside air enters
the top of the fresh air module via an air duct, which is part of the cowl drain tray. The air is pulled into the
interior module, through the evaporator core, by the dual scroll blower assembly. The blower then pushes the
air through the remainder of the interior module. The temperature blend air door diverts air either through the
heater core or past it depending on the temperature selected for the outlet air. The air proceeds to the mode
doors where the doors direct the output air to both the defrost ducts, and the floor ducts. Item E (Figure 4)
shows air passing through, and around the heater core (temperature control set around midrange).

Item F (Figure 4) illustrates the system airflow when operating in the Defrost mode. The Defrost mode is
identical to the Bi-Level Defrost/Heat mode; except, the mode doors direct all of the output air to the defrost
ducts.

6
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

A/C Refrigerant Flow

1. RAM AIR 10. COLD AIR

2. CONDENSER 11. EVAPORATOR
3. SERVICE PORT (HIGH 12. WARM AIR
PRESSURE) 13. FREEZE PROBE
4. DISCHARGE LINE 14. EXPANSION VALVE
5. COMPRESSOR 15. FILTER-DRIER
6. SUCTION LINE 16. HIGH PRESSURE GAS
7. PRESSURE TRANSDUCER 17. HIGH PRESSURE LIQUID
8. LOW PRESSURE SWITCH 18. LOW PRESSURE LIQUID
9. SERVICE PORT (LOW 19. LOW PRESSURE GAS
PRESSURE)
Figure 5 A/C Refrigerant Flow Diagram

The refrigerant cycle consists of four phases: compression, condensation, expansion, and evaporation.
Consider the starting point at the compressor.

7
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

When any air conditioning position is selected on the HVAC control panel, the clutch assembly mounted on the
front of the compressor becomes engaged. When engaged, the clutch armature assembly is magnetically
drawn to the pulley assembly on the compressor shaft, thereby engaging the clutch and driving the compressor.

The suction side of the compressor draws low pressure refrigerant vapor (5 to 50 psi, or 34 to 345 kPa) from
the low side of the system, coming from the evaporator, through the thermostatic expansion valve. The
compressor then compresses the refrigerant vapor and discharges it at increased temperature and pressure
(120 to 300 psi, or 8 to 21 bar) through the high side line, which connects the compressor to the condenser.

An internal lubricating system uses the suction side intake crankcase pressure differential to coat internal parts
with a thin film of oil. This lubrication also travels along with the refrigerant throughout the air conditioning
system to lubricate various system components.

High pressure/high temperature refrigerant vapor from the compressor enters at the top of the condenser,
circulates down through the coils, and exits at the bottom of the condenser as high-pressure/high-temperature
refrigerant liquid. As the vapor condenses (changes state), some of its heat is released to the coils and fins of
the condenser. This heat is continually carried away by the outside air, which passes over the external fin
surfaces as it flows through the condenser.

The efficiency of the condenser operation is affected by ram air flowing through the condenser. For this reason,
it is important that the engine cooling fan be operating properly. Also, that the condenser cooling fins must
remain free of airborne contamination (leaves, insects, dirt, etc.), which can block the fins and cause system
temperatures to run higher than normal.

When operating properly, the condenser acts as an efficient heat exchanger, containing refrigerant vapor in
approximately two-thirds of the upper portion of its coils and condensed refrigerant liquid in the lower one-third
portion. A pressure transducer located in the output line of the condenser is used to control system operation
by providing inputs to the Body Controller. The condenser passes high temperature/high pressure liquid
refrigerant to the filter-drier. The primary function of the filter-drier is the removal of any moisture or solid
contamination from the refrigerant before it can cycle through the system and cause internal damage.

The next component in the refrigerant system is the expansion valve. The expansion valve is the dividing line
between the high- and low-pressure sides of the system. High-pressure liquid refrigerant enters the expansion
valve from the filter-drier. The valve senses the temperature of the refrigerant leaving the evaporator core.
Then, based on the sensed temperature, the valve regulates the amount of refrigerant that it passes to the
evaporator core. While leaving the expansion valve, the refrigerant starts to expand, entering the evaporator
core as a low-pressure, low-temperature liquid.

Within the evaporator core, the lower pressure permits the liquid refrigerant to boil or evaporate, changing its
state from a liquid to a low-pressure/low-temperature vapor; and absorbing heat from the evaporator core
and the air surrounding it. Cooling and dehumidifying of the cab's interior takes place as the refrigerant vapor
passes through the evaporator's finned tubes and absorbs heat from the cab air pulled through the evaporator
core by the system blower. Humidity condenses on the external surfaces of the cooled evaporator fins and
is channeled (drained) out of the interior module through drain valves. The refrigerant exits the evaporator
outlet as a low-pressure/low-temperature vapor and is drawn through the low-pressure side of the expansion
valve by the suction created by the compressor. The refrigerant pressure is monitored by a low pressure
switch that is mounted on the low-side of the filter-drier (suction line). The refrigerant pressure measured by
the low-pressure switch is monitored by the Body Controller, which is used to control A/C system operation
and detect system faults. A freeze probe is mounted on the evaporator core, to monitor the temperature and
prevent evaporator freeze up.

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

vapor that is pumped to the condenser, where the cycle is repeated.

8
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

Rear HVAC System

NOTE – The following paragraphs describe operation of the sleeper HVAC system only. On vehicles
equipped with sleeper cabs, separate control panels make it possible for the front and rear HVAC
systems to operate in different modes and at different temperatures. For rapid heating or cooling of the
entire cab/sleeper area both systems should be set to the same approximate temperature range.

The addition of the sleeper HVAC system does not affect the operation of the front (cab) A/C system.
Troubleshooting the electrical control systems for the sleeper HVAC system are covered in the Diagnosis and
Troubleshooting section (page 140) of this manual.

In general, the blower speed and air discharge temperature of the sleeper HVAC system can be adjusted
from either the rear control panel or the sleeper HVAC switches located on the instrument panel. Also, the air
conditioning mode is automatically requested by the sleeper HVAC controller whenever the active temperature
control for the sleeper system is set to a temperature lower than the temperature currently being sensed
by the temperature sensor in the rear HVAC unit.

NOTE – To energize the A/C compressor, the engine must be running and the blower speed controls for
both the front and rear HVAC systems must be ON.

The sleeper Blend-Air air conditioning and heating system is a system of components designed to provide
conditioned air to the occupants of the vehicle’s sleeper area. The sleeper system is a subsystem of the
vehicle’s overall HVAC system, and therefore shares many common components. The main components of
the sleeper HVAC system are contained in the rear HVAC unit located under the lower sleeper bunk, on the
passenger side of the vehicle (Figure 6 and Figure 7).

1. OUTLET DUCT, REAR HVAC 3. AIR INLET

2. REAR HVAC UNIT 4. AIR OUTLET
Figure 6 Location, Rear HVAC UNIT

9
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

Figure 7 Rear HVAC Unit

10
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

1. THERMAL EXPANSION VALVE 10. REAR HVAC CONTROLLER

(TXV) 11. COVER, HEATER CORE
2. FOAM SEAL (AIR INLET) 12. BLEND DOOR ACTUATOR
3. REAR HVAC UNIT, LOWER 13. DISCHARGE DUCT
HOUSING TEMPERATURE SENSOR
4. BLOWER ASSEMBLY 14. BLEND AIR DOOR
5. UPPER CLAMP PLATE (TXV) 15. HEATER CORE
6. EVAPORATOR CORE 16. INLET/OUTLET TUBE, HEATER
7. REAR HVAC UNIT, UPPER CORE
HOUSING 17. FOAM SEAL (UNDER BUNK
8. FILTER ELEMENT (AIR INLET) OUTLET)
9. LINEAR POWER MODULE
Figure 8 Major Components of the Rear HVAC System

11
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

The evaporator core, expansion valve, heater core, blend air door, air door actuator, blower, linear power
module, rear HVAC controller, temperature sensor, and air filter are located in, or on, the rear HVAC unit
(Figure 8).

The rear HVAC control panel (Figure 9, Item 6) is located on the driver’s side of the sleeper rear wall. These
HVAC controls are available in either digital or analog form, as determined by vehicle trim level. Two switch
pack switches mounted in the center console of the dash instrument panel (Figure 9, Items 3 and 4) can also
be used to control the blower and temperature settings for the sleeper HVAC system.

1. DIGITAL CONTROL, SLEEPER 4. SLEEPER TEMPERATURE

CONTROL PANEL SWITCH, FRONT CONTROL
2. ANALOG CONTROL, SLEEPER PANEL
CONTROL PANEL 5. FRONT CONTROL PANEL
3. SLEEPER FAN SWITCH, FRONT 6. SLEEPER CONTROL PANEL
CONTROL PANEL
Figure 9 Front and Rear Sleeper Controls
Rear Air Distribution (General)

The rear HVAC system operates in a recirculate mode 100% of the time. The blower assembly draws air
into the unit through the air intake at the front bulkhead of the bunk. A filter, located at the air intake, is
accessible when the bunk is raised. Air from the blower is conditioned by forcing it though the evaporator
core; and, depending on the temperature setting, the heater core. Conditioned air is output from the rear
HVAC unit through an under bunk floor outlet; and through the main outlet duct, which is connected to the
sleeper duct system.

The temperature of the air output from the rear HVAC unit is determined by the position of the temperature
blend door. The electrically actuated door diverts air from the blower assembly, either through the heater core,
or around it, as determined by the rear HVAC controller. Inputs to the controller include; the temperature
control on the rear HVAC control panel, the SLPR TEMP switch on the instrument panel, and the discharge
duct temperature sensor. The controller sets the temperature setting of the sleeper HVAC system according to
whichever sleeper temperature control was adjusted last. This allows the sleeper temperature to be controlled
by either the sleeper control panel or the switch in the instrument panel. When either sleeper temperature
control is adjusted, it is sensed by the rear HVAC controller, and it becomes the active control. The rear
controller then adjusts the temperature blend door to match the setting of that control. Engine coolant flows
through the heater core at all times (unless the vehicle is equipped with a heater shutoff valve).

12
GENERAL DESCRIPTION SYSTEM OPERATIONAL DESCRIPTION

The speed of the rear system blower motor, which controls the volume of air moved through the rear HVAC
system, is also determined by the rear HVAC controller. The blower speed inputs to the controller include; the
fan speed control on the rear HVAC control panel, the SLPR FAN switch on the instrument panel, and the
engine controller (via the body controller). The controller sets the blower speed of the sleeper HVAC system
according to whichever sleeper blower speed control was adjusted last. This allows the sleeper blower speed
to be controlled by either the sleeper control panel or the switch in the instrument panel. When either blower
speed control is adjusted, it is sensed by the rear HVAC controller, and it becomes the active control. The rear
controller then adjusts the sleeper blower speed to match the setting of that control.
Rear Air Distribution (Air Conditioning)

In the A/C mode the air is pushed by the blower assembly, through the evaporator core, to the temperature
blend air door. Normally, in this mode, the door diverts all or most of the air around the heater core and
out to the sleeper duct system.
Rear Air Distribution (Heat)

In the Heat mode the air is pushed by the blower assembly, through the evaporator core, to the temperature
blend air door. In this mode, the door diverts all or most of the air through the heater core and out to the
sleeper duct system.

13
SYSTEM OPERATIONAL DESCRIPTION GENERAL DESCRIPTION

A/C Refrigerant Flow – Sleeper A/C System

1. RAM AIR 13. THERMISTOR (INLET)

2. CONDENSER 14. EXPANSION VALVE
3. SERVICE PORT (HIGH 15. FILTER-DRIER
PRESSURE) 16. FRONT A/C FLOW DIAGRAM
4. DISCHARGE LINE 17. REAR A/C FLOW DIAGRAM
5. A/C COMPRESSOR 18. REAR EVAPORATOR
6. SUCTION LINE 19. REAR COLD AIR (OUTLET)
7. PRESSURE TRANSDUCER 20. REAR EXPANSION VALVE
8. LOW PRESSURE SWITCH 21. REAR WARM AIR (INLET)
9. SERVICE PORT (LOW 22. HIGH PRESSURE GAS
PRESSURE) 23. HIGH PRESSURE LIQUID
10. COLD AIR (OUTLET) 24. LOW PRESSURE LIQUID
11. FRONT EVAPORATOR 25. LOW PRESSURE GAS
12. WARM AIR (INLET)
Figure 10 A/C Refrigerant Flow Diagram (with Sleeper System)

The addition of the sleeper HVAC system does not affect the operation of the front (cab) A/C system.

In general, the air conditioning mode is automatically requested by the sleeper HVAC controller whenever
the active temperature control for the sleeper system is set to a temperature that is lower than the current

14
GENERAL DESCRIPTION COMPONENTS

temperature sensed by the rear HVAC unit. Upon receiving the A/C request, the body controller will energize
the A/C compressor if all requirements are met. For example, to energize the A/C compressor, the blower
control on the front HVAC control panel must NOT be set to OFF. Troubleshooting the electrical control
systems for the sleeper HVAC system are covered in the Diagnosis and Troubleshooting section of this manual
(See DIAGNOSIS AND TROUBLESHOOTING, page 140).

The rear thermostatic expansion valve and evaporator core are connected in parallel with the filter-drier,
expansion valve, and evaporator core of the front A/C system (Figure 10). With the A/C compressor energized,
the rear expansion valve regulates the amount of refrigerant that it passes to the evaporator core. While
leaving the expansion valve, the refrigerant starts to expand, entering the evaporator core as a low pressure,
low temperature liquid. Within the evaporator core, the lower pressure permits the liquid refrigerant to boil or
evaporate, changing its state from a liquid to a low pressure/low temperature vapor; and absorbing heat from
the evaporator core and the air surrounding it. Cooling of the sleeper’s interior takes place as the refrigerant
vapor passes through the evaporator and absorbs heat from the sleeper air pushed through the evaporator
core by the system blower. The refrigerant exits the evaporator outlet as a low pressure/low temperature vapor
and is drawn through the low pressure side of the expansion valve by the suction created by the compressor.

2.2. COMPONENTS

1. INTERIOR MODULE 7. LOW PRESSURE SWITCH

2. RECIRCULATION FILTER 8. THERMOSTATIC EXPANSION
3. HVAC FILTER ACCESS COVER VALVE (TXV)
4. FRESH AIR MODULE 9. FREEZE PROBE
5. LOW SIDE SERVICE PORT 10. LINEAR POWER MODULE
6. DRAIN TUBE (LPM)
Figure 11 HVAC Unit

15
COMPONENTS GENERAL DESCRIPTION

Thermostatic Expansion Valve (TXV)

The thermostatic expansion valve controls the amount of liquid refrigerant that enters the evaporator core. The
valve is connected to both the input and output lines of the evaporator core. By sensing the temperature of
the refrigerant at the output of the evaporator, the valve determines the amount of refrigerant needed at the
evaporator input to keep the evaporator operating within operational parameters.
Freeze Probe

The freeze probe is located in the fins of the evaporator, and is used to measure temperature so as to
prevent evaporator freeze up.

Low Pressure Switch

The low pressure switch is a device that disengages the compressor clutch when the system pressure drops
below a predetermined level. The low pressure switch is mounted in the evaporator outlet line (suction line).
The refrigerant pressure measured by the low pressure switch is monitored by the Body Controller, which is
used to control A/C system operation and detect system faults. The refrigerant system must be discharged
before removing and replacing the low pressure switch.
Linear Power Module

The Linear Power Module (LPM) is mounted on the blower scroll housing (part of the interior module), located
in the cab under the right side of the instrument panel. The LPM establishes the blower speed by reading
the HVAC control panel output signal whose value is based on the setting of the blower speed control knob.
As the blower speed control is turned cw, the LPM increases the voltage across the blower motor, and the
blower speed increases.

Recirculation Filter

CAUTION

To prevent damage to HVAC components, maintain clean filters.

The recirculation filters are mounted in front of the recirculation inlets, on each side of the interior module. The
recirculation filters clean particles out of the air, during recirculation mode, that may damage or reduce the
performance of any of the HVAC unit components.

HVAC Control Panel

The HVAC control panel is located in the center console of the instrument panel. The control panel consists
of three knobs actuating three long-life potentiometers. Internally, the control panel contains circuitry that
electronically controls the blower motor speed and the three air door actuator motors. The blower speed
control is detented to provide seven distinct blower speeds, in addition to the OFF position. The temperature
control has fifteen detents. The mode control is used to select the HVAC operating mode, indicated by seven
mode icons and five dots (for 'in-between' modes). The 'heat only' system has five mode icons, and four
dots for 'in-between' modes.

Rear HVAC Components

Only those components unique to the sleeper HVAC system are described in the following paragraphs.
All information covering the front HVAC system in these vehicles can be found in the paragraphs above.
Troubleshooting the electrical control systems for the sleeper HVAC system are covered in the Diagnosis and
Troubleshooting section of this manual (See DIAGNOSIS AND TROUBLESHOOTING, page 140).

Refer to Figure 8 for locations of the components described in the following paragraphs.

16
GENERAL DESCRIPTION COMPONENTS

Rear Thermostatic Expansion Valve (TXV)

Figure 12 Rear Thermostatic Expansion Valve (TXV)

The rear expansion valve controls the amount of liquid refrigerant that enters the rear evaporator core. The
valve is connected to both the input and output lines of the evaporator core. By sensing the temperature of the
refrigerant at the output of the evaporator, the valve determines what amount of refrigerant is needed at the
evaporator input to keep the evaporator operating within operational parameters. The rear TXV is serviced
from under the vehicle cab, after discharging the A/C system.

Rear Evaporator

The evaporator core is located in the rear HVAC unit. The core is a cooling assembly made of fin and tube
construction. The inlet and outlet tubes protrude through the floor of the cab for connection directly to the rear
TXV. Servicing the evaporator core requires splitting the rear HVAC unit and discharging the A/C system.
Rear HVAC Plumbing

Two under cab A/C lines are used to splice the rear A/C components into the front A/C lines near the front
evaporator housing. International® “C-plate” style block fittings are utilized on the refrigerant line connections
to the front system. This block fitting incorporates a secondary moisture and dirt seal within a unique plate
inserted into the block fitting. The primary O-ring seal has a large cross section for improved sealing as well.
Connections at the rear TXV are via O-rings and clamping plates. Refrigerant hose assemblies are constructed
from steel tubing coupled to Goodyear Galaxy hose. This nylon barrier type of hose prevents the refrigerant
from escaping through the walls of the hose into the atmosphere. When servicing air conditioning systems,
use only replacement hoses approved for air conditioning systems.

Two under cab heater lines connect the rear heater core in parallel with the front heater core. The lines are
spliced into the front heater hoses using ’T’ fittings.

Rear Heater Core

The rear heater core is located in the rear HVAC unit. The heater core is a heating assembly made of fin and
tube construction and is connected in parallel with the front heater core. The inlet and outlet tubes protrude
through the floor of the cab for connection to under cab heater lines. Engine coolant flows through the heater
core at all times. The heater core can be serviced without splitting the rear HVAC unit housings.

17
COMPONENTS GENERAL DESCRIPTION

Rear Blower Assembly

The rear blower assembly is mounted to the rear HVAC unit. The blower assembly used in the sleeper HVAC
system consists of a permanent magnet motor attached to a balanced ’squirrel-cage’ fan unit. The motor
speed is controlled by the rear HVAC controller. The blower provides air circulation through the evaporator
and heater core, and delivery of the treated air throughout the sleeper interior. The blower assembly can be
serviced without splitting the rear HVAC unit housings.

Rear Linear Power Module

Figure 13 Rear Linear Power Module

The rear Linear Power Module (LPM) is mounted to the rear HVAC unit near the blower. The LPM allows a
low current signal, from the rear HVAC controller, to control the speed of the higher current blower assembly.
The LPM establishes the blower speed by reading the rear HVAC controller output signal, whose value is
determined by the setting of either the blower speed control in the sleeper or the SLPR FAN switch in the
instrument panel (whichever was adjusted last). Troubleshooting the electrical control systems for the sleeper
HVAC system are covered in the Diagnosis and Troubleshooting section of this manual (See DIAGNOSIS
AND TROUBLESHOOTING, page 140).

Rear Temperature Blend Air Door Actuator

The temperature blend air door actuator is located on the rear HVAC unit. The actuator rotates the blend air
door according to signals provided by the rear HVAC controller. The position of the blend air door determines
the amount of air flowing through the heater core, and therefore, the temperature of the air being output
by the rear HVAC unit.

Rear HVAC Controller

The rear HVAC controller is mounted on the rear HVAC unit. The controller sets the blower speed, and
temperature setting, of the sleeper HVAC system, based on the last sleeper HVAC control adjusted. This
allows the sleeper system to be controlled by either the sleeper control panel or the switches in the instrument
panel. When any sleeper related HVAC control is adjusted, it is sensed by the rear HVAC controller, and it
becomes the active control. The rear controller then adjusts the blower speed, or blend air door, to match the
setting of that control.

In general, the air conditioning mode is automatically requested by the sleeper HVAC controller whenever
the active temperature control for the sleeper system is set to a temperature that is lower than the current
temperature sensed by the rear HVAC unit. Upon receiving the A/C request, the body controller will energize
the A/C compressor if all requirements are met. For example, to energize the A/C compressor, the blower
control on the front HVAC control panel must NOT be set to OFF. Troubleshooting the electrical control
systems for the sleeper HVAC system are covered in the Diagnosis and Troubleshooting section of this manual
(See DIAGNOSIS AND TROUBLESHOOTING, page 140).

18
GENERAL DESCRIPTION COMPONENTS

Rear HVAC Control Panel

The rear HVAC control panel is located on the driver’s side of the sleeper rear wall. These HVAC controls are
available in either digital or analog form, as determined by vehicle trim level.

The analog control panel consists of two knobs actuating two long life potentiometers. The settings of these
controls are read and interpreted by the rear HVAC controller. When these controls are active, the controller
uses their settings to determine the rear blower motor speed and the position of the temperature blend air door.

The digital control panel consists of four push buttons and a digital display. The push buttons allow up and
down adjustment of the temperature and the blower speed. The actuations of these controls are read and
interpreted by the rear HVAC controller. The display provides two bar graphs indicating the temperature and
blower speed settings, as interpreted by the controller. When one of the buttons is pressed, the controller
adjusts the setting of the blower motor speed, or temperature blend air door, to reflect the button actuation.

Rear HVAC Control Switches (Located in Instrument Panel)

Two rocker switches, located in the center console of the instrument panel, allow the driver to adjusts
the temperature setting and blower speed of the sleeper HVAC system. The rocker switches allow up and
down adjustment of the temperature and the blower speed. The actuations of these switches are read and
interpreted by the rear HVAC controller. When either switch is actuated, the controller adjusts the setting of the
blower motor speed, or temperature blend air door, to reflect the switch actuation.

19
INTERNAL COMPONENTS GENERAL DESCRIPTION

2.3. INTERNAL COMPONENTS

1. HVAC FILTER 6. EVAPORATOR

2. HEATER CORE 7. RECIRCULATION FILTER
3. MODE DOOR ACTUATOR 8. FILTER-DRIER
4. BLEND DOOR ACTUATOR 9. RECIRCULATION DOOR
5. BLOWER MOTOR ACTUATOR
Figure 14 HVAC Unit (Side Housing Removed for Clarity)
Filter-Drier

The primary function of the filter-drier is to remove any moisture or solid contamination from the refrigerant
before it can cycle through the system and cause internal damage. A drying agent (desiccant) separates and
absorbs any moisture contained in the liquid refrigerant. The desiccant also contains a dye to allow easier
detection of refrigerant leaks.

The filter-drier itself is not repairable, and must be replaced if found to be defective. The filter-drier must
also be replaced whenever the system becomes contaminated due to an internal compressor failure or any
extended exposure to the atmosphere (30 minutes or longer). This action will help prevent subsequent
corrosion and damage to the system.

Heater Core

The heater core is located in the interior module mounted in the cab under the right side of the instrument
panel. The heater core is a heating assembly made of fin and tube construction, with inlet and outlet fittings for
connecting the heater hoses from the engine cooling system. The inlet and outlet fittings protrude through the
cowl next to the fresh air module. Engine coolant flows through the heater core at all times. The temperature
of the air output by the heating/air conditioning system is determined by diverting more or less of the input air
through the heater core. The heater core is serviced from inside the cab.

20
GENERAL DESCRIPTION UNDER HOOD COMPONENTS

Blower Assembly

The blower assembly is located in the blower scroll housing (part of the interior module), mounted in the cab
under the right side of the instrument panel. The blower assembly used in the heater or heater-air conditioning
system consists of a permanent magnet motor attached to a balanced 'squirrel-cage' fan unit. The motor speed
is controlled by the left knob on the HVAC control panel on the instrument panel. The blower provides air
circulation through the heater core and evaporator, and delivery of the treated air throughout the cab interior.

Evaporator Core

The evaporator core is located in the interior module mounted in the cab under the right side of the instrument
panel. The core is a cooling assembly made of tube and fin construction, with “C-plate” block-style inlet and
outlet fittings. Drain valves for both condensate and rain water are incorporated in the bottom of the interior
module.

HVAC Filter

CAUTION

To prevent damage to HVAC components, maintain clean filters.

The HVAC filter cleans particles out of the air, during fresh air mode, that may damage or reduce the
performance of any of the HVAC unit components. The HVAC filter is located inside the fresh air module. The
HVAC filter can be serviced through the HVAC filter access cover located on front of the fresh air module.

2.4. UNDER HOOD COMPONENTS

Pressure Transducer

The pressure transducer is a pressure-sensing device threaded into the condenser refrigerant output line. The
transducer provides an electrical signal to the Body Controller, which monitors and controls the operation of the
A/C system. The refrigerant system does not have to be discharged to replace the pressure transducer.

Compressor and Clutch

The system uses a compressor configured with a proprietary international head to accommodate the “C-plate”
block-style fittings. It is mounted on the engine and is belt-driven through an electromagnetic clutch, which
acts to engage (turn ON) or disengage (turn OFF) the compressor in response to the air conditioning system
controls (HVAC control panel and Body Controller). When engaged, the clutch armature assembly is
magnetically drawn to the pulley assembly on the compressor shaft, thereby engaging the clutch and allowing
the drive belt to drive the compressor. A pressure-relief valve on the compressor offers protection to the
compressor in extreme high-pressure conditions.
Condenser

The air conditioning condenser is located at the front of the vehicle between the engine radiator and the
grille. The condenser is a heat exchanger made of fin and tube construction, with “C-plate” block-style inlet
and outlet fittings.

A/C Plumbing

International® “C-plate” style block fittings are utilized on all refrigerant line connections except the TXV. This
block fitting incorporates a secondary moisture and dirt seal within a unique plate inserted in the block fitting.
The primary O-ring seal has a large cross section for improved sealing. The nylon barrier type of hose used
prevents the refrigerant from escaping through the walls of the hose into the atmosphere. When servicing air
conditioning systems, use only replacement hoses approved for air conditioning systems.

21
HVAC ELECTRICAL SYSTEM OVERVIEW GENERAL DESCRIPTION

2.5. HVAC ELECTRICAL SYSTEM OVERVIEW

The heater/ventilation/air conditioning (HVAC) system contains both mechanical and electrical components.
The mechanical and electrical system is described in this manual. For information covering the electrical part
of the system, refer to the DIAGNOSIS AND TROUBLESHOOTING section (page 140) in this manual.

Malfunctions in the HVAC system could be attributed to either mechanical or electrical failures in the system.
Diagnosis of a malfunctioning system should always begin by performing the procedures in the DIAGNOSIS
AND TROUBLESHOOTING section (page 140) to determine what part of the system is malfunctioning.

General Operation Of The HVAC Electrical System

The controls on the HVAC control head are used to adjust the cab air temperature mix, select the blower
speed, and select the system operating mode, including recirculation and distribution of cab air. The blower
speed is controlled by varying the amount of voltage applied to the blower motor. The temperature mix and
system operating mode are selected by electronically controlling the actuators that position the airflow doors
located in the interior module. The HVAC control head also communicates with the body controller to request
compressor turn on (for AC and defrost operation).

The control head communicates fault conditions to the body controller for certain conditions monitored by the
control head (operation of the air door actuator motors). If the HVAC control head detects a fault condition, the
body controller will log a diagnostic trouble code.

The body controller controls the cycling of the air conditioner compressor. In general the body controller
monitors the refrigerant sensors (transducer, freeze probe, and the low pressure switch) and other system
parameters to determine if all parameters are within acceptable limits. If parameters are acceptable, the body
controller will turn on the compressor when requested by the HVAC control head, and will cycle the compressor
to keep the system within acceptable operating parameters.

When the body controller detects readings outside of the acceptable ranges, it will generate and log a
diagnostic trouble code. If the body controller determines that continued operation would be destructive, it
shuts down the A/C system by preventing the compressor from turning on.
General Operation of the Rear HVAC Electrical System

The sleeper HVAC system contains both mechanical and electrical components. The mechanical system is
described in this manual. For information covering the electrical part of the system refer to DIAGNOSIS AND
TROUBLESHOOTING section (page 140).

Malfunctions in the HVAC system could be attributed to either mechanical or electrical failures in the system.
Diagnosis of a malfunctioning system should always begin by performing the procedures in the DIAGNOSIS
AND TROUBLESHOOTING section to determine what part of the system is malfunctioning.

The rear HVAC controller adjusts the blower speed and temperature setting of the sleeper HVAC system,
based on the settings of the sleeper HVAC controls. The blower speed is controlled by varying the amount of
voltage applied to the blower motor, via the LPM. The temperature mix is selected by electronically controlling
the actuator that positions the blend air door. When the temperature settings call for cooler temperatures, the
controller communicates with the body controller to request refrigerant compressor turn on (for A/C operation).

The rear HVAC controller also communicates fault conditions to the body controller for certain conditions
monitored by the controller. If the HVAC controller detects a fault condition, the body controller will log a
diagnostic trouble code.

22
SYSTEM OPERATION CONTROL ASSEMBLY

3. SYSTEM OPERATION
The operation of the Blend-Air system is based on standard automotive air conditioning and heating principles.

NOTE – The following descriptions cover the 'heater/air conditioner' version of the system. Operation
of the 'heater only' system (available on some models) is nearly identical, except all air conditioning
information can be ignored.

3.1. CONTROL ASSEMBLY

1. BLOWER FAN SPEED CONTROL 4. HEATER ONLY CONTROL

2. TEMPERATURE CONTROL 5. AIR CONDITIONER/HEATER
3. MODE CONTROL CONTROL
Figure 15 HVAC Control Panel Assembly

All major functions of the A/C-heater system are controlled from the control panel assembly. It consists of three
rotary knobs, which electronically control the blower fan speed, the A/C compressor clutch, and the actuators
that move the air doors used to control system air distribution and temperature.

3.2. BLOWER FAN SPEED CONTROL

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

3.3. TEMPERATURE CONTROL

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

3.4. MODE CONTROL

This control selects the operating mode of the system (HEAT, VENTILATE, DEFROST, and A/C) and controls
which outlets in the cab are used to distribute the air. This is accomplished by electronically controlling the A/C
compressor clutch, as well as three air doors located in the in-cab interior module. In addition to the modes
indicated by icons, the mode control can select 'in between' modes indicated by dots. These positions allow
fine tuning of the air distribution by providing a distribution mix that is between the mixes provided by the icons
on either side of the selected dot (refer to Table 1).

23
MODE CONTROL SYSTEM OPERATION

The air conditioning settings are indicated by icons with snowflakes.

Table 2 Air Distribution Chart

CONTROL KNOB POSITION AIRFLOW

Air Conditioner Systems Heater Only Systems Panel Floor Windshield

MAX A/C PANEL 100%

NORM A/C 100%

DOT 1 50% 50%

BI-LEVEL DOT 1 75% 25%

DOT 2 BI-LEVEL 50% 50%

PANEL 100%

DOT 3 DOT 2 25% 75%

FLOOR FLOOR 100%

DOT 4 DOT 3 75% 25%

MIX BLEND 50% 50%

DOT 5 DOT 4 25% 75%

DEFROST DEFROST 100%

MAX Air Conditioning Mode

In this mode, all airflow is directed to the panel air outlets, and the air is recirculated inside the vehicle. In the
MAX A/C mode, the fresh/recirculate air door is in the recirculate position; outside air is blocked by the door.
Use this mode to block out any outside odors, smoke, or dust and to cool the interior rapidly upon initial startup
in very hot or humid weather. When this mode is selected, the HVAC control panel (control head) sends a
signal to the Body Controller requesting that the A/C compressor be turned on.

NOTE – Continuous use of the Recirculate mode may make the inside air stuffy. Use of this mode for
longer than fifteen minutes is not recommended.

NORM Air Conditioning Mode

In this mode, all airflow is directed to the panel air outlets. Fresh (outside) air is used to cool the vehicle in
this mode. When this mode is selected, the HVAC control panel (control head) sends a signal to the Body
Controller requesting that the A/C compressor be turned on.

24
SYSTEM OPERATION DEHUMIDIFYING

Bi-Level Air Conditioning Mode

In this mode, 75% of the airflow is directed to the panel air outlets, 25% of the airflow is directed to the floor air
outlets, and fresh (outside) air is circulated inside the vehicle.

Vent Mode

In this mode, all airflow is directed to the panel air outlets and fresh (outside) air is circulated inside the vehicle.

Floor Mode

In this mode, all airflow is directed to the floor air outlets and fresh (outside) air is circulated inside the vehicle.

Mix Mode

In this mode, 50% of the airflow is directed to the defrost and side demist air outlets, 50% of the airflow is
directed to the floor air outlets, and fresh (outside) air is circulated inside the vehicle. The A/C compressor
turns on automatically when in this mode to reduce humidity levels and help reduce moisture buildup on the
windshield. To improve defroster efficiency, remove ice and/or snow from the windshield prior to starting
the vehicle.
Defrost

In this mode, all of the airflow is directed to the defrost and side demist air outlets, and fresh (outside) air is
circulated inside the vehicle. The A/C compressor turns on automatically, when in this mode, to reduce
humidity levels and help reduce moisture build up on the windshield. To improve defroster efficiency, remove
ice and/or snow from the windshield prior to starting the vehicle.

3.5. DEHUMIDIFYING
In mild weather with high humidity conditions, the heater system can be operated simultaneously with the air
conditioner to dehumidify moist air. Set the mode control to either the NORM or A/C bi-level position, place
the fan speed control to any setting, and move the temperature control towards HOT (clockwise) until a
comfortable temperature is maintained. The air conditioner will remove the humidity while the heater keeps the
cab comfortable.

25
DEHUMIDIFYING SERVICE PROCEDURES FOR R-134A

4. SERVICE PROCEDURES FOR R-134A

Vehicle received for service/repair:

1. Sealant check
2. Refrigerant identification
3. Leak check (if a leak is suspected)
4. Diagnose A/C system (may include A/C system performance test – A/C SYSTEM TEST MODE)
5. Discharge A/C system (RECYCLE)
6. Repair A/C (may include a leak check)
7. Flush A/C system (if contaminated)
8. Evacuate A/C system (includes a leak test to verify repair)
9. Charge A/C system (CHARGE)
10. Calculate and add refrigerant oil
11. Perform A/C system performance test (A/C SYSTEM TEST MODE)

26
SERVICE PROCEDURES FOR R-134A R-134A SERVICE PRECAUTIONS

4.1. R-134A SERVICE PRECAUTIONS

WARNING

To prevent personal injury or death, before doing any of the work below, read the
SERVICE WARNINGS. Failure to read the Service Warnings, and to be aware of the
dangers involved when working with refrigerant could lead to serious personal injury
or death.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant intended for recovery. Detection
devices are readily available to check for the presence of these chemicals and are highly
recommended to protect the RHS980C-NAV.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

NOTE – When servicing the A/C system, insure that the inner gaskets are present in both service port
caps; and verify that the caps are installed when service is completed. The service port caps, with
functioning gaskets, are an important part of maintaining a leak free A/C system.

In addition to the Safety Precautions, special attention to the following rules during servicing, and component
remove and install, will aid in avoiding unnecessary and time-consuming problems.

1. Perform service inside a warm, well-ventilated dry shop.

2. When working on the A/C system, keep the work area and tools as clean as possible. Also, clean all
connections, ports or fittings before disconnecting or removing components.

3. Never use hot steam to clean the inside of the system. Flushing the system with the International® A/C
Servicing System is recommended for this purpose.

4. All A/C component and refrigerant line openings should be immediately plugged during removal and
remain so until re-installation to prevent the entry of dirt, moisture and other foreign material. Even the
slightest particle can cause problems if carried to a vulnerable place within the system.

5. Never remove protective caps from components until the moment of assembly into the system.

6. Never install non-sealed components.

27
R-134A SERVICE PRECAUTIONS SERVICE PROCEDURES FOR R-134A

1. O-RING 2. C-PLATE
Figure 16 Fitting C-Plate and O-Ring

7. Anytime an A/C fitting is disconnected, the O-ring and C-plate must be replaced. The new O-ring must
be lubricated with MINERAL-BASED oil (International® P/N ZGGR6912). The C-plate does not require
lubrication. Never use grease, penetrating oil, motor oil, Ester or PAG oil, etc. to lubricate O-rings and
fittings.

8. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original positions.

Never bend a hose to a radius less than ten times the diameter of the hose.

Never route a hose any closer than four inches from the exhaust manifold or related piping.

Periodically inspect hoses for leaks or brittleness. Replace lines immediately if damaged.

9. All fittings must be tightened as specified in the TORQUE CHART (See Table 32, page 178). Use only a
torque wrench known to be accurate.

10. Whenever possible, use a backup wrench when loosening or tightening fittings.

11. Replace the filter-drier on any system, which has been opened for more than a short period (approximately
30 minutes); after the system has been flushed; and/or when the system has become contaminated (such
as due to an internal compressor failure). If the filter-drier is one of multiple components being installed in
the system, the filter-drier should be one of the last components installed. This reduces the amount of
time that the filter-drier desiccant is exposed to atmospheric moisture.

12. Refrigerant oil quickly absorbs moisture. Store oil only in moisture-free containers and keep oil containers
closed until ready to use. Close refrigerant oil container immediately after use.

13. The air conditioning system must be flushed any time the system has become contaminated (such as
due to an internal compressor failure). Refer to FLUSHING THE AIR CONDITIONING SYSTEM, (See
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM, page 42).

14. Whenever the system is discharged, the refrigerant oil level must be checked and/or replaced as specified
in OIL FILL GUIDELINES (page 46).

15. Any system that has been discharged due to leakage, or opened to replace a component, must be
evacuated (and the system oil quantity must be returned to normal).

28
SERVICE PROCEDURES FOR R-134A R-134A SERVICE PRECAUTIONS

16. Use extreme care to prevent moisture from entering the system. Moisture can freeze at the thermostatic
expansion valve and block refrigerant flow during system operation. Always properly evacuate the system
after service to remove any moisture and air from the system.

17. Spare components should be sealed and stored in a warm, dry facility.

29
RECOMMENDED SERVICE TOOLS SERVICE PROCEDURES FOR R-134A

4.2. RECOMMENDED SERVICE TOOLS

The service procedures provided in this manual are written around the following recommended service tools;
the RHS980C-NAV Servicing System, 12401-NAV Air Conditioning Oil and Dye Injection Equipment and the
D400A or D440–NAV Leak Detector. For more information on these tools, refer to SPECIAL TOOLS.

It is the servicer's responsibility to obtain, read, and understand the operator manuals for all service equipment.
If other equivalent service tools are used, refer to the instructions provided by the tool manufacturer.

4.3. SEALANT DETECTION

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant intended for recovery. Detection
devices are readily available to check for the presence of these chemicals and are highly
recommended to protect the RHS980C-NAV.

Before any work is done on an A/C system, the refrigerant should be checked for sealants and leak stop
chemicals.

Sealants and leak stop chemicals in A/C systems may cause serious damage to the RHS980C-NAV if they
are present in the refrigerant intended for recovery. Detection devices are readily available to check for the
presence of these chemicals and are highly recommended to protect the RHS980C-NAV. If a sealant is
detected, do not service vehicle.

30
SERVICE PROCEDURES FOR R-134A REFRIGERANT IDENTIFICATION

4.4. REFRIGERANT IDENTIFICATION

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

check refrigerant I.D. hose for oil or UV dye contamination before connecting. Replace
hose if necessary.

NOTE – The procedures described below, refer to the International® A/C Servicing System
(RHS980C-NAV) refrigerant identifier to verify R-134A refrigerant. If a different refrigerant identifier is
being used, refer to the instructions provided by the tool manufacturer.

Before any work is done on an AC system, the refrigerant should be identified.

Figure 17 Refrigerant Identifier Hose

The refrigerant identifier hose is found on the rear of the RHS980C-NAV. The RHS980C-NAV screen will
guide you through connection and refrigerant sample process. If vehicle A/C system contains less than
98% R-134a, or substances other than R-134a, do not service vehicle. A system with some or all air in it,
would indicate a leak that can be repaired.

31
LEAK DETECTION SERVICE PROCEDURES FOR R-134A

4.5. LEAK DETECTION

NOTE – When servicing the A/C system, ensure that the inner gaskets are present in both service port
caps; and verify that the caps are installed when service is completed. The service port caps, with
functioning gaskets, are an important part of maintaining a leak free A/C system.

NOTE – Refrigerant leaks are often indicated by an oily residue at the point of the leak.

There are several methods of refrigerant leak detection including: the RHS980C-NAV (in high pressure mode),
the D440A-NAV Leak Detector, D400A Leak Detector, an Ultraviolet Lamp, and high pressure Nitrogen
with an Ultrasonic Sensor. Navistar recommends using the RHS980C-NAV and the D400A or D440A Leak
Detectors whenever practical. If different leak detection tools are used, refer to the instructions provided by
the tool manufacturer.

The methods used to locate a refrigerant leak depend on how and when the leak is discovered.

A. If the system is received with a known or suspected leak, start the leak search BEFORE
discharging the system.

1. Perform the sealer detection check and refrigerant identification check. refer to
SEALANT DETECTION and REFRIGERANT IDENTIFICATION.
2. Visually inspect the system for component damage and/or oily leak residue.
3. Use the Ultraviolet (UV) Lamp to inspect the system for signs of phosphor dye,
indicating a leak point.
4. If the system still contains refrigerant, use the D440A-NAV Leak Detector or D400A
Leak Detector to check all connections and fittings. The connections and joints of the
condenser and evaporator should also be checked with the leak detector.
5. Use the RHS980C-NAV to recover the refrigerant; then use the High Pressure Leak
Detect mode and the D440A-NAV or D400A Leak Detector to check for leaks in
the A/C system, or individual components. When the leak check is complete, the
refrigerant in the system or component must be recovered before repairing the leak.
6. As an alternate method the discharged A/C system can be charged with high pressure
nitrogen and an ultrasonic leak detector used to locate the leak site.
B. If the leak is first detected by the RHS980C-NAV during the evacuation mode leak test;
follow the on-screen instructions to locate the leak by using the High Pressure mode and the
D-400A/D440A-NAV Leak Detector.
RHS980C-NAV Leak Detection

The RHS980C-NAV automatically detects leaks during the AUTOMATIC and VACUUM (evacuation) modes.
The RHS980C-NAV determines that a leak is present when the A/C system being evacuated is unable to
reach or maintain a specified vacuum level. Once the leak is detected, the RHS980C-NAV will stop the
current operation and display a failure message.

To provide a method of locating a detected leak, follow the on-screen instructions to place the RHS980C-NAV
into the High Pressure Leak Detect mode. This mode overcharges the A/C system with R-134A refrigerant
causing the leak to become more detectable by other tools, such as the D400A or D440A-NAV Leak Detector.

32
SERVICE PROCEDURES FOR R-134A LEAK DETECTION

CAUTION

To prevent damage to the A/C compressor, the vehicle A/C system must not be started if
the High Pressure Leak Detect procedure was used. The A/C system must be discharged
(RECYCLE) following the High Pressure Leak Detect procedure.

NOTE – The A/C system must be discharged before it can be opened for repairs.

Once the leak is located select the RECYCLE mode and follow the on-screen instructions to discharge the
system and disconnect the blue and red hoses from the service ports.
D440A-NAV and D400A Leak Detectors

1. D400A LEAK DETECTOR 2. D440A-NAV LEAK DETECTOR

Figure 18 Leak Detectors

The D440A-NAV and D400A Leak Detectors are hand-held devices having a flexible probe used to seek
out refrigerant leaks. An audio leak indicator signals a warning in the presence of a leak. It is important
to become familiar with the leak detector instructions. The speed at which the probe is moved over the
component being checked is very important in locating larger than permissible leaks. Leak check procedure
should be in accordance with SAE J2791. The detectors are also listed in the SPECIAL TOOLS section
(See SPECIAL TOOLS).

Before using this detector to look for leaks, it is recommended to clean away all oil or grease, and blow away
refrigerant residue from fittings and A/C components. All suspected areas should be cleaned using soap and
water, not a solvent. A detected leak should be a flow of refrigerant, not a residual condition of refrigerant that
is trapped under an oil film, etc. A detected leak rate in excess of 1.0 oz./year is unacceptable.

Ultrasonic Leak Detectors

An ultrasonic leak detector listens for the distinctive “sound” of a gas passing through an opening. To use this
type of detector effectively, the refrigerant system is first discharged, and then pressurized to 300 psi using
dry nitrogen and a manifold gauge set. Refer to REFRIGERANT LEAK TESTING WITH NITROGEN. The
detector is then used to scan the suspected joints or components. Depending on the detector being used,
a leak may be indicated by a visual or audible signal. Suspected leaks should not be cleaned with a soap
solution prior to scanning with this tool, as any solution remaining at the leak site may mask the leak. The unit
is a hand-held device and may include attachments to vary the directional sensitivity of the unit. Because
this type of sensor does not sample the gas used in the system, it may be used with any refrigerant system.

33
LEAK DETECTION SERVICE PROCEDURES FOR R-134A

It may also be used to detect leaks in the vehicle air system. It is important to become familiar with the
instructions for the leak detector being used.

Refrigerant Leak Testing with Nitrogen

1. LOW PRESSURE VALVE AND 2. HIGH PRESSURE VALVE AND

GAUGE (MANIFOLD GAUGE GAUGE (MANIFOLD GAUGE
SET) SET)
3. NITROGEN CYLINDER AND
REGULATOR
Figure 19 Using Nitrogen to Pressurize the A/C System

NOTE – Before pressurizing the system with nitrogen the system refrigerant must be recovered.

When checking for refrigerant leaks using an ultrasonic detector, the refrigerant in the system must first be
recovered; then, the system must be pressurized to 300 psi with dry nitrogen, as follows.

1. Connect a manifold gauge set to the A/C system. Refer to Figure 19.

A. Initially keep both gauge valves on manifold gauge set closed.

B. High pressure hose (red) to high pressure port on vehicle. (Open quick connect valve.)
C. Low pressure hose (blue) is not connected. (Keep gauge valve and quick connect valve
closed.)

CAUTION

Opening the low pressure gauge valve while the system is pressurized may damage the
low pressure gauge.

2. Connect pressurized nitrogen cylinder to the manifold gauge set and pressurize A/C system to 300 psi.

A. Connect manifold gauge set yellow hose to nitrogen source.

B. Set output pressure at nitrogen cylinder regulator to 300 psi.

34
SERVICE PROCEDURES FOR R-134A LEAK DETECTION

C. Slowly open high side gauge valve on manifold gauge set to pressurize A/C system (high
side gauge should read 300 psi).

3. Test for leaks using an ultrasonic detector.

4. After locating the leak, set the nitrogen cylinder regulator to 0 psi.

WARNING

To prevent personal injury or death, in the following step, the pressure must be released
in a manner that does not trap pressure in the A/C system.

5. Before disconnecting the manifold gauge set, slowly release the pressure from the A/C system by partially
disconnecting a fitting until the pressure is released.

6. Remove the manifold gauge set from the A/C system and repair the leak.

7. Evacuate the system; refer to EVACUATING THE SYSTEM.

8. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM.

35
AUTOMATIC MODE SERVICE PROCEDURES FOR R-134A

4.6. AUTOMATIC MODE

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant intended for recovery. Detection
devices are readily available to check for the presence of these chemicals and are highly
recommended to protect the RHS980C-NAV.

NOTE – The procedures below describe using the automatic mode of the International® A/C Servicing
System (RHS980C-NAV) to perform the recycle, vacuum, and charge operations on the A/C system. If a
different A/C servicing system is being used, refer to the instructions provided by the tool manufacturer.

In the automatic mode, the RHS980C-NAV can be used to perform a fully automatic A/C service. The
technician will be prompted for entry of data such as charge amount, and given options like vacuum leak
test. If the internal A/C database is used, some data will be provided based on the vehicle information
entered. Entry data can also be found in the specifications section of this manual, refer to SPECIFICATIONS
(See SPECIFICATIONS, page 178). Once the necessary data has been entered, the RHS980C-NAV will
automatically perform the complete A/C service (recycle, vacuum, and charge) and alert the technician for
interaction or that the service is complete.

Tips for fastest refrigerant recovery:

1. Run truck with hood closed, cab heat set to floor or vent, and temperature set full clockwise
(HOT). The A/C and defrost modes must not be selected. Run until heater air is very warm (the
warmer the better).
2. Turn engine off, and return key to ON (engine off), set mode control to MAX A/C and blower to
LOW. (This blows warm air over the evaporator during the refrigerant recovery process.)
3. Recover or Recycle refrigerant with A/C machine.
4. Turn ignition key off after refrigerant recovery (to save truck battery life).

The Automatic Mode is NOT to be used for discharging the system to make repairs on the A/C system; the
automatic mode will automatically charge the system when it is complete. The intended use of the automatic
mode is for complete service (recycle, vacuum, and charge) of the system and/or to verify the level of
charge when a system appears to be undercharged or overcharged, and possibly to start a leak check. Use
“RECYCLE” mode when opening the A/C system is necessary for making repairs.

36
SERVICE PROCEDURES FOR R-134A AUTOMATIC MODE

1. CONDENSER TO EVAPORATOR 3. COMPRESSOR TO

LINE CONDENSER LINE
2. HIGH SIDE PRESSURE PORT 4. LOW SIDE PRESSURE PORT
Figure 20 A/C Service connection location

NOTE – Ensure that the oil drain bottle has enough remaining capacity to perform a service. Adjust
the o-ring slider so it is level with the oil in the oil drain bottle, and note amount of oil recovered once
automatic mode is completed.

1. Remove the protection caps from both service ports.

2. Review “Tips for fastest refrigerant recovery”.

3. Turn machine on, select Automatic on the International® A/C Service System and follow on-screen
instructions.

4. Once automatic mode is complete, follow the on-screen instructions to disconnect the blue and red hoses
from the service ports on the vehicle and add oil to the system. Refer to AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT (page 186) and OIL FILL GUIDELINES (page 46).

5. Ensure that protection caps are reinstalled on service ports (with inner gaskets).

NOTE – If the RHS980C-NAV detects a problem such as a leak while operating in Automatic mode, the
machine will halt operation and display a message on the screen. If this occurs follow the on-screen
instructions.

37
DISCHARGING THE SYSTEM (RECYCLE MODE) SERVICE PROCEDURES FOR R-134A

4.7. DISCHARGING THE SYSTEM (RECYCLE MODE)

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant intended for recovery. Detection
devices are readily available to check for the presence of these chemicals and are highly
recommended to protect the RHS980C-NAV.

CAUTION

To prevent damage HVAC components, the amount of oil lost during the recovery
process, component replacement, or purging/flushing must be replaced with new oil.
The method for determining how much refrigerant oil must be added to the A/C system
is located in the OIL FILL GUIDELINES (page 46).

CAUTION

To prevent damage HVAC components, do not re-use recovered oil. Be sure to dispose
of recovered oil properly to avoid an environmental hazard.

NOTE – The procedures below describe using the RECYCLE mode of the International® A/C Servicing
System (RHS980C-NAV) to discharge R-134A refrigerant from the A/C system. If a different A/C servicing
system is being used, refer to the instructions provided by the tool manufacturer.

NOTE – If the system is being discharged because a leak is suspected, it may be helpful to begin leak
detection before discharging the system. This depends on the method of leak detection used. Refer to
LEAK DETECTION.

The RHS980C-NAV keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE)
to allow the technician to jump directly to any one of these functions. Recycle mode is used to discharge
the system (refrigerant recovery). The system must be discharged prior to removal and replacement of
malfunctioning components.

Tips for fastest refrigerant recovery:

1. Run truck with hood closed, cab heat set to floor or vent, and temperature set full clockwise
(HOT). The A/C and defrost modes must not be selected. Run until heater air is very warm (the
warmer the better).
2. Turn engine off, and return key to ON (engine off), set mode control to MAX A/C and blower to
LOW. (This blows warm air over the evaporator during the refrigerant recovery process.)
3. Recover or Recycle refrigerant with A/C machine.
4. Turn ignition key off after refrigerant recovery (to save truck battery life).

38
SERVICE PROCEDURES FOR R-134A DISCHARGING THE SYSTEM (RECYCLE MODE)

NOTE – Ensure that the oil drain bottle has enough remaining capacity to perform a service. Adjust the
o-ring slider so it is level with the oil in the oil drain bottle and note amount of oil recovered once recycle
mode is completed.

Refer to Figure 20 for the following steps:

1. Remove the protection caps from both service ports.

2. Review “Tips for fastest refrigerant recovery”.

3. Turn machine on, select Recycle on the International® A/C Servicing System and follow on screen
instructions.

4. Once the recycle mode is complete, follow on-screen instructions to disconnect the blue and red hoses
from the service ports on the vehicle.

5. Record the amount of oil recovered by discharging the system and ensure that protective caps (with
inner gaskets) are reinstalled on service ports.

6. Work may now begin on the air conditioning system.

39
EVACUATING THE SYSTEM (VACUUM MODE) SERVICE PROCEDURES FOR R-134A

4.8. EVACUATING THE SYSTEM (VACUUM MODE)

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

take extreme precaution to ensure that other refrigerants are not recovered into the
RHS980C-NAV. A refrigerant identifier is recommended for evaluating refrigerant in
the A/C system prior to servicing. Recovering other refrigerants will contaminate the
refrigerant in the RHS980C-NAV charge cylinder.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

sealants and leak-stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant recovered intended for recovery.
Detection devices are readily available to check for the presence of these chemicals
and are highly recommended to protect the RHS980C-NAV.

NOTE – The procedures below describe using the vacuum mode of the International® A/C Servicing
System (RHS980C-NAV) to evacuate the A/C system. If a different A/C servicing system is being used,
refer to the instructions provided by the tool manufacturer.

Whenever the air conditioning system has been discharged, the system must be completely evacuated of air
and moisture before being recharged.

NOTE – If the A/C system is to be flushed an/or purged, those procedures must be completed prior to
evacuating and recharging the system.

NOTE – If the A/C system being evacuated required replacement of the refrigerant compressor, the
correct amount of refrigerant oil must be added to the new compressor prior to evacuation of the system.
The amount of oil required must be determined (refer to OIL FILL GUIDELINES), and that amount of oil
should be added to the new compressor prior to installation.

The RHS980C-NAV keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE) to
allow the technician to jump directly to any one of these functions. Vacuum mode is used to evacuate the
system and test the system for leaks.

When this mode is initiated, the RHS980C-NAV will draw a vacuum on the system for a specified time.
Then the vacuum level will be monitored for 60 seconds. If the vacuum level rises above a specified level,
an error screen will be displayed (refer to LEAK DETECTION). If the vacuum level is maintained for 60
seconds, the RHS980C-NAV will resume drawing a vacuum on the system for an additional specified time. At
the completion of the evacuation cycle, the system vacuum should measure 1000 microns or less. If this
value cannot be reached, refer to LEAK DETECTION. Specified times and vacuum levels used during the
evacuation mode are established on the RHS980C-NAV SETUP/DEFAULT VALUES screens.

Refer to Figure 20 for the following steps:

1. Remove the protection caps from both service ports.

2. Review “Tips for fastest refrigerant recovery”.

3. Turn machine on, select Vacuum on the International® A/C Servicing System and follow on screen
instructions.

40
SERVICE PROCEDURES FOR R-134A CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE)

4. If any leaks are detected repair accordingly or refer to Leak Detection in this manual.

5. Once the Vacuum mode is complete, the system is ready to be charged, DO NOT disconnect the blue and
red hoses from the service ports, until instructed to do so.

4.9. CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE)

CAUTION

To prevent damage to HVAC components, use only new or recycled R-134a refrigerant;
not any of the so called “direct replacement” refrigerants. Use of equipment dedicated
for R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility
concerns.

CAUTION

To prevent damage HVAC components, when charging the A/C system the refrigerant
tank must be kept upright. If the tank is not in the upright position, liquid refrigerant may
enter the system and cause compressor damage.

NOTE – The procedures below describe using the CHARGE mode of the International® A/C Servicing
System (RHS980C-NAV) to charge the A/C system with R-134a refrigerant. If a different A/C servicing
system is being used, refer to the instructions provided by the tool manufacturer.

Perform the Charging procedures, using new or recycled refrigerant, only after the following actions have
been completed:

• System components repaired and/or replaced.

• System flushed or purged (if required).
• System oil level restored (only necessary if compressor replaced)
• System completely evacuated.

The RHS980C-NAV keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM and CHARGE) to
allow the technician to jump directly to any one of these functions. Charge mode is used to charge the
system to a full charge.

Refer to Figure 20 for the following steps:

1. The RHS980C-NAV red and blue hoses should still be connected as they were during the evacuation
operation.

2. Determine the amount of refrigerant to be charged. This information can be found in the SPECIFICATIONS
(See Table 18) section of this manual.

3. Select Charge on the International® A/C Servicing System and follow on screen instructions.

4. Once the charge operation is complete, follow the on-screen instructions to perform A/C SYSTEM
PERFORMANCE TEST.

5. Once the A/C SYSTEM PERFORMANCE TEST is complete, follow the on-screen instructions to clear the
hoses; then disconnect the blue and red hoses from the service ports on the vehicles service port fittings.

41
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM SERVICE PROCEDURES FOR R-134A

6. Add the appropriate amount of refrigerant oil to the system. Refer to AIR CONDITIONING OIL AND DYE
INJECTION EQUIPMENT and OIL FILL GUIDELINES (page 46).

7. Install the protective caps (with inner gaskets) on both of the vehicle service port fittings.

4.10. FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM

CAUTION

To prevent damage to HVAC components, never flush more than one component with
one attached hose at a time.

Systems that have had an internal compressor failure, been overcharged with refrigeration oil, or been left
open for an extended period of time will need to be flushed, purged, or both. Flushing and purging remove
contaminants that would have a negative effect on the life and operation of the air conditioning system, if
not removed.

Flushing removes contamination, excessive refrigerant oil, and moisture from A/C system components. When
a component is flushed, a liquid flushing agent (refrigerant or a solvent) is forced through it in a reverse
direction; the liquid cleans the part, picks up contaminants and flushes them out.

Purging can be performed in place of flushing when the system has not been contaminated by a compressor
failure. Purging must always be performed after using a solvent to flush the system. Purging removes flushing
solvent, excessive refrigerant oil, damp air, and loose particles from A/C system components. This assures
that A/C system components are dry and free of any contaminants.

Flushing and purging are performed on a system after the refrigerant has been recovered and before the
system is reassembled and evacuated. The only components that can be flushed or purged are the condenser,
evaporator, and hoses. The compressor, filter-drier, and expansion valve cannot be flushed or purged, and
must be replaced if contaminated.

When performing flushing and/or purging operations, adapters are required to connect the service equipment
to the HVAC system components. Refer to FLUSH/PURGE FITTING ADAPTERS for complete information on
these service adapters.

42
SERVICE PROCEDURES FOR R-134A FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM

Flushing Using the RHS980C-NAV (Recommended Method)

NOTE – The procedures below describe using the REFRIGERANT FLUSH mode of the International®
A/C Servicing System (RHS980C-NAV). If a different A/C servicing system is being used, refer to the
instructions provided by the tool manufacturer.

The use of the International® A/C Servicing System is recommended if the A/C system becomes contaminated.
A refrigerant flush, performed by the RTI machine, will force liquid refrigerant in a reverse flow through a
component, or components, to remove contaminants and oil. Contaminants are captured in an external filter
before returning the refrigerant to the service equipment. Because refrigerant is used as the flushing agent in
this method, a purging procedure is not required after flushing the system with the RTI machine.

The following procedures must be observed whenever a component or system is flushed.

• Never flush the entire system. Flush the system in segments (never larger than one component and
one hose).
• Never flush the compressor, thermostatic expansion valve (TXV), or filter-drier.
• Flush each system section or component in the opposite direction of normal refrigerant flow.
• If the system has experienced an internal compressor failure (or other source of heavy contamination),
replace the compressor, the TXV, and the filter-drier prior to evacuating and charging the system. Refer
to OIL FILL GUIDELINES (page 46).
• If the system did not experience an internal compressor failure (or other source of heavy contamination),
change oil in the compressor (refer to OIL FILL GUIDELINES), reinstall the TXV, and replace the filter-drier
prior to evacuating and charging the system.

NOTE – The following procedures for flushing are general. The actual fittings and adapters required for
each procedure will vary according to the component or components being connected.

43
FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM SERVICE PROCEDURES FOR R-134A

1. RTI MACHINE 6. TYPICAL COMPONENT

2. BLUE HOSE 7. ADAPTER
3. FLUSH FILTER 8. RED HOSE
4. YELLOW HOSE 9. TYPICAL HOSE
5. EVAPORATOR CORE
Figure 21 Typical Flush Filter Hook-up

1. Select REFRIGERANT FLUSH on the RHS980C-NAV screen and press START.

2. Using the keypad, enter how long the component is to be flushed. Typical flush time is 10 minutes, times
may vary dependent on which component is being flushed and the severity of contamination.

NOTE – It is recommended 10 minutes per component as a base line to flush the component. Then to
evaluate the system and do another 10 minutes, repeating this until clean.

3. Follow the on-screen instructions. When instructed, connect flush filter and component to be flushed
to the RHS980C-NAV.

4. When screen indicates that flush is finished, verify that the pressure gauges indicate 0 psi or less before
carefully removing the connections from the component under test. If the pressure gauges indicate
pressure greater than 0 psi, perform the RECYCLE mode before disconnecting the component.

5. Following the on-screen instructions, empty the oil bottle and replace the flush filter.

44
SERVICE PROCEDURES FOR R-134A FLUSHING AND PURGING THE AIR CONDITIONING SYSTEM

Alternate Method for Flushing (and Purging) the A/C System

While flushing the system with RHS980C-NAV is the recommended method, the system can be flushed and/or
purged using pressurized dry nitrogen gas and a flushing solvent. A flush gun and adapters are also required if
this method is used. As this is an alternate method, step-by-step procedures are not provided.

WARNING

To prevent personal injury or death, dry nitrogen gas is recommended for flushing and/or
purging. Do not use nitrogen at pressures over 200 psi (1378 kPa). Personal injury or
death may result from doing so. Commercial cylinders of dry nitrogen contain pressures
in excess of 2000 psi (13780 kPa). This pressure must be reduced, using a pressure
regulator, to 200 psi (1378 kPa) for purging.

CAUTION

To prevent damage and/or contamination to HVAC components and R-134a refrigerant,

when flushing and/or purging components of the system use only dry nitrogen. The
introduction of compressed air into the A/C system may cause contamination of the
system.

When using this method, heavier contamination must be flushed using the pressurized nitrogen to force a
liquid flushing solvent through components. Purging components of lighter contamination and moisture or
leftover flushing solvent can be accomplished using only the pressurized nitrogen.

Flushing is generally necessary only after an internal compressor failure has contaminated the refrigerant
system. Purging must always be performed: after flushing the system with a solvent; any time there is
excessive refrigerant oil found in the system; or, when the system has been left open for an extended period
of time. Purging removes flushing solvent, excessive refrigerant oil, damp air, and loose particles from A/C
system components by passing a stream of inert, dry nitrogen gas through parts of the system or individual
components.

Flushing and purging are performed on a system after the refrigerant has been recovered and before the
system is reassembled and evacuated.

The following procedures must be observed whenever a component or system is flushed or purged:

• Never flush or purge the entire system. Flush or purge the system in segments (never larger than one
component and one hose) to lessen the chance of blowing contaminants throughout the system.
• Never flush or purge the compressor, thermostatic expansion valve (TXV), or filter-drier.
• Flush or purge each system section or component in the opposite direction of normal refrigerant flow.
• If the system requires purging only, change oil in the compressor (refer to OIL FILL GUIDELINES), reinstall
the TXV, and replace the filter-drier prior to evacuating and charging the system.
• If the system requires both flushing and purging, replace the compressor, the TXV, and the filter-drier prior
to evacuating and charging the system. Refer to OIL FILL GUIDELINES (page 46).

45
OIL FILL GUIDELINES SERVICE PROCEDURES FOR R-134A

4.11. OIL FILL GUIDELINES

WARNING

To prevent personal injury or death, before doing any of the work below, read the
SERVICE WARNINGS. Failure to read the Service Warnings, and to be aware of the
dangers involved when working with refrigerant could lead to serious personal injury
or death.

CAUTION

To prevent damage and/or contamination to the RHS980C-NAV and R-134a refrigerant,

do not re-use recovered oil. Be sure to dispose of recovered oil properly to avoid an
environmental hazard.

CAUTION

Replacement compressors contain a quantity of oil when shipped. To prevent damage

to HVAC components, this oil must be drained from the new compressor to verify and/or
adjust the quantity before refilling the compressor (and system) with the correct amount
of oil. Oil drained from a new compressor may be used to refill the compressor prior to
installation.

CAUTION

During normal A/C operation, oil is circulated through the system with the refrigerant,
and a small amount is retained in each component. If certain components of the system
are removed, some of the refrigerant oil will go with the component. To prevent damage
to HVAC components and maintain the original total oil charge, it is necessary to
compensate for the oil lost by adding oil to the system with the new part.

The correct volume of refrigerant oil in the A/C system is critical for proper system operation. Insufficient
oil will result in compressor failure. Too much oil decreases cooling efficiency, resulting in poor system
cooling performance. In general, when servicing the system, ensure that the amount of oil (retained or
added) in the repaired system (compressor and components) equals the total system capacity indicated
in SPECIFICATIONS (See SPECIFICATIONS, page 178). Replacement oil may be added directly into
the compressor before evacuation, or injected into the system at any time after recharge. The following
paragraphs describe how to determine the quantity of refill oil needed under the most common conditions.

NOTE – Unless stated otherwise, the following procedures assume that the system is not being flushed
and/or purged.

A. If the refrigerant was only recovered for the purpose of measuring the refrigerant charge, or
to replace a low pressure switch, add the amount of oil removed from the system during the
refrigerant recovery procedure.

• Total replacement oil quantity = oil from refrigerant recovery procedure.

46
SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES

B. If a compressor is replaced (and the system was not contaminated and had no leaks) refill the
new compressor with the amount of oil removed from the system during the refrigerant recovery
procedure, plus the quantity of oil that was contained in the old compressor. NOTE: New
compressors must be drained of shipping oil to verify and/or adjust the quantity before refilling the
compressor with the correct amount of oil. Refer to CHECKING COMPRESSOR OIL LEVEL, that
follows, for the procedures to drain and fill the oil in the refrigerant compressor.

• Total replacement oil quantity = oil from refrigerant recovery procedure + oil drained from
old compressor.
C. If a component other than the compressor is replaced, and there is no oil leak, add the amount of
oil removed from the system during the refrigerant recovery procedure, plus the amount indicated
for the replaced component in table 3.

• Total replacement oil quantity = oil from refrigerant recovery procedure + oil indicated in
component table.
D. If the amount of oil in the system is unknown (due to an oil leak, ruptured hose, etc.); refer to
EXCESSIVE OIL LOSS DUE TO REFRIGERANT LEAK, below.
E. Whenever the refrigerant system has become contaminated; make the necessary repairs, flush
the system, and replace the compressor, expansion valve, and filter-drier. The new compressor
must be drained of shipping oil to verify and/or adjust the quantity before refilling the compressor
with the correct amount of oil. Refer to CHECKING COMPRESSOR OIL LEVEL that follows, for
the procedures to drain and fill the oil in the refrigerant compressor. The replacement oil should be
added directly to the compressor before installing it. Refill the system with a full refill of oil.

• Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 178) .

Table 3 Oil Capacity by Component

Typical oil amount

Component cc fl.oz.
Evaporator 60 2.0
Condenser 30 1.0
Filter-drier 15 0.5
Expansion valve 0 0
Hoses (normal length) 10 0.3
Low Pressure Switch 0 0

Oil Separation During Refrigerant Recovery

The oil removed from the system during the refrigerant recovery process must be replaced. Always empty the
refrigerant station oil catch bottle before recovering the refrigerant. After recovering the refrigerant, check
the calibrated bottle to determine how much oil has been removed from the system. This quantity is used
to help determine the amount of oil that must be added to the system before or after the recharging of the
A/C system. Do not use recovered refrigerant oil.

47
OIL FILL GUIDELINES SERVICE PROCEDURES FOR R-134A

Excessive Oil Loss Due to Refrigerant Leaks

CAUTION

After servicing the A/C system, always use new O-rings and C-plates when reassembling
the system components. O-rings must be lubricated with mineral oil.

When there is a significant refrigerant leak, an unknown amount of oil escapes from the system with the
refrigerant. When a significant leak is detected, perform the following procedures to replace the old system
oil with a full refill of new oil.

1. Use the service equipment and observation to determine the location of the leak. Refer to LEAK
DETECTION page 32.

2. Discharge the system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE)page 38.

3. Make any necessary repairs.

4. If the refrigerant system appears contaminated, such as after an internal compressor failure, it must be
flushed. Refer to FLUSHING THE AIR CONDITIONING SYSTEM (See FLUSHING AND PURGING
THE AIR CONDITIONING SYSTEM, page 42).

5. If the refrigerant system DOES NOT appear to be contaminated, either;

• flush the system using the RHS980C-NAV International® A/C Servicing System. Refer to FLUSHING
USING THE RHS980C-NAV.
• or purge the system using the alternate method for flushing (and purging) the A/C system. Refer to
ALTERNATE METHOD FOR FLUSHING (AND PURGING) THE A/C SYSTEM.

6. If the system was not contaminated:

A. Reinstall the expansion valve (removed for flushing).

B. Drain and discard the old oil from the compressor. Refer to CHECKING COMPRESSOR OIL
LEVEL that follows.
C. Refill compressor with new oil and then install the compressor.

Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 178).
D. Install a new filter-drier.

7. If the system was contaminated:

A. Install a new expansion valve.

B. Replace the compressor. Verify that the new compressor contains the correct amount of oil.
The new compressor must be drained of shipping oil to verify and/or adjust the quantity before
refilling the compressor with the correct amount of oil. Refer to CHECKING COMPRESSOR
OIL LEVEL that follows. The replacement oil should be added directly to the compressor
before installing it.

Total replacement oil quantity = total system capacity as specified in SPECIFICATIONS (See
SPECIFICATIONS, page 178).

48
SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES

C. Install a new filter-drier.

8. Evacuate the system; refer to EVACUATING THE SYSTEM (VACUUM MODE)page 40.

9. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM (CHARGE MODE)page 41.

10. After repairing a leak, remove all traces of the fluorescent dye from the repaired area before retesting the
area. The dye can be removed with UV Dye Cleaner, ZTSE4618–2.

11. After running the system, retest the repaired area to verify the repair.

49
CHECKING COMPRESSOR OIL LEVEL SERVICE PROCEDURES FOR R-134A

4.12. CHECKING COMPRESSOR OIL LEVEL

WARNING

To prevent personal injury or death, do not remove the oil fill plug to check the oil level in
the refrigerant compressor after the A/C system has been charged with refrigerant. The
crankcase side of the compressor is under pressure and personal injury or death may
result.

It is not possible to check the oil level in the compressor on an A/C system that is under system pressure. If it
is suspected that there is not enough oil in the A/C system, it will be necessary to remove all of the oil currently
in the system and refill the system with a full oil charge.

The compressor oil level can be accurately checked only by removing the compressor from the vehicle and
draining the oil into a clean, calibrated container.

1. Verify that the system is discharged.

2. Remove the compressor.

Figure 22 Drain as Much Oil as Possible

3. Remove the oil plug and drain as much oil as possible into a suitable clean, calibrated container.

4. Remove the caps (if present) from the suction and discharge ports.

50
SERVICE PROCEDURES FOR R-134A CHECKING COMPRESSOR OIL LEVEL

Figure 23 Drain Oil While Turning Shaft

5. Drain remaining compressor oil from the suction and discharge ports, into the calibrated container, while
turning the shaft (clockwise only) by hand or with a socket wrench on the armature retaining nut. Turn
shaft one half turn every minute for approximately 3 minutes. Replace the caps on the suction and
discharge ports.

6. Measure and record the amount of oil drained from the compressor.

7. Inspect the oil for signs of contamination such as discoloration or foreign material.

8. If the oil shows signs of contamination, replace the compressor. Verify that the new compressor contains
the correct amount of oil (continue this procedure starting at step 3).

Figure 24 Add New Oil to Compressor

9. If the oil is not contaminated, add the correct amount of oil to the compressor as determined by the OIL
FILL GUIDELINES (page 46).

51
CHECKING COMPRESSOR OIL LEVEL SERVICE PROCEDURES FOR R-134A

NOTE – Oil drained from a NEW compressor may be used to refill the compressor. DO NOT USE
recovered oil or oil drained from a used compressor.

10. Install oil fill plug taking care not to twist the O-ring seal. Replace the O-ring if damaged. Torque oil plug to
11 to 15 lbf-ft (15 to 20 N•m). Do not over-tighten plug to stop a leak. Stop leaks first by fixing any seat
damage, removing dirt and installing a new O-ring.

52
REMOVE AND INSTALL PROCEDURES CHECKING COMPRESSOR OIL LEVEL

5. REMOVE AND INSTALL PROCEDURES

WARNING

To prevent personal injury or death, always turn the vehicle ignition key OFF before
performing Removal and Installation procedures.

NOTE – Special attention to the following, during component removal and installation, will aid in avoiding
unnecessary and time-consuming problems.

1. O-RING 2. C-PLATE
Figure 25 A/C Fitting C-Plate and O-Ring

A. When working on the A/C system keep the work area and tools as clean as possible. Also, clean
all connections, ports or fittings before disconnecting or removing components.
B. All A/C component and refrigerant line openings should be immediately covered or plugged
during removal and remain so until re-installation to prevent the entry of dirt, moisture and other
foreign material. Even the slightest particle can cause problems if carried to a vulnerable place
within the system.
C. Never remove protective caps from components until the moment of assembly into the system.
D. Never install non-sealed components.
E. If the filter-drier is one of multiple components being installed in the system, it should be the last
component installed. This reduces the amount of time that the filter-drier desiccant is exposed to
atmospheric moisture.
F. Anytime an A/C fitting is disconnected, the O-ring and/or C-plate must be replaced (Figure 25). The
new O-ring must be lubricated with MINERAL-BASED oil. The C-plate does not require lubrication.
Never use grease, penetrating oil, motor oil, Ester or PAG oil, etc. to lubricate O-rings and fittings.
G. All refrigerant hose and tubing support clamps and strap locks must be re-installed in their original
positions.

Never bend a hose to a radius less than ten times the diameter of the hose.

Never route a hose any closer than four inches from the exhaust manifold or related piping.
H. Whenever possible use a backup wrench when loosening or tightening fittings (Figure 15).
I. All fittings must be tightened as specified in the TORQUE CHART (See Table 32, page 178). Use
only a torque wrench known to be accurate.

53
PRESSURE TRANSDUCER REMOVE AND INSTALL PROCEDURES

NOTE – The following figures and procedures cover most typical engine/chassis configurations. Some
configurations may differ slightly due to component mounting locations and/or hose routings.

5.1. PRESSURE TRANSDUCER

CAUTION

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

damage to the A/C system replace a defective pressure transducer only with the
recommended part.

NOTE – The pressure transducer can be removed and installed without removing the refrigerant from
the A/C system.

The pressure transducer is located on the condenser-to-evaporator refrigerant line.

Pressure Transducer – Removal

1. PRESSURE TRANSDUCER 3. ELECTRICAL CONNECTOR

2. CONDENSER-TO-EVAPORATOR 4. RADIATOR
LINE
Figure 26 Pressure Transducer

1. Disconnect electrical connection to pressure transducer.

2. Unscrew pressure transducer from condenser-to-evaporator refrigerant line and cap open fitting.

54
REMOVE AND INSTALL PROCEDURES LOW PRESSURE SWITCH

Pressure Transducer – Installation

1. Install a new O-ring on transducer fitting and lubricate O-ring and threads with mineral-based oil (Figure
26, Item 1).

2. Screw pressure transducer onto A/C line fitting (Figure26, Items 1 and 2) and tighten to 5 to 10 lbf-ft (7
to 14 N•m).

3. Connect electrical connector to pressure transducer (Figure 26, Items 1 and 3).

5.2. LOW PRESSURE SWITCH

WARNING

To prevent personal injury or death, the low pressure switch CANNOT be removed and
installed without removing the refrigerant from the AC system.

Low Pressure Switch – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38).

1. SUCTION LINE 3. ELECTRICAL CONNECTOR

2. LOW PRESSURE SWITCH
Figure 27 Low Pressure Switch

2. Cut wires ties as necessary; disconnect electrical connector from low pressure switch.

3. Unscrew low pressure switch from its fitting in the suction line and cap open fitting.

55
FREEZE PROBE REMOVE AND INSTALL PROCEDURES

Low Pressure Switch – Installation

1. Ensure a new O-ring is installed on the new low pressure switch, and lubricate O-ring and threads with
mineral-based oil.

2. Screw low pressure switch into its fitting (Figure 27, Item 2) and tighten to 5 to 10 lbf-ft (7 to 14 N•m).

3. Connect electrical connector to low pressure switch and secure with wire ties as necessary (Figure 27,
Items 2 and 3).

4. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

5.3. FREEZE PROBE

Freeze Probe – Removal

1. Remove blower scroll housing (See BLOWER SCROLL HOUSING, page 97).

1. ELECTRICAL CONNECTOR 4. FREEZE PROBE

2. GROMMET 5. EVAPORATOR
3. INTERIOR MODULE
Figure 28 Freeze Probe

2. Cut wires ties as necessary, and disconnect freeze probe electrical connector.

3. Press grommet through interior module with electrical connector.

NOTE – Prior to removing freeze probe, note how deep the freeze probe is inserted.

4. Gently pull the freeze probe out of exposed side of the evaporator (See Figure 28, page 56).

56
REMOVE AND INSTALL PROCEDURES FREEZE PROBE

Freeze Probe – Installation

1. Gently push the freeze probe into exposed side of the evaporator to the depth noted during removal
(See Figure 28, page 56).

2. Pull electrical connector through interior module with grommet (See Figure 28, page 56). Ensure grommet
seats properly in interior module .

3. Connect freeze probe electrical connector and secure using wire ties as necessary (See Figure 28,
page 56).

4. Install blower scroll housing (See BLOWER SCROLL HOUSING, page 97).

57
HVAC AIR FILTER REMOVE AND INSTALL PROCEDURES

5.4. HVAC AIR FILTER

HVAC Air Filter – Removal

1. Unlatch and raise hood.

1. FRESH AIR MODULE 3. HVAC FILTER COVER

2. FASTENERS 4. FILTER ELEMENT
Figure 29 HVAC Filter

2. Locate HVAC filter cover and then turn fasteners counterclockwise to release HVAC filter cover.

3. Remove HVAC filter cover, firmly grasp HVAC filter, and remove HVAC filter from fresh air module.

HVAC Air Filter – Installation

1. Install a new (or cleaned) HVAC filter into fresh air module (Figure 29, Items 1 and 4).

2. Install HVAC filter cover and secure by turning fasteners clockwise until fasteners lock HVAC filter cover in
place (Figure 29, Items 2 and 3).

3. Lower and latch hood.

58
REMOVE AND INSTALL PROCEDURES REFRIGERANT LINE

5.5. REFRIGERANT LINE

The three A/C refrigerant hoses/lines are connected in the same way; however, the number of mounting
straps and clamps may be different for each hose. Also, the routing of each hose varies for each vehicle
model/engine combination.

Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant lines may require
the removal of nearby assemblies (right splash panel, fixed grille, or recirculation shield) to gain access to the
fittings, or to remove the A/C lines. Refer to the appropriate Service Manual for additional procedures.

Refrigerant Line – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38)..

1. HOSE SUPPORT CLAMP 5. CONDENSER

2. EVAPORATOR-TO-COMPRESSOR 6. PRESSURE TRANSDUCER
LINE 7. COMPRESSOR
3. SUCTION LINE 8. CONDENSER-TO-EVAPORATOR
4. CONNECTION FITTING LINE
Figure 30 Refrigerant Lines

59
REFRIGERANT LINE REMOVE AND INSTALL PROCEDURES

1. FRESH AIR MODULE 5. REAR

2. NUT EVAPORATOR-TO-COMPRESSOR
3. EVAPORATOR-TO-COMPRESSOR LINE
LINE 6. FILTER-DRIER-TO-REAR
4. CONDENSER-TO-EVAPORATOR EVAPORATOR LINE
LINE 7. FILTER COVER
Figure 31 Refrigerant Lines with Rear HVAC

NOTE – When removing Condenser-to-Evaporator Hose disconnect electrical connection to pressure

transducer.

2. Disconnect fitting at each end of hose/line being removed.

3. Unclip or remove all hose support clamps and strap locks used to secure hose/line. Note location and
orientation of each clamp and strap lock to allow for correct routing during installation.

4. Remove A/C hose/line.

NOTE – When replacing Condenser-to-Evaporator line, remove pressure transducer from old line for
transfer to new line.
Refrigerant Line – Installation

NOTE – Before installing a new Condenser-to-Evaporator line it may be necessary to transfer pressure
transducer from the old line to the new line.

1. If A/C system is to be flushed, perform that operation before reassembling the system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM.

2. Place new A/C hose/line in its approximate location.

NOTE – Always lubricate O-rings with mineral-based oil during installation.

60
REMOVE AND INSTALL PROCEDURES REFRIGERANT LINE

3. Using new O-rings and C-plates connect fittings at each end of the A/C hose/line (Figure 30), (Figure 31).
Torque C-plate nuts to 14 to 15 lbf-ft (19 to 21 N•m).

4. Secure the hose/line using all support clamps and strap locks removed during removal.

5. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

61
FILTER-DRIER REMOVE AND INSTALL PROCEDURES

5.6. FILTER-DRIER
The filter-drier inlet and outlet lines are part of the filter-drier assembly.

NOTE – If the filter-drier is one of multiple components being replaced in the system, the filter-drier
should be one of the last components installed. This reduces the amount of time that the filter-drier
desiccant is exposed to atmospheric moisture.

Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components
may require the removal of nearby assemblies (right splash panel, etc.) to gain access to the components or
related A/C lines. Refer to the appropriate Master Service Manual for additional procedures.

Filter-Drier – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38)..

1. EXPANSION VALVE 7. FILTER-DRIER-TO-REAR

2. LOCK PLATE SCREW EVAPORATOR LINE
3. FILTER-DRIER 8. CONDENSER-TO-EVAPORATOR
4. LOW PRESSURE SWITCH LINE
5. EVAPORATOR-TO-COMPRESSOR 9. FILTER-DRIER COVER SCREWS
LINE 10. FILTER-DRIER COVER
6. NUT 11. ELECTRICAL CONNECTOR,
LOW PRESSURE SWITCH
Figure 32 Filter-Drier

2. Disconnect electrical connector from low pressure switch.

3. Remove low pressure switch and retain for install.

4. Remove nut and disconnect condenser-to-evaporator line from connection block.

5. Remove nut and disconnect evaporator-to-compressor line from connection block.

62
REMOVE AND INSTALL PROCEDURES FILTER-DRIER

6. Remove nut and disconnect drier-to-rear evaporator line from connection block.

7. Remove screw from locking plate on front of the expansion valve.

8. While supporting filter-drier, remove screws from filter-drier cover, slide cover down and remove.

9. Remove filter-drier by lifting it free of expansion valve.

Filter-Drier – Installation

1. If A/C system is to be flushed, perform that operation before reassembling the system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM.

NOTE – During installation always lubricate O-rings on fittings with mineral-based oil.

2. Install and lubricate O-rings on tubes of the expansion valve. While supporting the filter-drier in place,
insert the tubes into the expansion valve; then secure the filter-drier by installing the filter-drier cover
with screws (Figure 32).

3. Install locking plate with one screw to secure the tubes to the expansion valve (Figure 32, Item 2).

4. Using a new O-ring and C-plate, connect drier-to-rear evaporator line to filter-drier connection block
(Figure 32, items 3 and 7). Torque C-plate nut to 14 to 15 lbf-ft (19 to 20 N•m).

5. Using a new O-ring and C-plate, connect evaporator-to-compressor line to filter-drier connection block
(Figure 32, Items 3 and 5). Torque C-plate nut to 14 to 15 lbf-ft (19 to 20 N•m).

6. Using a new O-ring and C-plate connect condenser-to-evaporator line to filter-drier connection block
(Figure 32, Items 3 and 8). Torque C-plate nut to 14 to 15 lbf-ft (19 to 20 N•m).

7. Install low pressure switch (Figure 32, Item 4).

8. Connect electrical connector to low pressure switch (Figure 32, Items 4 and 11).

9. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

10. Install right side splash panel, if previously removed.

63
THERMOSTATIC EXPANSION VALVE (TXV) REMOVE AND INSTALL PROCEDURES

5.7. THERMOSTATIC EXPANSION VALVE (TXV)

Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components
may require the removal of nearby assemblies (right splash panel, etc.) to gain access to the components or
related A/C lines. Refer to the appropriate Master Service Manual for additional procedures.

CAUTION

To prevent damage to HVAC components, while handling the thermostatic expansion

valve in the following procedures, it is important to keep it and the entire A/C system as
dirt-free as possible.

Thermostatic Expansion Valve (TXV) – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38)..

2. Remove filter-drier. Refer to FILTER-DRIER.

1. REAR LOCKING PLATE 3. ALLEN SCREW

2. EXPANSION VALVE
Figure 33 Expansion Valve (TXV)

3. With front locking plate removed from expansion valve, remove two Allen head screws from expansion
valve body. Remove and retain rear locking plate.

4. Remove expansion valve (TXV).

64
REMOVE AND INSTALL PROCEDURES FRESH AIR MODULE

Thermostatic Expansion Valve (TXV) – Installation

1. If A/C system is to be flushed, perform that operation before reassembling the system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM.

NOTE – During installation always lubricate O-rings on fittings with mineral-based oil.

NOTE – Before installing new O-rings in the following steps, ensure that the old O-rings have been
removed.

2. Ensure that new lubricated O-rings are installed on all lines being connected to expansion valve.

3. Position rear locking plate over evaporator inlet and outlet lines (Figure 33).

4. Install expansion valve on rear locking plate over the inlet and outlet lines and secure expansion valve
with two Allen head screws (Figure 33).

5. Install filter-drier. Refer to FILTER-DRIER.

6. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

5.8. FRESH AIR MODULE

Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components
may require the removal of nearby assemblies (right splash panel, etc.) to gain access to the components or
related A/C lines. Refer to the appropriate Master Service Manual for additional procedures.

Fresh Air Module – Removal

1. Remove engine air filter housing and mounting brackets (if applicable).

2. If necessary, remove right side splash panel.

3. Remove cab cowl tray. Refer to appropriate CAB Service Manual.

65
FRESH AIR MODULE REMOVE AND INSTALL PROCEDURES

1. FRESH AIR MODULE 3. ENGINE

2. NUT
Figure 34 Engine Side of Fresh Air Module

4. Remove nut from engine side of fresh air module.

66
REMOVE AND INSTALL PROCEDURES INTERIOR MODULE TRIM COVER

1. NUT 2. FRESH AIR MODULE

Figure 35 Fresh Air Module

5. Remove three nuts from fresh air module.

6. Carefully remove fresh air module from engine side of dash panel.

Fresh Air Module – Installation

1. Using a new gasket/seal, install fresh air module onto mounting studs located on dash panel using four
nuts (Figure 34, Item 2 and Figure 35, Item 1). Torque nuts to 58 lbf-in (7 N•m).

2. Install cab cowl tray. Refer to appropriate CAB Service Manual.

3. If engine air cleaner and mounting bracket were removed:

a. Install engine air cleaner mounting bracket.
b. Install engine air cleaner on its mounting bracket.
c. Connect electrical connections to all components mounted on air cleaner mounting bracket.
d. Connect air tube and wiring to engine air cleaner housing.

4. Install right side splash panel, if previously removed.

5.9. INTERIOR MODULE TRIM COVER

The interior module trim cover must be removed prior to removing any of the HVAC components located under
the right side of the instrument panel (IP). Removal and installation of the interior module trim cover may
require the removal of other trim panels. The panels that must be removed vary by vehicle model and trim
level. Refer to the appropriate CAB Service Manual for additional procedures.

67
FRESH / RECIRCULATE DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES

Interior Module Trim Cover – Removal

1. Remove fuse panel cover from passenger side instrument panel by pulling top of cover away from IP to
release spring clips and then lift cover up.

2. Remove trim panels, as necessary, to gain access to mounting screws for interior module trim cover.

1. SCREW 2. INTERIOR MODULE TRIM

COVER
Figure 36 Interior Module Trim Cover

3. Remove eight screws from interior module trim cover.

4. Remove cover by pulling it straight back.

Interior Module Trim Cover – Installation

1. Secure interior module trim cover to interior module with eight screws (Figure 36). Torque screws to 20
lbf-in (2.26 N•m).

2. Install all additional trim panels removed to gain access to interior module trim cover.

3. Install fuse panel cover by inserting two tabs at bottom of cover into sockets in IP; then press top of
cover toward IP to engage spring clips.

5.10. FRESH / RECIRCULATE DOOR ACTUATOR

The interior module trim cover must be removed prior to removing any of the HVAC components located under
the right side of the instrument panel (IP). Removal and installation of the interior module trim cover may

68
REMOVE AND INSTALL PROCEDURES FRESH / RECIRCULATE DOOR ACTUATOR

require the removal of other trim panels. The panels that must be removed vary by vehicle model and trim
level. Refer to the appropriate CAB Service Manual for additional procedures.

Fresh/Recirculate Door Actuator – Removal

1. Remove interior module. Refer to INTERIOR MODULE.

1. MODE DOOR ACTUATOR 4. BLEND DOOR ACTUATOR

2. FRESH/RECIRCULATE DOOR 5. ELECTRICAL CONNECTOR
ACTUATOR 6. SCREW
3. INTERIOR MODULE
Figure 37 Fresh/Recirculate Door Actuator

2. Disconnect electrical connector from fresh/recirculate door actuator.

3. Remove three screws from fresh/recirculate door actuator and remove fresh/recirculate door actuator.

Fresh/Recirculate Door Actuator – Installation

CAUTION

To prevent damage to actuator, in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, perform the following
procedure. Forcing the drive collar may result in a broken actuator.

1. Install actuator by rotating door until flats on door shaft align with actuator drive collar, then carefully slip
the actuator onto end of door shaft so that mounting holes are properly aligned, if possible. If actuator
drive collar must be moved to allow alignment, do the following:
a. Place the actuator in its approximate position.

69
BLEND DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES

b. Connect a 9-volt battery across pins A and F of the actuator connector, to rotate the drive collar.
(Reverse the connection to rotate the drive collar in the opposite direction.)
c. Allow drive collar to rotate until it is aligned with door shaft and blend door actuator mounting screws
can be inserted. Then, disconnect the battery.

2. Secure fresh/recirculate door actuator to interior module using three screws (Figure 37, Items 2, 3, and 6).
Torque screws to 20 lbf-in (2.26 N•m).

3. Connect electrical connector to fresh/recirculate door actuator (Figure 37, Items 2 and 5).

NOTE – In the following step, the actuator may also be recalibrated by disconnecting the vehicle battery
for 30 seconds; however, this method may result in disrupting other electrical equipment (such as radio
presets).

4. Initiate calibration procedure manually by following the actuator / door position recalibration procedure
page 149.

5. Install interior module. Refer to INTERIOR MODULE.

5.11. BLEND DOOR ACTUATOR

Accessing the temperature blend door actuator may require the removal of trim panels not described in this
manual. The panels that must be removed vary by vehicle model and trim level. Refer to the appropriate CAB
Service Manual for additional procedures.

Blend Door Actuator – Removal

1. Remove interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.

70
REMOVE AND INSTALL PROCEDURES BLEND DOOR ACTUATOR

1. MODE DOOR ACTUATOR 5. ELECTRICAL CONNECTOR

2. BLEND DOOR ACTUATOR 6. FRESH/RECIRCULATE DOOR
3. SCREW ACTUATOR
4. INTERIOR MODULE
Figure 38 Blend Door Actuator

2. Disconnect electrical connector from blend door actuator.

3. Remove three screws from blend door actuator and remove blend door actuator.

Blend Door Actuator – Installation

CAUTION

To prevent damage to actuator in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, complete the following
procedure. Forcing the drive collar may result in a broken actuator.

1. Install blend door actuator by rotating door until flats on door shaft align with blend door actuator drive
collar, if possible. Then carefully slip the blend door actuator onto end of door shaft so that mounting holes
are properly aligned. If blend door actuator drive collar must be moved to allow alignment, do the following:
a. Place blend door actuator in its approximate position.
b. To rotate drive collar, connect a 9-volt battery across the active pins of the blend door actuator
connector (check mating connector, if necessary). (Reverse connection to rotate drive collar in
opposite direction.)
c. Allow drive collar to rotate until it is aligned with door shaft and blend door actuator mounting screws
can be inserted. Then, disconnect the battery.

71
MODE DOOR ACTUATOR REMOVE AND INSTALL PROCEDURES

2. Secure blend door actuator to interior module using three screws (Figure 38, Items 2, 3, and 4). Torque
screws to 20 lbf-in (2.26 N•m).

3. Connect electrical connector to blend door actuator (Figure 38, Items 2 and 5).

NOTE – In the following step, the actuator may also be recalibrated by disconnecting the vehicle battery
for 30 seconds; however, this method may result in disrupting other electrical equipment (such as radio
presets).

4. Initiate calibration procedure manually by following the actuator / door position recalibration procedure
page 149.

5. Install interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.

5.12. MODE DOOR ACTUATOR

Accessing the mode door actuator may require the removal of trim panels not described in this manual. The
panels that must be removed vary by vehicle model and trim level. Refer to the appropriate CAB Service
Manual for additional procedures.
Mode Door Actuator – Removal

1. Remove interior module. Refer to INTERIOR MODULE.

1. SCREW 5. BLEND DOOR ACTUATOR

2. MODE DOOR ACTUATOR 6. FRESH/RECIRCULATE DOOR
3. ELECTRICAL CONNECTOR ACTUATOR
4. INTERIOR MODULE
Figure 39 Mode Door Actuator

72
REMOVE AND INSTALL PROCEDURES FRESH/RECIRCULATE DOOR GEAR TRAIN

2. Disconnect electrical connector from mode door actuator.

3. Remove three screws securing mode door actuator to interior module, and pull mode door actuator
straight off of mode door shaft.

Mode Door Actuator – Installation

CAUTION

To prevent damage to actuator, in the following step, never force the actuator drive
collar into position. If the drive collar position must be changed, complete the following
procedure. Forcing the drive collar may result in a broken actuator.

1. Carefully slip mode door actuator onto end of mode door shaft so that mounting holes are properly aligned,
if possible. If mode door actuator drive collar must be moved to allow alignment complete the following:
a. Place mode door actuator in its approximate position.
b. To rotate drive collar, connect a 9-Volt battery across the active pins of the mode door actuator
connector (check mating connector if necessary). (Reverse connection to rotate drive collar in
opposite direction.)
c. Allow drive collar to rotate until it is aligned with door shaft and blend door actuator mounting screws
can be inserted. Then, disconnect the battery.

2. Secure mode door actuator to interior module using three screws (Figure 39, Items 1, 2 and 4). Torque
screws to 20 lbf-in (2.26 N•m).

3. Connect electrical connector to mode door actuator (Figure 39, Items 2 and 3).

NOTE – In the following step the actuator may also be recalibrated by disconnecting the vehicle battery
for 30 seconds; however, this method may result in disrupting other electrical equipment (such as radio
presets).

4. Initiate calibration procedure manually by following the actuator / door position recalibration procedure
page 149.

5. Install interior module. Refer to INTERIOR MODULE.

5.13. FRESH/RECIRCULATE DOOR GEAR TRAIN

Fresh/Recirculate Door Gear Train – Removal

1. Remove interior module from vehicle. Refer to INTERIOR MODULE.

2. Remove fresh/recirculate door actuator. Refer to FRESH/RECIRCULATE DOOR ACTUATOR.

3. Remove left side recirculation filter. Refer to RECIRCULATION FILTERS.

73
FRESH/RECIRCULATE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. RECIRCULATE FILTER CAGE 2. SCREW

Figure 40 Recirculate Filter Cage

4. Remove two screws from recirculate filter cage and remove recirculate filter cage.

NOTE – Make note of the location of each gear prior to removal.

74
REMOVE AND INSTALL PROCEDURES FRESH/RECIRCULATE DOOR GEAR TRAIN

1. UPPER DOOR CONTROL 3. FRESH/RECIRCULATE DOOR

LINKAGE GEAR
2. LOWER DOOR CONTROL
LINKAGE
Figure 41 Recirculate Door Gear

5. Remove two door control linkages and fresh/recirculate door gear.

Fresh/Recirculate Door Gear Train – Installation

NOTE – An indexing tooth is on the fresh/recirculate gear to ensure proper timing of the fresh/recirculate
door and to prevent incorrect installation. Fresh/Recirculate gear will install only one way, do not force
gears in place.

75
BLEND DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. UPPER DOOR CONTROL 4. FRESH/RECIRCULATE DOOR

LINKAGE GEAR
2. FRESH/RECIRCULATE DOOR 5. LOWER DOOR CONTROL
3. INDEXING TEETH LINKAGE
Figure 42 Fresh/Recirculate Gear Indexing Teeth

1. Align indexing teeth of fresh/recirculate door gear with fresh/recirculate door and install with upper and
lower door control linkages.

NOTE – Check for proper operation of fresh/recirculate door by turning fresh/recirculate gear by hand.
Ensure lower door control linkage is not installed backwards.

2. Install recirculation filter cage and secure with two screws (Figure 40, Items 1 and 2).

3. Install left side recirculation filter. Refer to RECIRCULATION FILTERS.

4. Install fresh/recirculate door actuator. Refer to FRESH/RECIRCULATE DOOR ACTUATOR.

5. Install interior module. Refer to INTERIOR MODULE.

5.14. BLEND DOOR GEAR TRAIN

Blend Door Gear Train – Removal

1. Remove interior module from vehicle. Refer to INTERIOR MODULE.

2. Remove blend door actuator. Refer to BLEND DOOR ACTUATOR.

76
REMOVE AND INSTALL PROCEDURES BLEND DOOR GEAR TRAIN

1. SCREW 2. BLEND DOOR GEAR TRAIN

COVER
Figure 43 Blend Door Gear Train Cover

3. Remove three screws from blend door gear train cover and remove blend door gear train cover.

NOTE – Make note of the location of each gear prior to removal.

77
BLEND DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. TOP GEAR 3. INTERIOR MODULE

2. CAM LEVER GEAR 4. CAM LEVER
Figure 44 Blend Door Cam Lever

4. Remove cam lever and cam lever gear from interior module.

5. Remove top gear from interior module.

78
REMOVE AND INSTALL PROCEDURES BLEND DOOR GEAR TRAIN

1. BOTTOM GEAR 2. INTERIOR MODULE

Figure 45 Blend Door Bottom Gear

6. Remove bottom gear from interior module.

Blend Door Gear Train – Installation

NOTE – An indexing tooth is on each gear to ensure proper timing of the blend doors and to prevent
incorrect installation. Gears will install only one way, do not force gears in place.

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MODE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. TOP GEAR 4. CAM LEVER

2. CAM LEVER GEAR 5. INDEXING TEETH
3. BOTTOM GEAR
Figure 46 Blend Door Gears Indexing Teeth

1. Install bottom gear with cam lever into interior module.

2. Ensure indexing teeth are aligned properly, and install top gear with cam lever gear into interior module.

3. Install blend door gear train cover and secure with three screws (Figure 43, Items 1 and 2).

4. Install blend door actuator. Refer to BLEND DOOR ACTUATOR.

5. Install interior module. Refer to INTERIOR MODULE.

5.15. MODE DOOR GEAR TRAIN

Mode Door Gear Train – Removal

1. Remove interior module from vehicle. Refer to INTERIOR MODULE.

2. Remove mode door actuator. Refer to MODE DOOR ACTUATOR.

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REMOVE AND INSTALL PROCEDURES MODE DOOR GEAR TRAIN

1. SCREW 2. MODE DOOR GEAR TRAIN

COVER
Figure 47 Mode Door Gear Train Cover

3. Remove three screws from mode door gear train cover and remove mode door gear train cover.

NOTE – Make note of the location of each gear prior to removal.

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MODE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. CAM LEVER 2. CAM LEVER GEAR

Figure 48 Mode Door Cam Lever

4. Remove cam lever and cam lever gear together.

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REMOVE AND INSTALL PROCEDURES MODE DOOR GEAR TRAIN

1. INTERIOR MODULE 3. FRONT GEAR

2. IDLER GEAR 4. REAR GEAR
Figure 49 Mode Door Gears

5. Remove remaining three gears from interior module.

Mode Door Gear Train – Installation

NOTE – An indexing tooth is on each gear to ensure proper timing of the mode doors and to prevent
incorrect installation. Gears will install only one way; do not force gears in place.

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MODE DOOR GEAR TRAIN REMOVE AND INSTALL PROCEDURES

1. REAR GEAR 4. CAM LEVER

2. INDEXING TEETH 5. FRONT GEAR
3. IDLER GEAR 6. CAM LEVER GEAR
Figure 50 Mode Door Gears Indexing Teeth

1. Align indexing teeth and install idler gear and rear gear onto interior module.

2. Align indexing teeth of front gear and cam lever gear.

3. Install cam lever, cam lever gear, and front gear onto interior module.

4. Install mode door gear train cover and secure with three screws (Figure 47, Items 1 and 2).

5. Install mode door actuator. Refer to MODE DOOR ACTUATOR.

6. Install interior module. Refer to INTERIOR MODULE.

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REMOVE AND INSTALL PROCEDURES RECIRCULATION FILTERS

5.16. RECIRCULATION FILTERS

Recirculation Filters – Removal

1. HVAC UNIT 3. BOLT

2. DUCT TRIM PANEL
Figure 51 Duct Trim Panel

1. Remove bolt from duct trim panel.

2. Carefully pull duct trim panel away from HVAC unit and remove duct trim panel.

3. Remove interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.

85
RECIRCULATION FILTERS REMOVE AND INSTALL PROCEDURES

1. INTERIOR MODULE 3. RIGHT RECIRCULATION FILTER

2. RECIRCULATION FILTER CAGE 4. LEFT RECIRCULATION FILTER
Figure 52 Recirculation Filters

4. Carefully pull right recirculation filter out of recirculation filter cage.

5. Carefully pull left recirculation filter out of recirculation filter cage.

Recirculation Filters – Installation

1. Carefully press left recirculation filter into recirculation filter cage, making sure not to damage filter and
ensure recirculation filter goes all the way in, so recirculation filter cage secures filter in place (Figure 52,
Items 2 and 4).

2. Carefully press right recirculation filter into recirculation filter cage, making sure not to damage filter and
ensure recirculation filter goes all the way in, so recirculation filter cage secures filter in place (Figure 52,
Items 2 and 3).

3. Install interior module trim cover (See INTERIOR MODULE TRIM COVER, page 67).

4. Install duct trim panel and vent trim panel over interior module. Snap duct trim panel in place and secure
with bolt (Figure 51, Items 2 and 3).

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REMOVE AND INSTALL PROCEDURES LINEAR POWER MODULE (LPM)

5.17. LINEAR POWER MODULE (LPM)

Linear Power Module (LPM) – Removal

1. HVAC UNIT 3. BOLT

2. DUCT TRIM PANEL
Figure 53 Duct Trim Panel

1. Remove bolt from duct trim panel.

2. Carefully pull duct trim panel away from HVAC unit and remove duct trim panel.

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BLOWER ASSEMBLY REMOVE AND INSTALL PROCEDURES

1. SCREWS 5. TRUCK HARNESS CONNECTOR

2. INTERIOR MODULE (1220)
3. BLOWER MOTOR CONNECTOR 6. LINEAR POWER MODULE (LPM)
4. DRIP LOOPS
Figure 54 Linear Power Module (LPM)

3. Locate LPM on interior module and disconnect two electrical connectors.

4. Remove two screws from LPM and remove LPM.

Linear Power Module (LPM) – Installation

1. Install LPM to interior module and secure with two screws (See Figure 54, page 88). Torque screws
to 20 lbf-in (2.26 N•m).

2. To connect electrical cables to LPM, perform the following:.

a. Connect two electrical connectors to LPM (See Figure 54, page 88).
b. Route connector cables to form drip loops lower than electrical connectors (See Figure 54, page 88).

3. Install duct trim panel and vent trim panel over interior module. Snap duct trim panel in place and secure
with bolt (See Figure 53, page 87).

5.18. BLOWER ASSEMBLY

Blower Assembly – Removal

1. Remove blower scroll housing (See BLOWER SCROLL HOUSING, page 97).

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REMOVE AND INSTALL PROCEDURES HEATER CORE

1. FRONT VIEW OF BLOWER 4. REAR VIEW OF BLOWER

SCROLL HOUSING SCROLL HOUSING
2. GROMMET 5. SCREW
3. ELECTRICAL CONNECTOR 6. BLOWER ASSEMBLY
Figure 55 Blower Assembly

2. Remove two screws from front of blower scroll housing.

3. Carefully pull grommet and electrical connector through blower scroll housing.

4. Remove two screws from rear of blower scroll housing and remove blower assembly.

Blower Assembly – Installation

1. Insert blower assembly into blower scroll housing and secure with four screws (Figure 55, Items 4, 5, and
6). Torque screws to 20 lbf-in (2.26 N•m).

2. Pull electrical connector through blower scroll housing (Figure 55, Items 1, 3, and 4).

3. Secure grommet in blower scroll housing (Figure 55, Items 2 and 4).

4. Install blower scroll housing (See BLOWER SCROLL HOUSING, page 97)

5.19. HEATER CORE

Access to the heater hoses may require the removal of other assemblies (such as right splash panel and/or air
filter). The assemblies that must be removed vary by vehicle model and engine combinations. Refer to the
appropriate Service Manual for additional procedures.

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HEATER CORE REMOVE AND INSTALL PROCEDURES

• For most other under hood assemblies that may require removal, refer to the appropriate HOOD, GRILLE,
and FENDERS Service Manual.

Heater Core – Removal

WARNING

Failure to observe the following warning may cause property damage, personal injury,
or death. Allow the engine to cool down before removing the pressure cap from the
deaeration tank. ALWAYS INSULATE the cap by wrapping it with a thick, heavy cloth. To
prevent personal injury or death, from scalding water or steam, DO NOT pull the pressure
cap off immediately when it has been loosened to the first "notch." Pause momentarily
to allow time for excess pressure to release through the overflow tube.

1. Drain engine coolant from heater core and connected heater lines. Refer to the appropriate COOLING
Service Manual.

NOTE – Before removing heater hoses in the following step, label hoses to ensure correct installation.

1. FRESH AIR MODULE 3. ENGINE

2. SPRING CLAMP 4. HEATER HOSE
Figure 56 Heater Hoses

2. Remove two spring clamps and disconnect both heater hoses from heater core tubes on engine side of
cowl.

3. From inside cab, remove blower scroll housing. Refer to BLOWER SCROLL HOUSING.

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REMOVE AND INSTALL PROCEDURES HEATER CORE

1. INTERIOR MODULE 2. HEATER CORE

Figure 57 Heater Core

NOTE – The heater core is mounted at a slight angle and therefore retains a small amount of coolant in
the core. Be careful to keep the core in an upright position until the coolant can be drained.

4. Pull heater core out of interior module.

Heater Core – Installation

NOTE – In the following step, ensure that the interior module seal that surrounds the heater core tubes
does not become dislodged while installing the heater core.

1. From inside cab, carefully position heater core in interior module so that tube ends of core protrude
through dash panel seal (Figure 57).

2. Install blower scroll housing. Refer to BLOWER SCROLL HOUSING.

NOTE – In the following step, position the heater hose clamps to allow easy access for their next removal.

3. On engine side of cowl, install heater hoses and clamps (Figure 56).

4. Fill cooling system with coolant. Refer to the appropriate COOLING Service Manual, or the Operator
Manual supplied with the vehicle.

NOTE – Verify that coolant system is leak-free.

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HVAC CONTROL PANEL ASSEMBLY REMOVE AND INSTALL PROCEDURES

5.20. HVAC CONTROL PANEL ASSEMBLY

HVAC Control Panel Assembly – Removal

CAUTION

To prevent damage to vehicle electrical system, place the ignition key in the OFF position
before removing or installing the HVAC control panel assembly.

1. The decorative bezel on center section of IP is secured by spring clips. Carefully pry the bezel from
center section of the IP.

2. Remove four screws securing HVAC control panel assembly to IP.

1. INSTRUMENT PANEL 3. FRONT HVAC CONTROL PANEL

2. DECORATIVE CENTER BEZEL
Figure 58 Front HVAC Control panel

3. Remove control panel assembly from instrument panel by pulling it straight out of its IP mounting cavity.

4. Disconnect wiring connector from rear of HVAC control panel.

HVAC Control Panel Assembly – Installation

CAUTION

To prevent damage to vehicle electrical system, place the ignition key in the OFF position
before removing or installing the HVAC control panel assembly.

1. Connect wiring connector to rear of HVAC control panel (not shown).

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REMOVE AND INSTALL PROCEDURES COMPRESSOR/CLUTCH

2. With HVAC control panel assembly correctly oriented, insert it straight into IP mounting cavity (Figure
58, Item 2).

3. Verify that control panel assembly is fully seated, then secure assembly using four screws (Figure 58,
Items 2 and 3). Torque screws to 20 to 27 lbf-in (2 to 3 N•m).

4. Install bezel in the center section of IP by aligning spring clips and carefully pressing bezel into position
(Figure 58, Item 1).

5.21. COMPRESSOR/CLUTCH
Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components
may require the removal of nearby assemblies (right splash panel, etc.) to gain access to the components or
related A/C lines. Refer to the appropriate Master Service Manual for additional procedures.

Compressor/Clutch – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38)..

2. Remove or loosen compressor belt.

1. DISCHARGE PORT/LINE 6. TOP VIEW

2. COMPRESSOR 7. W/ REAR PORTS
3. MOUNTING BOLTS 8. W/ TOP PORTS
4. SUCTION PORT/LINE 9. REAR VIEW
5. ELECTRICAL CONNECTOR
Figure 59 A/C Compressor (Typical Installation)

3. Disconnect compressor clutch wiring connector from engine wire harness.

4. Disconnect both refrigerant line fittings at compressor.

CAUTION

When removing mounting bolts from side mounted compressors, support compressor
to prevent damage to mounting bolts and/or compressor.

93
A/C CONDENSER REMOVE AND INSTALL PROCEDURES

5. Remove four compressor mounting bolts, noting location and orientation of any brackets secured by
mounting bolts.

6. Remove compressor assembly from engine.

Compressor/Clutch – Installation

NOTE – Verify that the clutch is installed on the compressor before performing steps in the following
installation procedure.

1. If A/C system is to be flushed, perform that operation before reassembling system. Refer to FLUSHING
AND PURGING THE AIR CONDITIONING SYSTEM (See FLUSHING AND PURGING THE AIR
CONDITIONING SYSTEM, page 42).

2. Before installing compressor, refer to OIL FILL GUIDELINES (page 46). The oil shipped in new
compressors must be drained when determining the correct amount of refrigerant oil to be added to
the system.

3. Install compressor assembly including any brackets previously secured by the compressor mounting bolts
(Figure 59, Items 2 and 3). Tighten to 17 to 21 lbf-ft (23 to 28 N•m).

NOTE – Always lubricate O-rings with mineral-based oil during installation.

4. Using new O-rings and C-plates, connect refrigerant line fittings at compressor (Figure 59, Items 1, 2, and
4). Torque C-plate nuts to 14 to 15 lbf-ft (19 to 20 N•m)

5. Connect compressor clutch electrical connector to engine harness (Figure 59, Items 2 and 5).

6. Install and align compressor belt (not shown).

7. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

8. Install any assemblies that were removed to gain access to the compressor.

5.22. A/C CONDENSER

For A/C condenser removal and installation, refer to the appropriate COOLING Service Manual for vehicle
model/engine combination being serviced.

5.23. HEATER HOSES/LINES

WARNING

Allow the engine to cool down before removing the pressure cap from the deaeration
tank. ALWAYS INSULATE the cap by wrapping it with a thick, heavy cloth. To prevent
personal injury or death, from scalding water or steam, DO NOT pull the pressure cap off
immediately when it has been loosened to the first "notch." Pause momentarily to allow
time for excess pressure to release through the overflow tube.

94
REMOVE AND INSTALL PROCEDURES EVAPORATOR

Engine coolant is routed to and from the heater core using a combination of hoses and hard lines that vary by
vehicle model and engine. Most hoses and lines are replaced using common practices, standard hose clamps,
or threaded fittings. Only new or unique equipment is described in this section. In all cases, replacement hoses
and lines must be routed and secured in the same manner as the original equipment. Additional information for
the coolant system may be found in the appropriate Service Manual.

Some heater line connections now employ a peanut fitting that is sealed with an O-ring and secured with one
nut. Before installing a peanut fitting, always verify that a new O-ring is in place.

Depending on the vehicle model/engine combination, replacement of specific heater lines may require the
removal of nearby assemblies (such as right splash panel, cab cowl tray) to gain access to the hoses/lines.
Refer to the appropriate Service Manual for additional procedures.

• The cab cowl tray exists in several variations. Refer to the appropriate CAB Service Manual for procedures
covering cab cowl trays.
• For most other under hood assemblies that may require removal, refer to the appropriate HOOD, GRILLE,
and FENDERS Service Manual.
• For information on draining and filling engine coolant, refer to the appropriate COOLING Service Manual.

5.24. EVAPORATOR
Evaporator – Removal

1. Discharge A/C system (See DISCHARGING THE SYSTEM (RECYCLE MODE), page 38).

2. Remove blower scroll housing (See BLOWER SCROLL HOUSING, page 97).

3. Remove expansion valve (See BLOWER SCROLL HOUSING, page 97).

4. Remove black tape seal between top center of evaporator and top of interior module case, if applicable.

95
EVAPORATOR REMOVE AND INSTALL PROCEDURES

1. GROMMET 3. INTERIOR MODULE

2. EVAPORATOR TUBE 4. EVAPORATOR
Figure 60 Evaporator

5. Carefully press evaporator tube grommet through interior module housing. May be helpful to use a flat tip
screwdriver to work grommet seal off.

6. Carefully maneuver evaporator out of interior module. Use caution not to damage evaporator tubes
or the evaporator itself.

7. Once evaporator is out of the interior module, remove the grommet from the evaporator tubes.

Evaporator – Installation

1. Install grommet onto evaporator tubes (See Figure 60, page 96).

NOTE – Installation may require additional personnel to aid with grommet installation while the
evaporator is being installed.

NOTE – Lubrication may be required when installing the grommet.

2. Install evaporator into interior module while guiding the evaporator tubes and grommet through outside the
vehicle. Ensure grommet seats properly (See Figure 60, page 96).

NOTE – Seals available after January 2013 will fill the gap between top of the evaporator and interior
module housing.

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REMOVE AND INSTALL PROCEDURES BLOWER SCROLL HOUSING

3. Install expansion valve. Refer to THERMOSTATIC EXPANSION VALVE (See THERMOSTATIC

EXPANSION VALVE (TXV), page 64).

4. Install blower scroll housing. Refer to BLOWER SCROLL HOUSING (See BLOWER SCROLL HOUSING,
page 97).

5. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT (See AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT, page 186)
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE (See AUTOMATIC MODE, page 36)

5.25. BLOWER SCROLL HOUSING

The blower scroll housing must be removed prior to removing the heater core, the evaporator, the interior
module, or any of the components within the interior module. Accessing the blower scroll housing may
require the removal of trim panels not described in this manual (refer to appropriate cab service manual for
vehicle being serviced).

Blower Scroll Housing – Removal

1. Remove interior module trim cover (See INTERIOR MODULE TRIM COVER, page 67).

1. SCREWS 4. LPM ELECTRICAL CONNECTOR

2. INTERIOR MODULE 5. LPM
3. HVAC/BODY HARNESS 6. BLOWER SCROLL HOUSING
ELECTRICAL CONNECTOR 7. ACTUATORS
Figure 61 Blower Scroll Housing

97
SPLITTING/SEPARATING BLOWER SCROLL HOUSING REMOVE AND INSTALL PROCEDURES

2. Remove wire ties as necessary; disconnect electrical connectors from three actuators and position
wiring out of the way.

3. Disconnect electrical connector from LPM.

4. Remove eight screws from blower scroll housing.

5. Remove blower scroll housing from interior module.

Blower Scroll Housing – Installation

1. Position blower scroll housing on interior module and secure with eight screws (See Figure 61, page 97).
Torque screws to 20 lbf-in (2.26 N•m).

2. Route wiring across blower scroll housing, secure using wire ties, and connect electrical connectors to
three door actuators (See Figure 61, page 97).

3. Connect electrical connector to LPM )(See Figure 61, page 97).

4. Install interior module trim cover (See INTERIOR MODULE TRIM COVER, page 67).

5.26. SPLITTING/SEPARATING BLOWER SCROLL HOUSING

Splitting/Separating Blower Scroll Housing – Removal

1. Remove blower scroll housing (See BLOWER SCROLL HOUSING, page 97).

2. Remove blower assembly (See BLOWER ASSEMBLY, page 88).

3. Remove blend door actuator (See BLEND DOOR ACTUATOR, page 70).

4. Remove blend door gear train (See BLEND DOOR GEAR TRAIN, page 76).

98
REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING BLOWER SCROLL HOUSING

1. BLOWER SCROLL HOUSING 2. SCREW

Figure 62 Blower Scroll Housing

5. Remove four screws from blower scroll housing.

99
SPLITTING/SEPARATING BLOWER SCROLL HOUSING REMOVE AND INSTALL PROCEDURES

1. RIGHT SIDE OF BLOWER 3. LEFT SIDE OF BLOWER

SCROLL HOUSING SCROLL HOUSING
2. BLEND DOOR 4. HEATER SCRUB DOOR
Figure 63 Splitting/Separating Blower Scroll Housing

6. Carefully pull right side of blower scroll housing away from left side of blower scroll housing.

NOTE – To aid in ease of installation, mark position of heater scrub and blend doors prior to removal.

7. Once blower scroll housing is separated, heater scrub door and blend door may be removed.

Splitting/Separating Blower Scroll Housing – Installation

1. Install heater scrub door and blend door into left side of blower scroll housing (Figure 63).

NOTE – Ensure heater scrub door and blend door are installed correctly before continuing to next step.

2. Attach right side of blower scroll housing to left side of blower scroll housing and secure with four screws
(Figure 62).

3. Install blend door gear train. Refer to BLEND DOOR GEAR TRAIN.

4. Install blend door actuator. Refer to BLEND DOOR ACTUATOR.

5. Install blower assembly. Refer to BLOWER ASSEMBLY.

6. Install blower scroll housing. Refer to BLOWER SCROLL HOUSING.

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REMOVE AND INSTALL PROCEDURES INTERIOR MODULE

5.27. INTERIOR MODULE

NOTE – Removing and installing the interior module requires detaching and raising the Instrument Panel
(IP), gauge cluster, and several trim panels. Refer to the appropriate CAB Service Manual for additional
procedures. Replacement of the interior module is necessary only if either the mode door mechanism
or the interior module itself is damaged. If mode / recirc doors or any mode / recirc door mechanism is
damaged, the interior module must be removed and the case split. If interior module itself is damaged,
the entire interior module is replaced as an assembly.

The Instrument Panel (IP) must be detached and raised prior to removing the interior module. Accessing the IP
mounting hardware may require the removal of trim panels not described in this manual. The panels that must
be removed vary by vehicle model and trim level. The procedures provided here cover a basic installation.
Interior Module – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (RECYCLE MODE) (page 38).

2. Remove engine housing cover and any required trim panels.

3. Remove interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.

4. Remove passenger side seat.

5. Inside cab, remove A-pillar trim from driver’s side.

6. Remove assist handle and A-pillar trim from passenger’s side.

7. Remove or disconnect trim panels from under IP to allow access to IP mounting hardware removed
in the following steps.

101
INTERIOR MODULE REMOVE AND INSTALL PROCEDURES

1. TOP INSTRUMENT PANEL 3. SIDE INSTRUMENT PANEL

MOUNTING BOLTS MOUNTING BOLTS
2. STEERING MODULE BOLTS 4. TOP VIEW
5. BOTTOM VIEW
Figure 64 Instrument Panel Mounting

8. Remove only the IP mounting hardware required to allow IP to be raised about one inch. More complete
procedures for removing the IP can be found in the appropriate CAB Service Manual. Typically, the
following mounting hardware must be removed:
a. Five bolts securing top of IP to dash panel (located near windshield).

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REMOVE AND INSTALL PROCEDURES INTERIOR MODULE

b. Two bolts securing steering column module to IP.

c. Two bolts securing each side of IP to dash panel.

NOTE – The driver side duct is connected to the interior module with a snap mount (slip-lock). This duct
is also mounted to the dash panel with one mounting screw.

NOTE – There are two gaskets attached to the exterior of the interior module. There is one gasket where
the interior module mounts to the dash panel; and another gasket where the IP rests on top of the interior
module. If the gaskets are damaged when moving the interior module or the IP, they must be replaced.

NOTE – In the following step, it will be necessary to raise the IP slightly while removing the interior
module. This may require a second or third person.

9. Lift the IP and support it so that it provides the greatest amount of clearance for removing interior module.

10. Remove gauge cluster to access driver side floor duct screw (bezel, cluster, connectors – wing panel bezel
first). Refer to the appropriate CAB Service Manual for additional procedures.

1. DASH PANEL 5. ALIGNMENT TAB

2. SNAP MOUNT (SLIP-LOCK) 6. INTERIOR MODULE
3. PASSENGER SIDE UPPER 7. TOP GASKET
DUCT 8. DRIVER SIDE FLOOR DUCT
4. PASSENGER SIDE LOWER 9. SCREW
DUCT
Figure 65 Duct Work

11. Disconnect passenger side floor duct from interior module.

a. Bottom section of duct is mounted to side of module with one alignment tab. After removing duct from
alignment tab, bottom section may be removed to provide better access to top section.
b. Top section of duct is connected to module with a snap mount (slip-lock), and is disconnected by
pulling duct away from module.

12. Remove mounting screw from driver side floor duct and disconnect driver side floor duct (snap lock at
interior module) from interior module.

103
INTERIOR MODULE REMOVE AND INSTALL PROCEDURES

WARNING

Allow the engine to cool down before removing the pressure cap from the deaeration
tank. ALWAYS INSULATE the cap by wrapping it with a thick, heavy cloth. To prevent
personal injury or death, from scalding water or steam, DO NOT pull the pressure cap off
immediately when it has been loosened to the first "notch." Pause momentarily to allow
time for excess pressure to release through the overflow tube.

13. Drain engine coolant from heater core and connected heater lines. Refer to the appropriate COOLING
Service Manual.

NOTE – Before removing heater hoses in the following step, label hoses to ensure correct installation.

1. FRESH AIR MODULE 3. ENGINE

2. SPRING CLAMP 4. HEATER HOSE
Figure 66 Heater Hoses

14. Remove two spring clamps and disconnect both heater hoses from heater core tubes on engine side of
cowl.

15. On engine side of dash panel, remove three c-plate nuts from refrigerant lines and disconnect three
refrigerant lines (Figure 31).

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REMOVE AND INSTALL PROCEDURES INTERIOR MODULE

1. MOUNTING NUT 2. FRESH AIR MODULE

Figure 67 Interior Module Mounting

16. On engine side of dash panel, remove four nuts from interior module mounting studs.

1. INSTRUMENT PANEL 2. TOP GASKET

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INTERIOR MODULE REMOVE AND INSTALL PROCEDURES

3. REAR GASKET 5. INTERIOR MODULE

4. HVAC WIRING HARNESS
CONNECTOR
Figure 68 Interior Module

17. Disconnect HVAC wiring harness from instrument panel wiring harness.

18. Pull interior module to rear (to allow its mounting studs to clear dash panel). Interior module should
now be clear to slide out from under IP.
Interior Module – Installation

NOTE – In the following step, the IP must be raised slightly while installing the interior module. This may
require a second or third person. To ensure proper alignment and compression of the interior module
top gasket, the IP must remain raised until the interior module is securely mounted.

NOTE – While performing the following steps, be careful not to damage the gaskets when moving the
interior module or the IP.

1. Lift and brace IP so that it provides adequate clearance for installing interior module (Figure 64).

2. With IP raised, carefully position interior module under passenger side instrument panel, so that its
mounting studs protrude through matching holes in dash panel (Figure 67, Items 1 and 4 and Figure
68, Item 5).

3. When installing:
a. Ensure that drain tube is in place and functioning correctly.
b. Attach upper passenger side floor duct to interior module if detached earlier. This is a slip-lock type
snap joint (Figure 65, Items 2 and 3). This should be done before placing interior module in final
position.
c. Slip bottom section of passenger side floor duct onto top section and secure to side of interior module
alignment tab (Figure 65, Items 4 and 5). Attach diffuser if it was removed .
d. Start interior module mounting nuts, but leave loose (Figure 67, Item 1).
e. Connect driver side floor duct (snap lock) to interior module, then tighten interior module mounting
nuts (Figure 67, Items 1 and 2). Torque nuts to 58 lbf-in (7 N•m).

NOTE – To aid in installation of the driver side floor duct screw, it is recommended to push screw through
sticky side of tape. Then fasten tape to socket, LIGHTLY. This keeps the screw from being dislodged
and should release once screw is tightened. If your socket connection is very loose, or your tape is
fastened to the socket too firmly, the socket may stay with the screw when the extension is removed.

4. Secure floor duct to dash panel under instrument panel using its mounting screw (Figure 65). Attach
diffuser if it was removed .

5. Install gauge cluster (bezel, cluster, connectors). Refer to the appropriate CAB Service Manual for
additional procedures.

NOTE – In the following step, position the heater hose clamps to allow easy access for their next removal.

6. On engine side of cowl, install heater hoses and clamps (Figure 66).

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REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING INTERIOR MODULE

7. Fill cooling system with coolant. Refer to the appropriate COOLING Service Manual, or the Operator
Manual supplied with the vehicle.

NOTE – Verify that coolant system is leak-free before proceeding with the following steps.

8. Carefully allow IP to return to its normal resting position (Figure 64).

9. Connect HVAC wiring harness to instrument panel wiring harness (Figure 68, Item 4).

10. On engine side of dash panel, remove three C-plate nuts from refrigerant lines and disconnect three
refrigerant lines (Figure 31).

11. Using a new lubricated O-ring and C-plate, connect refrigerant lines with three nuts (Figure 31). Torque
C-plate nuts to 14 to 15 lbf-ft (19 to 20 N•m).

12. Install IP mounting hardware that was removed earlier. More complete procedures for installing the IP
can be found in the appropriate CAB Service Manual. Typically, the following mounting hardware must
be installed:
a. Two bolts securing each side of IP to dash panel (Figure 64).
b. Two bolts securing steering column module to IP (Figure 64).
c. Five bolts securing top of IP to dash panel (located near windshield). (Figure 64).

13. Install or reconnect any trim panels under the IP that were removed to provide access to IP mounting
hardware (Figure 64).

14. Inside cab, install assist handle and A-pillar trim on passenger’s side (not shown).

15. Install A-pillar trim on driver’s side (not shown).

16. Install interior module trim cover. Refer to INTERIOR MODULE TRIM COVER.

17. Install engine housing cover and any required trim panels (not shown).

18. Install passenger side seat (not shown).

19. Recharge A/C system. Refer to:

a. ADDING OIL AND DYE TO THE SYSTEM
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE

5.28. SPLITTING/SEPARATING INTERIOR MODULE

Splitting/Separating Interior Module – Removal

1. Remove interior module from vehicle. Refer to INTERIOR MODULE.

2. Remove mode door actuator and fresh/recirculate door actuator. Refer to MODE DOOR ACTUATOR
AND FRESH/RECIRCULATE DOOR ACTUATOR.

3. Remove mode door gear train, and fresh/recirculate door gear train. Refer to MODE DOOR GEAR TRAIN
and FRESH/RECIRCULATE DOOR GEAR TRAIN.

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SPLITTING/SEPARATING INTERIOR MODULE REMOVE AND INSTALL PROCEDURES

4. Remove the blower scroll housing. Refer to BLOWER SCROLL HOUSING.

5. Remove the heater core. Refer to HEATER CORE.

6. Remove thermostatic expansion valve (TXV). Refer to THERMOSTATIC EXPANSION VALVE (TXV).

1. SCREW 3. INTERIOR MODULE DRAIN PAN

2. REAR SEAL
Figure 69 Interior Module Drain Pan

7. Carefully remove rear seal from interior module.

8. Remove nine screws from interior module drain pan and remove interior module drain pan.

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REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING INTERIOR MODULE

1. EVAPORATOR GROMMET 3. EVAPORATOR

2. INTERIOR MODULE
Figure 70 Evaporator

9. Carefully press evaporator grommet through interior module and remove evaporator from interior module.

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SPLITTING/SEPARATING INTERIOR MODULE REMOVE AND INSTALL PROCEDURES

1. TOP SEAL 3. LEFT SIDE OF INTERIOR

2. RIGHT SIDE OF INTERIOR MODULE
MODULE 4. SCREW
Figure 71 Splitting/Separating Interior Module

10. Using a utility knife, cut the top seal along the seam of the interior module.

11. Remove 10 screws from the interior module and separate the left side of the interior module from the
right side.

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REMOVE AND INSTALL PROCEDURES SPLITTING/SEPARATING INTERIOR MODULE

1. LEFT SIDE OF INTERIOR 4. RIGHT SIDE OF INTERIOR

MODULE MODULE
2. MODE DOOR 5. FRESH/RECIRCULATE DOOR
3. MODE DOOR
Figure 72 Recirculate/Mode/Blend Doors

NOTE – To aid in ease of installation, mark position of fresh/recirculate and mode doors prior to removal.

12. Once left and right side of interior module have been separated, the fresh/recirculate and mode doors
can be removed.

Splitting/Separating Interior Module – Installation

1. Install fresh/recirculate and mode doors into right side of interior module (Figure 72).

2. With the aid of an assistant, align doors with left side of interior module (Figure 72).

3. Secure left side of interior module to right side of interior module with 10 screws (Figure 71, Items 2,
3, and 4).

4. Install fresh/recirculate door gear train and mode door gear train. Refer to FRESH/RECIRCULATE DOOR
GEAR TRAIN and MODE DOOR GEAR TRAIN.

5. Install fresh/recirculate door actuator and mode door actuator. Refer to FRESH/RECIRCULATE DOOR
ACTUATOR and MODE DOOR ACTUATOR.

NOTE – Ensure fresh/recirculate and mode doors are operating properly prior to next step.

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FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS REMOVE AND INSTALL PROCEDURES

NOTE – Evaporator installation may require additional personnel to aid with grommet installation while
the evaporator is being installed.

NOTE – Lubrication may be required when installing the grommet.

6. Install evaporator into interior module, while guiding the evaporator tubes and grommet through outside
the interior module. Ensure grommet seats properly (Figure 70).

7. Install interior module drain pan and secure with nine screws (Figure 69, Items 1 and 3).

8. Install rear seal onto interior module (Figure 64, Item 2).

9. Install heater core. Refer to HEATER CORE.

10. Install blower scroll housing. Refer to BLOWER SCROLL HOUSING.

11. Install thermostatic expansion valve (TXV). Refer to THERMOSTATIC EXPANSION VALVE (TXV).

12. Install interior module into vehicle. Refer to INTERIOR MODULE.

5.29. FRESH/RECIRCULATE, MODE, AND BLEND AIR DOORS

The fresh/recirculate and mode air doors can be replaced after removing and splitting/separating the interior
module. Refer to SPLITTING/SEPARATING INTERIOR MODULE.

The heater scrub and blend air door can be replaced after removing the blower scroll housing. Refer to
BLOWER SCROLL HOUSING.

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REMOVE AND INSTALL PROCEDURES HVAC CONTROLS (SLEEPER)

5.30. HVAC CONTROLS (SLEEPER)

CAUTION

To prevent damage to the vehicle electrical system, place the ignition key in the OFF
position before removing or installing the sleeper HVAC controls.
HVAC Controls – Removal

1. ANALOG, SLEEPER CONTROL 2. DIGITAL, SLEEPER CONTROL

PANEL PANEL
Figure 73 Sleeper HVAC Control Panels

1. Carefully pry the outer trim bezel from the sleeper control panel (4 friction clips).

2. Remove the 4 screws (1 in each corner) securing the control panel to its mounting bracket.

3. Remove the following components, as necessary.

4. Digital Control Assembly

a. Disconnect electrical connection to the digital panel.

b. Remove 4 screws from the front of the control panel.
c. Remove digital panel from the rear of the control panel.

5. Rotary (Analog) Controls.

a. Disconnect electrical connections to the control being removed.

b. Remove knob from control.
c. Remove locknut from control shaft, and pull control from rear of panel. Remove remaining locknut
from control shaft and retain for use during installation.

Digital Controls – Installation

1. Insert digital panel from the rear of the control panel and secure with 4 screws from the front of the
control panel (Figure 73).

2. Install electrical connector to rear of digital panel. Ensure that connector locks are engaged (Figure 73).

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HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

3. Secure control panel to its mounting bracket with 4 screws (1 in each corner) (Figure 73).

4. Install the trim bezel onto the sleeper control panel (Figure 73).

Analog Controls – Installation

1. Ensure that one locknut is threaded onto the shaft of the new control. Transfer from removed control, if
necessary (Figure 73).

2. Insert control from the rear of the control panel and secure with locknut from the front of the control
panel (Figure 73).

3. Install electrical connector to control. Ensure that connector locks are engaged (Figure 73).

4. Install control knob (Figure 73).

5. Secure control panel to its mounting bracket with 4 screws (1 in each corner) (Figure 73) (screws not
shown).

6. Install the trim bezel onto the sleeper control panel (Figure 73).

5.31. HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT

Heater Hose Assembly – Removal

1. If vehicle is equipped with a heater line shut off valve, close the valve.

2. If vehicle is equipped with aerodynamic skirts, remove passenger side skirts and panels, as necessary, to
gain access to the AC/heater line hangers located under the cab floor.

Figure 74 Heater/AC Lines Clamped Under Cab

3. Under the cab, use clamping pliers to pinch both heater hoses closed. To prevent damage to the heater
hose, place the clamps in the long rubber section of the lines several inches from the metal/rubber joint.

4. Place a suitable clean drain pan under the heater core connections.

5. Remove the rear AC/heater line hanger.

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REMOVE AND INSTALL PROCEDURES HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT

6. Disconnect the heater hose(s) being replaced from the heater core tube(s). Allow coolant from heater core
to drain into container. Plug heater core tube(s).

7. Release the clamping pliers on the heater line being replaced. Allow coolant from heater line to drain into
container.

8. Under the hood, disconnect the heater line being replaced from the ’T’ fitting where it connects to the
front heater line. Plug all open lines.

9. Remove the front hose hanger and retain the heat shield for use during installation.

10. While placing as little strain on the A/C and heater lines as possible, loosen each of the remaining hose
hangers enough to remove the heater line(s) from the hanger. Leave the hangers connected to provide
support for the A/C lines.

11. Remove the disconnected line(s) towards the rear of the cab.

Heater Hose Assembly – Installation

1. With the ends sealed to prevent contamination, maneuver the new line into position from the rear (Figure
74).

2. Under the hood, connect the new heater line to the front heater line ’T’ fitting (Figure 74).

3. Under the vehicle, position the heater lines in the 3 middle line hangers. Leave the hangers loose at
this time (Figure 74).

4. Connect the heater core inlet/outlet hoses to the heater core tubes (Figure 74).

5. Remove all clamping pliers used to pinch the heater lines closed (Figure 74).

6. With the A/C and heater lines positioned correctly, loosely install the rear AC/heater line hanger (Figure 74).

7. Install the front hanger, including the heat shield removed earlier. Verify that heater and A/C lines are
positioned correctly in hangers, without binding; then tighten hanger bolt (Figure 74 and Figure 75).

8. Verify that heater and A/C lines are positioned correctly while tightening all remaining hanger bolts (Figure
74 and Figure 75).

9. Add coolant drained during removal, to the coolant system.

10. Open heater line shut off valve, if it was closed earlier.

11. If vehicle is equipped with aerodynamic skirts, install passenger side skirts and panels.

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A/C HOSE ASSEMBLY – TO REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.32. A/C HOSE ASSEMBLY – TO REAR HVAC UNIT

A/C Hose Assembly – Removal

1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (See DISCHARGING THE SYSTEM
(REFRIGERANT RECOVERY).

2. Under the hood, disconnect the A/C line to the rear HVAC unit where it connects to the front A/C line.
Plug all open lines.

3. If vehicle is equipped with aerodynamic skirts, remove passenger side skirts and panels, as necessary, to
gain access to the AC/heater line hangers located under the cab floor.

Figure 75 Rear A/C and Heater Line Connections

4. From under the vehicle, remove the rear AC/heater line hanger.

NOTE – In the following step, the threaded stud may unscrew from the TXV body. If so, examine the
condition of the stud and the retaining nut. If possible, clean the existing stud and install it into the TXV
body. Otherwise, install a new threaded stud. Retain the mounting nut, or replace if necessary.

5. Disconnect the A/C lines from the Thermostatic Expansion Valve (TXV). Retain the lock plate and lock
plate retaining nut. Plug all open tubes/ports.

6. Remove the front hose hanger and retain the heat shield for use during installation.

7. While placing as little strain on the A/C and heater lines as possible, loosen each of the remaining hose
hangers enough to remove the A/C line from the hanger. Leave the hangers connected to provide support
for the heater lines

8. Remove the disconnected line(s) towards the rear of the cab.

A/C Hose Assembly – Installation

1. With the ends sealed to prevent contamination, maneuver the new line into position from the rear (Figure
75).

2. Under the hood; using a new C-plate and lubricated O-ring, connect the new A/C line to the front A/C line
’splice’ fitting. Tighten to 15 to 16 lbf-ft (19 to 20 N•m).

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REMOVE AND INSTALL PROCEDURES A/C HOSE ASSEMBLY – TO REAR HVAC UNIT

3. Under the vehicle, position the A/C lines in the 3 middle line hangers. Leave the hangers loose at this
time (Figure 75).

NOTE – In the following step, keeping the A/C lines free of the hanger allows better alignment with the
TXV during installation.

Figure 76 Connecting A/C Lines to Rear Thermostatic Expansion Valve (TXV)

4. Before securing the A/C lines with the rear hanger, connect them to the thermostatic expansion valve
(TXV) using new O-rings, the lower lock plate, and the lock plate retaining nut. Tighten to 80 to 90 lbf-in (9
to 10 N•m).

5. Loosely install the rear hanger (Figure 75).

6. Install the front hanger, including the heat shield removed earlier. Verify that heater and A/C lines are
positioned correctly in hangers, without binding; then tighten hanger bolt.

7. Verify that heater and A/C lines are positioned correctly while tightening all remaining hanger bolts.

8. Recharge A/C system. Refer to CHARGING THE AIR CONDITIONING SYSTEM (See CHARGING THE
AIR CONDITIONING SYSTEM (FULL CHARGE).

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THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.33. THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT

Thermostatic Expansion Valve – Removal

1. Discharge A/C system (See DISCHARGING THE SYSTEM (RECYCLE MODE), page 38).

NOTE – It may be easier to disconnect the hoses in the following step if the rear AC/heater line hanger
is loosened or removed.

NOTE – In the following step the threaded stud may unscrew from the TXV body. If so, examine the
condition of the stud and the retaining nut. If possible, clean the existing stud and install it into the TXV
body. Otherwise, install a new threaded stud. Retain the mounting nut, or replace if necessary.

1. UPPER LOCKING PLATE 2. TORX HEAD SCREW

(LOCATED INSIDE REAR HVAC 3. LOCK PLATE RETAINING NUT
UNIT) 4. TXV
Figure 77 Installation of Rear Thermostatic Expansion Valve

2. From under the vehicle, disconnect the A/C lines from the Thermostatic Expansion Valve (TXV). Retain
the lock plate and lock plate retaining nut. Plug all open A/C lines.

3. Remove two Torx head screws securing TXV to upper lock plate. Remove TXV. Plug all open A/C lines
and tape over TXV ports to protect from contamination.

Thermostatic Expansion Valve – Installation

1. From under the vehicle, install new lubricated O-rings onto the evaporator tubes; then install the
Thermostatic Expansion Valve (TXV) onto the evaporator tubes. Secure the TXV to the upper locking
plate with the two Torx head screws removed earlier. Tighten to 35.4 to 38.0 lbf-in (4 to 4.3 N•m) Refer to
Figure 77.

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REMOVE AND INSTALL PROCEDURES THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT

2. Using new O-rings, connect the A/C lines to the TXV. Secure with the lower locking plate and the lock plate
retaining nut. Tighten to 80 to 90 lbf-in (9 to 10 N•m).

3. With the A/C and heater lines positioned correctly, install and tighten the rear AC/heater line hanger
(Figure 77).

4. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT (See AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT, page 186)
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE (See AUTOMATIC MODE, page 36)

119
BLOWER – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.34. BLOWER – REAR HVAC UNIT

Blower – Removal

1. Turn ignition key to OFF

1. BLOWER 4. LINEAR POWER MODULE (LPM)

2. TORX HEAD SCREW 5. REAR HVAC UNIT
3. BLOWER ELECTRICAL
CONNECTOR
Figure 78 Rear HVAC Unit Blower

2. Through the passenger side access door, disconnect blower electrical connector from linear power module
(LPM).

3. Remove four Torx head screws securing blower to rear HVAC unit.

4. Remove blower.
Blower – Installation

1. Position the blower onto the rear HVAC unit and secure with four Torx head screws (Figure 78, Items 1,
2, and 5).

2. Connect the blower electrical connector into the linear power module (Figure 78, Items 3 and 4).

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REMOVE AND INSTALL PROCEDURES FILTER ELEMENT – REAR HVAC UNIT

5.35. FILTER ELEMENT – REAR HVAC UNIT

Filter Element – Removal

1. Raise and support bunk.

1. FILTER ELEMENT 3. REAR HVAC UNIT

2. CAVITY
Figure 79 Filter Element

2. Remove filter element from the cavity in the rear HVAC unit.

Filter Element – Installation

1. With the pleats running horizontally, insert the filter element into the cavity in the rear HVAC unit (Figure 79).

2. Ensure that the filter element is fully seated.

3. Carefully lower the bunk.

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OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.36. OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT

Outlet Duct Temperature Sensor – Removal

1. Raise and support bunk.

1. ELECTRICAL CONNECTOR 3. HVAC UNIT HOUSING

2. OUTLET DUCT TEMPERATURE
SENSOR
Figure 80 Outlet Duct Temperature Sensor

2. Disconnect the electrical connector to the outlet duct temperature sensor.

3. Grasp the sensor body and pull it straight out of the rear HVAC unit housing.
Outlet Duct Temperature Sensor – Installation

1. Push the sensor into the rear HVAC unit housing until it is retained by friction (Figure 80, Items 2 and 3).

2. Connect the electrical connector to the outlet duct temperature sensor (Figure 80, Items 1 and 2).

122
REMOVE AND INSTALL PROCEDURES LINEAR POWER MODULE – REAR HVAC UNIT

5.37. LINEAR POWER MODULE – REAR HVAC UNIT

Linear Power Module – Removal

1. Set ignition key to OFF.

1. REAR LINEAR POWER MODULE 3. ELECTRICAL CONNECTOR

2. TORX SCREW 4. REAR HVAC UNIT
Figure 81 Linear Power Module (LPM)

2. Through the passenger side access door, disconnect the two electrical connectors from Linear Power
Module (LPM).

3. Remove two Torx screws securing LPM to rear HVAC unit.

4. Remove LPM.

Linear Power Module – Installation

1. Position the LPM onto the rear HVAC unit and secure with two Torx screws (Figure 81, Items 1, 2, and 4).

2. Connect the two electrical connectors to the LPM (Figure 81, Items 1 and 3).

123
BLEND DOOR ACTUATOR – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.38. BLEND DOOR ACTUATOR – REAR HVAC UNIT

Blend Door Actuator – Removal

1. Set ignition key to OFF.

2. Inside the sleeper, raise and support the bunk.

1. TORX HEAD SCREW 4. BLEND DOOR ACTUATOR

2. REAR HVAC UNIT 5. DRIVE COLLAR
3. ELECTRICAL CONNECTOR
Figure 82 Rear Blend Door Actuator

3. Disconnect the electrical connector on the blend door actuator on the top of the rear HVAC unit.

4. Remove two screws securing the blend door actuator to the rear HVAC unit. Remove blend door actuator.

Blend Door Actuator – Installation

1. Position the blend door so that it will align with the drive collar on the blend door actuator as it is installed
(Figure 82, Items 4 and 5).

2. Install the blend door actuator and secure with two screws (Figure 82, Items 1 and 4).

3. Connect the electrical connector to the blend door actuator (Figure 82, Items 3 and 4).

4. Calibrate the blend door actuator by unplugging the electrical connector at the rear HVAC controller
for at least 10 seconds, then reconnect. Calibration will occur the next time the IGN key is set to IGN
or ACCESSORY.

124
REMOVE AND INSTALL PROCEDURES SLEEPER HVAC CONTROLLER – REAR HVAC UNIT

5.39. SLEEPER HVAC CONTROLLER – REAR HVAC UNIT

Sleeper HVAC Controller – Removal

1. Set ignition key to OFF.

2. Raise and support bunk.

1. ELECTRICAL CONNECTOR 3. SLEEPER HVAC CONTROLLER

2. TORX HEAD SCREW 4. REAR HVAC UNIT
Figure 83 Sleeper HVAC Controller

3. Disconnect the electrical connector from the sleeper HVAC controller.

4. Remove two torx head screws securing sleeper HVAC controller to rear HVAC unit.

5. Remove sleeper HVAC controller.

Sleeper HVAC Controller – Installation

1. Position the sleeper HVAC controller onto the rear HVAC unit and secure with two torx head screws
(Figure 83, Items 2, 3, and 4).

2. Connect the electrical connector to the sleeper HVAC controller (Figure 83, Items 1 and 3).

3. Calibration of the blend door actuator will occur the next time the ignition key is set to IGN or ACCESSORY.

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HEATER CORE – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

5.40. HEATER CORE – REAR HVAC UNIT

Heater Core – Removal

Figure 84 Heater/AC Lines Clamped Under Cab

1. Under the vehicle, use clamping pliers to pinch the rubber section of the rear heater lines closed. Place the
clamps several inches from the metal/rubber joint.

2. Place a suitable drain pan under the heater core connections.

Figure 85 Rear A/C and Heater Line Connections

NOTE – It may be easier to disconnect the hoses in the following step if the rear AC/heater line hanger
is loosened or removed.

3. Disconnect the rubber hoses from the heater core tubes. Allow coolant from heater core to drain into
container. Plug all open tubes/hoses.

4. Inside the cab, raise and support the lower bunk.

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REMOVE AND INSTALL PROCEDURES HEATER CORE – REAR HVAC UNIT

1. CLAMP PLATE FOR 4. HEATER CORE CAVITY

INLET/OUTLET TUBES 5. REAR HEATER CORE
2. TORX HEAD SCREW 6. INLET/OUTLET TUBES
3. HEATER CORE COVER
Figure 86 Rear Heater Core Installation

5. Remove two screws securing the heater core cover. Remove the cover.

NOTE – In the following step, it may be easier to remove the clamp plate by raising the heater core
slightly out of its cavity.

6. Remove the torx head screw from the clamp plate securing the heater core inlet and outlet tubes.
Disconnect the tubes from the core, and rotate them out of the way. Plug all open tubes/hoses.

7. Remove the heater core.

8. If necessary, remove the heater core inlet and outlet tubes.

Heater Core – Installation

1. If the heater core inlet and outlet tubes were removed, note the position of the foam spacer and seal
(below the housing). Then carefully install the heater core inlet and outlet tubes (Figure 86, Item 6)
and rotate them out of the way.

2. Install the heater core (Figure 86, Item 5).

NOTE – In the following step it may be easier to insert the inlet/outlet tubes by raising the heater core
slightly out of its cavity.

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HEATER CORE – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

3. Install heater core cover and secure with two torx head screws (Figure 86, Items 2 and 3).

4. Under the cab, connect the heater core inlet/outlet hoses to the heater core tubes. Install or tighten the
rear AC/heater line hanger (Figure 85) if removed earlier.

5. Remove the clamping pliers used to pinch the heater lines closed (Figure 84).

6. Add coolant drained during removal, to the coolant system.

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REMOVE AND INSTALL PROCEDURES TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT

5.41. TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT

Temperature Blend Air Door – Removal

1. Set ignition key to OFF.

2. Under the vehicle, use clamping pliers to pinch the rubber section of the rear heater lines closed. Place
the clamps several inches from the metal/rubber joint (Figure 84).

NOTE – It may be easier to disconnect the hoses in the following step if the rear AC/heater line hanger
is loosened or removed.

3. With a clean drain pan positioned under the heater core connections, disconnect the hoses from the heater
core tubes. Plug all open tubes/hoses (Figure 85).

4. Remove blower (See BLOWER – REAR HVAC UNIT, page 120).

5. Inside the sleeper, raise and support bunk.

6. Remove heater core and heater core inlet/outlet tubes (See HEATER CORE – REAR HVAC UNIT, page
126).

7. Disconnect all remaining electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear linear power module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

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TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

1. OUTLET DUCT 4. AIR INLET

2. BOLT 5. REAR HVAC UNIT
3. AIR OUTLET VENT
Figure 87 Rear HVAC Unit Duct

NOTE – It may be helpful to loosen or remove some connected duct work.

8. Remove bolt from the outlet duct and remove outlet duct.

9. Remove bolt from air outlet vent and remove air outlet vent.

10. Remove the filter element from the air intake of the rear HVAC unit (See FILTER ELEMENT – REAR
HVAC UNIT, page 121).

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REMOVE AND INSTALL PROCEDURES TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT

1. SCREW 4. EVAPORATOR
2. TOP HOUSING 5. BOTTOM HOUSING
3. BLEND DOOR
Figure 88 Rear HVAC Unit

11. Remove 15 screws securing the top housing of the HVAC unit to the bottom housing. It is not necessary to
remove the LPM, HVAC controller, and blend door actuator from the top housing.

NOTE – Before the top housing can be removed from the bottom housing, the foam seals at the air inlet
and outlet (under bunk) must be cut near the joint between the housing halves.

NOTE – In the following step, to provide additional clearance when removing the top housing, raise the
top housing enough to reach inside and disengage the blend door from the top and bottom housings.
Lay the door in the bottom housing until the top housing is removed.

12. Lift the top housing off of the rear HVAC unit.

13. Remove the blend door.

Temperature Blend Air Door – Installation

NOTE – Before installing the top housing check the condition of the foam seals at the air inlet and outlet
(under bunk). If a seal requires replacement, the bottom housing must be removed from the vehicle.
The rear HVAC unit can then be reassembled on the bench (with new seals) before installation.

1. From inside the sleeper, temporarily install the blend door into the bottom housing to determine how the
door is to be oriented (Figure 88, Items 3 and 5).

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TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

NOTE – In the following step, it may be helpful to lay the blend door loosely in the bottom housing until
the top housing is nearly in position. Then lift the top housing enough to install the blend door into its
socket in the bottom housing.

2. Install the top housing onto the bottom housing so that the shaft of the blend door is inserted into the hub
of the actuator mounted on the top housing. The blend door must be captured between the top and
bottom housings (Figure 88, Items 2, 3, and 5).

3. Install 15 screws securing the top housing of the HVAC unit to the bottom housing (Figure 88, Items 1,
2, and 5)..

4. Install outlet duct and secure with bolt. Verify that all related duct work is positioned and secured correctly
(Figure 87, Items 1 and 2).

5. Install air outlet vent and secure with bolt (Figure 87, Items 2 and 3).

NOTE – In the following step it may be easier to insert the inlet/outlet tubes by raising the heater core
slightly out of its cavity.

6. Install the filter element into the air intake of the rear HVAC unit (See FILTER ELEMENT – REAR HVAC
UNIT, page 121).

7. Install the rear heater core and heater core inlet/outlet tubes (See HEATER CORE – REAR HVAC UNIT,
page 126).

8. Install blower (See BLOWER – REAR HVAC UNIT, page 120).

9. Connect all electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear Linear Power Module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

10. Under the vehicle, connect the heater core inlet/outlet hoses to the heater core tubes. Install or tighten the
rear AC/heater line hanger, if removed earlier (Figure 85).

11. Remove the clamping pliers used to pinch the heater lines closed (Figure 84).

12. Add coolant drained during removal to the coolant system.

13. Calibration of the blend door actuator will occur the next time the ignition key is set to IGN or ACCESSORY.

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REMOVE AND INSTALL PROCEDURES EVAPORATOR CORE – REAR HVAC UNIT

5.42. EVAPORATOR CORE – REAR HVAC UNIT

Evaporator Core – Removal

1. Set ignition key to OFF.

2. Discharge A/C system (See DISCHARGING THE SYSTEM (RECYCLE MODE), page 38).

3. If vehicle is equipped with aerodynamic side skirts, remove the rear passenger side skirt (refer to
appropriate cab service manual for vehicle being serviced).

4. Remove thermostatic expansion valve (TXV) (See THERMOSTATIC EXPANSION VALVE – REAR HVAC
UNIT, page 118)

5. Remove blower (See BLOWER – REAR HVAC UNIT, page 120).

6. Remove heater core (See HEATER CORE – REAR HVAC UNIT, page 126).

7. Disconnect all remaining electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear Linear Power Module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

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EVAPORATOR CORE – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

1. OUTLET DUCT 4. AIR INLET

2. BOLT 5. REAR HVAC UNIT
3. AIR OUTLET VENT
Figure 89 Rear HVAC Unit Duct

NOTE – It may be helpful to loosen or remove some connected duct work.

8. Remove bolt from the outlet duct and remove outlet duct.

9. Remove bolt from air outlet vent and remove air outlet vent.

10. Remove the filter element from the air intake of the rear HVAC unit (See FILTER ELEMENT – REAR
HVAC UNIT, page 121).

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REMOVE AND INSTALL PROCEDURES EVAPORATOR CORE – REAR HVAC UNIT

1. SCREW 4. EVAPORATOR
2. TOP HOUSING 5. BOTTOM HOUSING
3. BLEND DOOR
Figure 90 Rear HVAC Unit

11. Remove 15 screws securing the top housing of the HVAC unit to the bottom housing. It is not necessary to
remove the LPM, HVAC controller, and blend door actuator from the top housing.

NOTE – Before the top housing can be removed from the bottom housing, the foam seals at the air inlet
and outlet (under bunk) must be cut near the joint between the housing halves.

NOTE – In the following step, to provide additional clearance when removing the top housing, raise the
top housing enough to reach inside and disengage the blend door from the top and bottom housings.
Lay the door in the bottom housing until the top housing is removed.

12. Lift the top housing off of the rear HVAC unit.

NOTE – Note the location of all seals associated with the evaporator core and expansion valve. They
must be replaced correctly during installation.

13. Lift the evaporator core from the bottom housing. Retain the upper lock plate and all foam seals for
use during installation.

Evaporator Core – Installation

NOTE – Before installing the top housing check the condition of the foam seals at the air inlet and outlet
(under bunk). If a seal requires replacement, the bottom housing must be removed from the vehicle.
The rear HVAC unit can then be reassembled on the bench (with new seals) before installation.

1. From inside the sleeper, install the evaporator core into the bottom housing (Figure 90, Items 4 and 5).

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EVAPORATOR CORE – REAR HVAC UNIT REMOVE AND INSTALL PROCEDURES

NOTE – In the following step, it may be helpful to lay the blend door loosely in the bottom housing until
the top housing is nearly in position. Then lift the top housing enough to install the blend door into its
socket in the bottom housing.

2. Install the top housing onto the bottom housing so that the shaft of the blend door is inserted into the hub
of the actuator mounted on the top housing (Figure 90, Items 2, 3, and 5).

3. Install 15 screws securing the top housing of the HVAC unit to the bottom housing (Figure 90, Items 1,
2, and 5).

4. Install outlet duct and secure with bolt. Verify that all related duct work is positioned and secured correctly
(Figure 89, Items 1 and 2).

5. Install air outlet vent and secure with bolt (Figure 89, Items 2 and 3).

NOTE – In the following step it may be easier to insert the inlet/outlet tubes by raising the heater core
slightly out of its cavity.

6. Install the filter element into the air intake of the rear HVAC unit (See FILTER ELEMENT – REAR HVAC
UNIT, page 121).

7. Install the rear heater core and heater core inlet/outlet tubes (See HEATER CORE – REAR HVAC UNIT,
page 126).

8. Install blower (See BLOWER – REAR HVAC UNIT, page 120).

9. Connect all electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear Linear Power Module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

10. Under the vehicle, connect the heater core inlet/outlet hoses to the heater core tubes. Install or tighten the
rear AC/heater line hanger, if removed earlier (Figure 85).

11. Remove the clamping pliers used to pinch the heater lines closed (Figure 84).

12. Install thermostatic expansion valve (TXV) (See THERMOSTATIC EXPANSION VALVE – REAR HVAC
UNIT, page 118)

13. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT (See AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT, page 186)
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE (See AUTOMATIC MODE, page 36)

14. If aerodynamic side skirt was removed, install the rear passenger side skirt (refer to appropriate cab
service manual for vehicle being serviced).

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REMOVE AND INSTALL PROCEDURES REAR HVAC UNIT, COMPLETE

15. Add coolant drained during removal, to the coolant system.

16. Calibration of the blend door actuator will occur the next time the ignition key is set to IGN or ACCESSORY.

5.43. REAR HVAC UNIT, COMPLETE

In order to repair internal components, the rear HVAC unit may be disassembled in the cab or removed as a
unit and disassembled on the bench. The method used depends on the repair being performed.

Removing and installing the rear HVAC unit as an assembly requires discharging the A/C system and
disconnecting the rear heater core lines. All internal components of the rear HVAC unit can be replaced by
removing the top of the housing while the unit is mounted in the vehicle. Removal of the entire rear HVAC unit
is necessary only if the lower housing itself is damaged. In this situation, it may be beneficial to remove the
entire rear HVAC unit from the vehicle so the repairs can be performed on the bench, before installing the
unit into the vehicle. Whenever the rear HVAC unit is removed or installed, the heater core inlet/outlet tubes
should be removed to prevent damage to the tubes.
Rear HVAC Unit – Removal

1. Set ignition key to OFF.

2. Discharge A/C system (See DISCHARGING THE SYSTEM (RECYCLE MODE), page 38).

3. If vehicle is equipped with aerodynamic side skirts, remove the rear passenger side skirt (refer to
appropriate cab service manual for vehicle being serviced).

NOTE – It may be easier to disconnect the hoses in the following step if the rear AC/heater line hanger
is loosened or removed.

NOTE – In the following step the threaded stud may unscrew from the TXV body. If so, examine the
condition of the stud and the retaining nut. If possible, clean the existing stud and install it into the TXV
body. Otherwise, install a new threaded stud. Retain the mounting nut, or replace if necessary.

4. From under the vehicle, disconnect the A/C lines from the Thermostatic Expansion Valve (TXV). Retain the
lock plate and lock plate retaining nut. Plug all open tubes/ports (Figure 85).

5. Remove heater core (See HEATER CORE – REAR HVAC UNIT, page 126).

6. Disconnect all remaining electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear Linear Power Module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

7. Remove bolt from the outlet duct and remove outlet duct (Figure 89, Items 1 and 2).

8. Remove bolt from air outlet vent and remove air outlet vent (Figure 89, Items 2 and 3).

9. Remove air inlet grille from front of bunk to provide additional clearance (Figure 89, Item 4).

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REAR HVAC UNIT, COMPLETE REMOVE AND INSTALL PROCEDURES

10. Support bunk with a separate prop; then, disconnect the bottom of the bunk support strut and position it
out of the way (not shown).

1. BOLT 2. FRONT OF REAR HVAC UNIT

Figure 91 Rear HVAC Unit Mounting Bolt Locations

11. Remove five bolts securing rear HVAC unit to the floor.

12. Carefully remove the rear HVAC unit through the passenger side access door.

13. Lower or secure the bunk to prevent accidental closure.

Rear HVAC Unit – Installation

NOTE – To prevent damaging the heater core inlet/outlet tubes, the heater core and tubes should not be
installed into the rear HVAC unit until the unit is installed in the vehicle. If necessary remove the heater
core and tubes from the rear HVAC unit prior to installing the unit into the vehicle.

1. Support bunk with a sturdy, secure prop. The bottom connection of the regular strut must be disconnected.

2. Verify that the rear HVAC unit is ready for installation, as follows.

a. Expansion valve (TXV) is installed and ready for lower locking plate.
b. Foam seal surrounding TXV cavity is installed.
c. Spacer and foam seal for heater core inlet/outlet tubes is installed.
d. Foam seals at air intake and side outlet are installed and undamaged.

3. Carefully place the rear HVAC unit into the sleeper through the passenger side access door.

4. Without damaging the foam air seals, position the rear HVAC unit to align the holes for the mounting
bolts (Figure 91).

5. Secure the unit to the floor with five bolts (Figure 91).

6. Install outlet duct and secure with bolt. Verify that all related duct work is positioned and secured correctly
(Figure 89, Items 1 and 2).

7. Install air outlet vent and secure with bolt (Figure 89, Items 2 and 3).

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REMOVE AND INSTALL PROCEDURES REAR HVAC UNIT, COMPLETE

8. Install the inlet grille at the front of bunk (Figure 89, Item 4).

9. Install the rear heater core and heater core inlet/outlet tubes (See HEATER CORE – REAR HVAC UNIT,
page 126).

10. Connect all electrical connections to the rear HVAC unit.

a. Sleeper HVAC controller – one connector (Figure 83, Item 1)

b. Blend door actuator – one connector (Figure 82, Item 3)
c. Outlet duct temperature sensor – one connector (Figure 80, Item 1)
d. Rear Linear Power Module – one connector (harness), blower connector was removed with
blower (Figure 81, Item 3)

11. Connect the bottom of the bunk support strut to its mounting plate (not shown).

12. Install thermostatic expansion valve (TXV) (See THERMOSTATIC EXPANSION VALVE – REAR HVAC
UNIT, page 118)

13. Add coolant drained during removal to the coolant system.

14. Recharge A/C system (See DISCHARGING THE SYSTEM (RECYCLE MODE), page 38).

15. Recharge A/C system. Refer to:

a. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT (See AIR CONDITIONING OIL AND
DYE INJECTION EQUIPMENT, page 186)
b. OIL FILL GUIDELINES (page 46)
c. AUTOMATIC MODE (See AUTOMATIC MODE, page 36)

16. If aerodynamic side skirt was removed, install the rear passenger side skirt (refer to appropriate cab
service manual for vehicle being serviced).

17. Calibration of the blend door actuator will occur the next time the ignition key is set to IGN or ACCESSORY.

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PRELIMINARY CHECKS DIAGNOSIS AND TROUBLESHOOTING

6. DIAGNOSIS AND TROUBLESHOOTING

6.1. PRELIMINARY CHECKS
The following preliminary checks should be performed to identify some common causes of A/C system
problems.

Check for Obvious Damage

Perform a simple visual check of the HVAC system to verify that no obvious physical problems are present.
With the engine off, inspect the following items:

• compressor and clutch mounting

• compressor clutch coil wiring and connection
• compressor drive belt and tension
• all A/C and heater hoses and connections
• condenser mounting
• condenser fins (and blockage by debris)
• receiver-drier mounting
• expansion valve mounting
• filter element
• fresh air module drains
• fresh air module mounting and overall condition
• electrical connections to pressure transducer and low pressure switch
• electrical connections to actuators for airflow doors (recirculate, temperature, and mode doors)
Refrigerant Identification

NOTE – Before connecting any service equipment to the refrigerant system, the refrigerant in the system
must be identified. Failure to identify system refrigerant before connecting equipment could result in
contamination of service equipment and any refrigerant stored in the equipment.

Identify the refrigerant currently in the HVAC system to protect shop equipment and to identify a possible cause
of poor system operation. Refer to REFRIGERANT IDENTIFICATION.

Check for Noncondensable Gases

Verify that the system does not contain air or some other noncondensable gas, which can be a common cause
of poor system operation. When a Refrigerant Identifier is not available, a check of the system contents
should be performed (Table 3). This procedure can be performed in addition to refrigerant identification to
check for overcharged and undercharged conditions. The A/C system must be at ambient temperature
when performing this check.

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DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS

Table 4 Check for Noncondensable Gases

NOTE – The engine must not be running and A/C system must be at ambient temperature when
performing this check.
1. Connect International® A/C Servicing System • If gauges are >10 psig higher than the
to A/C system. table listings, system contains air or
some noncondensable gas. Discharge,
2. Using a temperature probe (refer to A/C System
evacuate, and recharge the system.
Test Mode), determine ambient temperature
Refer to SECTION 4. (See SERVICE
within a degree or two.
PROCEDURES FOR R-134A, page 26).
3. Record system pressures indicated (refer to A/C
System Test Mode). • If gauges are >10 psig lower than the table
listings, system is undercharged.
4. Compare gauge readings to Table 4 (See Table
5, page 141). Inspect all joints and seals using a leak
detector. Refer to LEAK DETECTION.
Repair any leaks.

Service the A/C system (discharge,

evacuate, and recharge the system OR
use Automatic mode). Refer to SERVICE
PROCEDURES FOR R-134A (See
SERVICE PROCEDURES FOR R-134A,
page 26).

Table 5 System Pressure Versus Ambient Temperature

Temperature °F R134A PSIG Temperature °F R134A PSIG

40 35.07 80 86.99
45 40.07 85 95.23
50 45.46 90 104.3
55 51.23 95 113.93
60 57.42 100 124.12
65 64.04 105 134.92
70 71.11 110 146.33
75 78.66
NOTE: The table is part of the Performance AC Chart TMT-3416.

6.2. PHYSICAL CHECKS

These Physical Checks are provided as general supplemental information. While not as precise as the
step-by-step procedures, these checks provide a simple convenient method of determining the condition of
the refrigerant system.

Physical Check Procedure

1. Start the engine and set the air conditioning control panel for maximum cooling, as follows:

A. Turn the knob fully clockwise to set blower speed control to highest speed.
B. Turn the knob fully counterclockwise to set temperature control for maximum cooling.
C. Turn the knob fully counterclockwise to set mode control to MAX.

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PHYSICAL CHECKS DIAGNOSIS AND TROUBLESHOOTING

2. Set the engine speed at 1500 RPM or above, and run the air conditioning system for at least 5 minutes.

WARNING

To prevent personal injury or death, avoid contact with moving belts, pulleys and/or
fan when making the following checks. Beware of extremely high temperatures at
compressor outlet (discharge) hoses and tubing, as personal injury may result.

3. With the system operating, feel all air conditioning system components and refrigerant lines for proper
operating temperatures, as indicated in the following paragraphs.

In general, from the discharge side of the compressor along the high-pressure line, through the condenser
and up to the filter-drier, everything should be hot or warm to the touch. The filter-drier is normally at
outside temperature. The expansion valve, evaporator, and all the lines on the low-pressure side leading
back to the compressor should be cool to the touch. Any deviation from the above conditions may indicate
a malfunction in the system.

Malfunctions or stoppages may be indicated by extreme cold or frosted areas (example: a cold filter-drier
frosted part way up indicates a stoppage or serious restriction in the filter-drier). A stoppage or severe
restriction in the refrigerant system can be located by looking for these indications. The following is a brief
description of symptoms or conditions that could exist if the vehicle air conditioning system is malfunctioning.
The conditions are listed by system component.
Refrigerant Compressor

NOTE – If the ambient temperature is very low, the engine may have to reach operating temperature
before the body controller will energize the compressor. After warm-up, underhood heat will allow the
compressor to cycle on at very low ambient temperatures.

Compressor problems are usually revealed in one of 5 ways: abnormal noise, seizure, leakage, high suction
pressure, or low discharge pressure.

CAUTION

To prevent damage to the compressor in the following step, the compressor should be
turned in a clockwise (cw) direction only (as viewed from the front).

Resonant noises are not a cause for alarm. Irregular noise or rattles are likely caused by broken parts. To
check for seizure, turn the engine off to de-energize the magnetic clutch and see if the drive plate can be
turned. If it will not turn, the compressor has seized.

Inspect the fittings, oil fill plug, and all gasket joints on the compressor for signs of refrigerant leakage.

Verify that the wires to the compressor clutch are in good condition and have not become disconnected.

Condenser

The condenser is usually trouble-free. Normally, the temperature of the condenser outlet line is noticeably
cooler than the inlet line.

When road debris (such as leaves or dirt) cakes up, airflow over the condenser fins is reduced and the air is
not able to absorb enough heat to turn the hot refrigerant gas into a liquid. High discharge pressure will result.

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DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS

In these cases, carefully clean off the outer surface of the condenser with soap and water and compressed air;
be careful not to bend the fins.

High discharge pressure will also occur if the condenser's tubing is abnormally bent, restricting or blocking the
flow of refrigerant. Frost will appear at the point where the flow of refrigerant is restricted.

Internal blockage (foreign material or metallic grit buildup) is less common and will restrict or stop the flow of
refrigerant.

Inspect the fittings and the condenser tubing for signs of refrigerant leakage.

Reduced performance may also result from excess oil in the refrigerant system. This excess oil tends to
collect in the bottom of the condenser.

Pressure Transducer

Verify that the wires to the pressure transducer are in good condition and have not become disconnected.

Inspect the transducer mounting for signs of refrigerant leakage.

Low Pressure Switch

Verify that the wires to the low pressure switches are in good condition and have not become disconnected.

Inspect the low pressure switch mountings for signs of refrigerant leakage.

Filter-Drier

The filter-drier is normally at or near outside temperature. To the touch, the entire length of the unit should be
the same temperature. If noticeable cold spots exist, replace the filter-drier.

A blockage at the filter-drier will cause high head pressure and little or no cooling.

Thermostatic Expansion Valve (TXV)

Problems that start in the thermostatic expansion valve show up as follows:

• When stuck closed, the evaporator core and thermostatic expansion valve will be at outside temperature,
and the system will not cool.
• When stuck open, both the evaporator core and the thermostatic expansion valve will be extremely
cold with possible frost or ice buildup.

Because the thermostatic expansion valve channels are very small, blockage in the system is usually found
here (the thermostatic expansion valve is very sensitive to contamination). Usually the contamination is water.
Less than a drop of water is all it takes to make the thermostatic expansion valve inoperative. When water
reaches the thermostatic expansion valve, the extreme cold that results from the pressure drop freezes the
water, forming an ice blockage. After the system shuts down and the thermostatic expansion valve warms
up, the thermostatic expansion valve operates again, only to freeze up when the moisture returns and the
temperature drops.

Intermittent thermostatic expansion valve freeze up indicates that the filter-drier is not removing the moisture
from the system.

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A/C SYSTEM TEST MODE DIAGNOSIS AND TROUBLESHOOTING

Evaporator

The evaporator core is basically trouble-free when airflow over the fins is not blocked. Normally, the evaporator
outlet tube will feel cool to cold. External blockage or (less often) internal blockage will cause low suction
pressure and as little or no cooling.

Evaporator freeze-ups are the result of the moisture in the air condensing and then freezing on an evaporator
core that is operating below 32°F. The ice on the fins blocks the airflow through the evaporator and stops the
cooling until the ice melts. Evaporator freeze-up may be caused by a faulty thermostatic expansion valve or a
problem with the freeze probe.

A flooded evaporator occurs when there is too much refrigerant flowing into the evaporator, and is generally
caused by a faulty thermostatic expansion valve. A starved evaporator occurs when there is not enough
refrigerant flowing into the evaporator. Starvation can be caused by a faulty thermostatic expansion valve
or a low refrigerant charge. A starved evaporator may cause the evaporator outlet tube to feel warmer than
usual, at or near ambient temperature.

If a leak exists in the system, and it cannot be traced to other parts or fittings, suspect damage to the
evaporator core.

The evaporator is the most difficult of all the components to inspect visually because of its enclosed location.
To detect airflow blockage due to debris, bent fins, and/or refrigerant leaks (oil smudges), inspect the inlet
side of the evaporator.

CAUTION

Never force the fresh/recirculate air door open. If the door position must be changed,
turn on ignition, set mode control to FLOOR, and turn off ignition. Forcing the door will
result in a broken door shaft and a costly repair.

Line Restrictions

A restricted suction line causes low suction pressure at the compressor and little or no cooling. A restriction
in a line between the compressor and the thermostatic expansion valve can cause high discharge and low
suction pressure, and poor cooling. Generally, if the line is not entirely blocked, the area immediately after
the restriction will be cold. A completely blocked line will result in high head pressures and no cooling, but
no physical symptoms at the blockage.

6.3. A/C SYSTEM TEST MODE

Perform this procedure when referenced from the troubleshooting tables. This test is used to determine if the
air conditioning system is properly charged with refrigerant and the refrigerant cycle is functioning correctly.
The test is performed using the International® A/C Servicing System (RHS980C-NAV), two temperature
probes (a third temperature probe is used with sleeper applications), and the D400A or D440A-NAV Leak
Detector. When a fault is detected, perform the repairs indicated.

After making repairs involving the refrigerant system, repeat this test to verify correct operation.

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DIAGNOSIS AND TROUBLESHOOTING A/C SYSTEM TEST MODE

WARNING

During system pressure tests the recovery machine is only being used to read high
and low pressures. DO NOT open either hand valve on recovery station for any reason.
Equipment can be damaged, and personal injury can result.

CAUTION

To prevent damage to the test equipment, make sure test equipment and all connections
are clear of all moving parts in the engine compartment.

NOTE – Before connecting any service equipment to the refrigerant system, the refrigerant in the system
must be identified. Failure to identify system refrigerant before connecting equipment could result in
contamination of your service equipment and any refrigerant stored in the equipment.

NOTE – In rare conditions, vehicles using a viscous fan drive and being operated with no load may
need to place a fan in front of the condenser large enough to develop airflow comparable to normal ram
airflow.

1. Prior to performing performance testing be sure to:

A. Park the vehicle so there is no solar loading and no wind.

B. Always conduct performance testing with blower motor, door position, and temperature probe
positioned as described.
C. Note humidity and ambient temperature, and then consult the appropriate system pressure
test chart to determine system performance.
D. Always troubleshoot the HVAC system using the Diagnostic Trouble Codes and Service
Manual.
E. Always make sure to use the correct system pressure test chart for the vehicle being serviced.

NOTE – Each temperature probe has a number on its tip end, either 1, 2, or 3.

2. Position the sensing end of the T1 temperature probe approximately 12 to 24 inches in front of the vehicle
grill to measure ambient temperature of air entering the condenser. Connect the other end to the #1 (top)
position on the International® A/C Servicing System.

3. Verify that the valves are closed at the quick-disconnect fittings by setting them in the fully counterclockwise
positions.

4. Connect the red hose to the high pressure service port.

5. Connect the blue hose to the low pressure service port.

6. Turn the knobs clockwise to open the valves on the quick-disconnect fittings connected to the service
ports on the vehicle.

7. If the vehicle has a solenoid controlled fan drive, engage it. The fan can be operated with a jumper wire
or by disconnecting the solenoid valve, depending on the system.

8. Slowly close the hood, being careful not to damage the test equipment connections.

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A/C SYSTEM TEST MODE DIAGNOSIS AND TROUBLESHOOTING

• Insert a second temperature probe cable (T2) into the passenger side, left instrument panel vent. Do
not allow temperature probe (T2) to touch the side of the duct. Connect the other end to the #2
(middle) position on the International® A/C Servicing System.
• The International® A/C Servicing System is equipped with a third temperature probe (T3) for testing
the performance of the A/C system within the bunk area, if so equipped.

9. Run the engine at 1500 RPM.

10. Open the windows and close both cab doors.

11. Set the air conditioning control panel as follows:

A. Mode control to NORM A/C.

B. Blower control to high (full cw).
C. Temperature control to maximum cooling (full ccw).

12. Operate the system for at least 5 minutes or until the gauge readings settle.

13. Record the relevant readings from the LCD screen, ambient air temperature, relative humidity (RH), and
the cab air duct temperature.

14. Compare the pressure readings recorded previously to the pressures shown in Table 4. (The table is part
of the Performance AC Chart TMT-3416.)

15. If the pressure is more than 10 psig higher than the pressure listed in the chart, the system contains air or
some noncondensable gas in the refrigerant system. The system needs to be discharged, evacuated,
and recharged (Automatic Mode). Refer to SERVICE PROCEDURES FOR R-134A (See SERVICE
PROCEDURES FOR R-134A, page 26).

EXAMPLE: If the ambient is 75°F, the system pressure should be in the 78–79 psig range. If the pressure
is 90 psig or higher, it indicates that there is air or some noncondensable gas in the system.

NOTE – A refrigerant identifier can also be used to verify the contents of the system. Refer to Refrigerant
Identifier.

16. If the pressure is more than 10 psig lower than the pressure listed in the chart, the system is undercharged.
The system needs to be discharged, evacuated, and recharged using the International® A/C Servicing
System. Undercharged systems should be inspected for a possible leak before being discharged. Refer to
SERVICE PROCEDURES FOR R-134A (See SERVICE PROCEDURES FOR R-134A, page 26).

17. If the system is operating properly, the high and low pressure readings will be within the listed pressure
ranges in the following SYSTEM PRESSURE TEST CHART. If the gauges are not reading within
the System Pressure Test Chart ranges, refer to ABNORMAL READINGS (See ABNORMAL GAUGE
READINGS, page 147).

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DIAGNOSIS AND TROUBLESHOOTING ABNORMAL GAUGE READINGS

Table 6 System Pressure Test Chart

Ambient Air Relative Vent Air Temperature Refrigerant Pressure Refrigerant Pressure Compressor
Temperature Humidity Left Passenger High Side Service Port Low Side Service Port Cycling ?
(°F) (°C) (% RH) (°F) (°C) (psig) (kPa g) (psig) (kPa g)
70 21.1 30-50 42-55 5.6-12.8 80-140 552-965 15-35 103-241 Yes
70 21.1 70-90 43-56 6.1-13.3 100-155 689-1069 15-35 103-241 Yes
80 26.7 30-50 44-56 6.7-13.3 120-165 827-1138 18-35 124-241 Yes / No
80 26.7 70-90 46-58 7.8-14.4 130-175 896-1207 20-35 138-241 Yes / No
90 32.2 30-50 52-60 11.1-15.6 150-195 1034-1345 20-35 124-241 No
90 32.2 70 54-65 12.2-18.3 160-210 1103-1445 25-40 173-276 No
100 37.8 30-50 58-67 14.4-19.4 180-230 1241-1586 30-40 207-276 No
100 37.8 70 68-78 18.3-25.6 185-260 1276-1793 35-50 241-345 No

6.4. ABNORMAL GAUGE READINGS

WARNING

Before performing any of the following procedures, read the SAFETY WARNINGS (See
SAFETY PRECAUTIONS, page ). Failure to read the safety warnings and to be aware of
the dangers involved when working with refrigerant could cause personal injury or death.

CAUTION

To prevent damage to the test equipment, make sure test equipment is clear of all moving
parts in the engine compartment.

NOTE – It is the servicer's responsibility to obtain, read, and understand the Operator Manuals for all
service equipment. If other equivalent service tools are used, refer to the instructions provided by the
tool manufacturer.

If a specified pressure cannot be achieved during the A/C Test Mode, check the following abnormal gauge
readings to help isolate the malfunctioning component in the A/C system.

Diagnosis of Abnormal Gauge Readings

1. Low suction pressure - High discharge pressure

• Indicates restriction in system at a location between compressor discharge port and inlet to
receiver-dryer

2. Extremely low suction pressure - Normal to low discharge pressure

• Restriction in system between outlet of receiver-dryer and compressor, usually at expansion valve
• Low refrigerant charge
• Moisture freezing in expansion valve

3. High suction pressure - Normal to slightly low discharge pressure

• Expansion valve stuck open

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ABNORMAL GAUGE READINGS DIAGNOSIS AND TROUBLESHOOTING

• Suction side of compressor not functioning

4. High suction pressure - High discharge pressure

• Excessive air or oil in system

• Overcharged system
• Condenser plugged with debris
• Engine fan not operating properly

5. High suction pressure - Normal to slightly high discharge pressure

• Heater core water valve not shut off completely

• Blend-air door not completely closed
• Vents or window open

6. Low suction pressure - Low discharge pressure

• Low refrigerant charge

• Compressor not functioning properly

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DIAGNOSIS AND TROUBLESHOOTING FRONT ACTUATOR / DOOR POSITION RECALIBRATION

6.5. FRONT ACTUATOR / DOOR POSITION RECALIBRATION

Perform this procedure as directed in the troubleshooting tables.

Recalibrate Front Actuator / Door Position

This procedure recalibrates front actuator and door positions for the front HVAC control panel so the actuator /
door positions match the settings selected on the control panel.

1. Turn the ignition switch to the ON position.

2. Set Blower Fan Speed Control to any speed (1 - 7).

3. Set Mode Control to Defrost.

4. Remove fuse panel cover, and remove the 5 Amp fuse for BTRY to HVAC Control (fuse position F1-B).

5. Wait approximately 30 seconds, and reinstall the fuse.

6. Listen for the sound of actuators moving the Mode, Blend, and Fresh / Recirculate doors through their full
range of motion.

NOTE – Do not operate the HVAC control panel controls during the recalibration.

7. Start the vehicle, and check for correct operation of all HVAC modes and temperature.

6.6. TROUBLESHOOTING TABLES

NOTE – It is strongly recommended that Diamond Logic Builder® (DLB) is used along with this
information to enhance diagnostic capabilities. See the diagnostic software manual for details on
using the software.

HVAC Fault Codes

Table 7 HVAC Fault Codes

SIGNAL B/C Pin SPN FMI DESCRIPTION ACTION

HVAC High HVAC Pressure
BC_RCD_Pressure_Raw_Signal 1600-B12 2609 16 Pressure Sensor Reading
Protection Above 480 PSI
5 volt sensor Short Circuit From
Switched_5V_Sense_Raw_Signal 1602-E6 1079 1 supply below 1602_E6 to 6201_C
normal
HVAC Control Open Circuit From
Head Circuit 1200_A9 to 1600_A2
RCD_HVAC_Ctrl_Head_Diag_Signal 1600-A3 3985 9 Failed To
Communicate
With BC

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 7 HVAC Fault Codes (cont.)

SIGNAL B/C Pin SPN FMI DESCRIPTION ACTION
HVAC Control HVAC Temperature
Head Temperature Door Stuck, HVAC
Mix DM1 Temperature Door
Stuck, Shorted
RCD_HVAC_Ctrl_Head_Diag_Signal 1600-A3 1552 2
Circuit 1200_B11
to Temp Actuator Pin
A, or 1200_B12 to
Temp Actuator Pin F
HVAC Control HVAC Mode Door
Head Mode Fault Stuck, Defective
DM1 Door Actuator,
or Open/Shorted
RCD_HVAC_Ctrl_Head_Diag_Signal 1600-A3 3981 2
Circuit 1200_B9 to
Mode Actuator A, or
1200_B10 to Mode
Actuator Pin F
HVAC Control HVAC Air Inlet Door
Head Air Inlet Stuck, Defective
DM1 Door Actuator,
RCD_HVAC_Ctrl_Head_Diag_Signal 1600-A3 3984 2 or Open/Shorted
Circuit 1200_B1 to
4202_A, or 1200_B2
to 4202_F
Rear HVAC Body Builder
Data Link Datalink Connecting
Communication Body Controller
Failure circuit failure, Rear
HVAC Controller
Not Powered Up or
J1939BB_Rcv_61217_058_033_Timer N/A 2058 9
Defective. Voltage
on Both WiresShould
Equal 5 volts.
Voltage on Each
Wire Should Not Be
Equal.
Rear HVAC Body Builder
Data Link Datalink Connecting
Communication Body Controller
Failure circuit failure, Rear
HVAC Controller
Not Powered Up or
J1939BB_Rcv_61217_058_033_Timer N/A 2058 14
Defective. Voltage
on Both Wires
Should Equal 5 volts.
Voltage on Each
Wire Should Not Be
Equal.

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DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Table 7 HVAC Fault Codes (cont.)

SIGNAL B/C Pin SPN FMI DESCRIPTION ACTION
HVAC Rear Faulty Switch
Blower Speed Actuator or Micro
Rear_HVAC_Blower_UP N/A 3982 2 Control Switch switch for HVAC
Error Rear Blower Speed
Control Switch
Rear HVAC Faulty Switch
Temperature Actuator or Micro
Rear_HVAC_Temp_UP N/A 3983 2 Control Switch switch for Rear
Error HVAC Temperature
Control Switch
HVAC Control HVAC Motor in
Head Multiple Wrong Position or
Motor Faults Jammed (HVAC
HVAC Control Head Multiple Motor N/A 520465 2
Control Head
Multiple Motor fault
DM1)

HVAC Control Circuit Test

NOTE – It is strongly recommended that Diamond Logic Builder® (DLB) is used along with this
information to enhance diagnostic capabilities. See the diagnostic software manual for details on
using the software.

NOTE – Ignition key must be in the ON position while performing HVAC Control Circuit Test.

Table 8 HVAC Control Circuit Test

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

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

Repair and retest circuit.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 8 HVAC Control Circuit Test (cont.)

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:
Does the HVAC Check for voltage from NO: Voltage is not within YES: 12 Vdc. ± 1.5
control head have HVAC control head pin specifications.
A/C request signal A4 to ground. Voltage is within
present? Suspect faulty HVAC specifications.
4.
control head.
Continue to step 5.
Repair and retest
system.
Does A/C control Key in ON position. NO: Voltage is not within YES: 12 Vdc ± 1.5
head supply voltage Air conditioner/heater specifications. Inspect
to the BC when control switch is ON. for open in A77 circuit Voltage is within
requesting A/C to Check for voltage at between the HVAC specifications.
operate? BC J3 connector, pin control head and BC.
A2 to ground. Repair and retest circuit.

5. NOTE – If HVAC
Control has power
and grounds present
and one or more
output features are
inoperative, suspect
internal control head
fault.

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DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Mode Door Actuator Checks

1. BLOWER FAN SPEED CONTROL 5. MODE CONTROL WITH AIR

2. TEMPERATURE CONTROL CONDITIONING
3. MODE CONTROL
4. MODE CONTROL WITHOUT AIR
CONDITIONING
Figure 92 HVAC Control Head

NOTE – To establish a known starting position, the HVAC control head runs the actuator and door
through a calibration procedure when battery voltage is first applied to the HVAC control head. Initiate
calibration procedure manually by following the actuator / door position recalibrationprocedure (page
149).

Cycling the ignition switch DOES NOT initiate the calibration procedure.

NOTE – The HVAC control head will occasionally lose the position of the actuators or doors. If a
malfunction is caused by a lack of Mode or Temperature control, first perform the calibration procedure
page 149.

NOTE – Whenever the door actuator motor is energized while disconnected (such as during testing), it
must be recalibrated after it is reconnected. After reassembling the door and actuator, and reconnecting
the actuator electrical connector, initiate calibration procedure by following the actuator / door position
recalibration procedure page 149.

Cycling the ignition switch DOES NOT initiate the calibration procedure.

NOTE – Ignition key must be in ON position.

NOTE – HVAC control head must be ON.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 9 Mode Door Actuator Circuit Test.

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Does current Calibrate control head NO: Problem persists YES: Control works properly
system air flow page 149. after recalibration. after recalibration.
and temperature
1.
(actuator position) Continue to Step 2. Repair complete.
match control head
setting?
Is voltage being Check for voltage at YES: Voltage is not YES: 12 Vdc. ± 1.5
supplied by the HVAC control head, within specifications.
HVAC control pin B9. Operate mode Suspect faulty HVAC Voltage is being supplied
2.
head? switch. Test all switch control head. Refer from control head.
positions. to HVAC Control
Circuit Test. Continue to step 2.
Does the actuator Disconnect mode NO: Test light does YES: Test light illuminated.
operate in all mode actuator harness NOT illuminate on
settings? connector. Connect a specific Mode NOTE – It is important to
a test light between setting. Suspect physically verify actuator
cavity A and cavity faulty HVAC control door operation in addition to
B. Move mode switch head. electrical troubleshooting.
through ALL mode
settings, testing circuit Test light does NOT
3.
in each mode. illuminate on all
Mode settings.
Inspect A74 and
A74A circuits for
open or short.

Repair and retest

circuit.

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DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Blend Door Actuator Checks

NOTE – To establish a known starting position, the control head runs the actuator and door through a
calibration procedure when battery voltage is first applied to the HVAC. Initiate calibration procedure
manually by following the actuator / door position recalibration procedure page 149.

Cycling the ignition switch DOES NOT initiate the calibration procedure.

NOTE – The HVAC control head will occasionally lose the position of the actuators or doors. If a
malfunction is caused by a lack of Mode or Temperature control, first perform the calibration procedure
page 149.

NOTE – Whenever the door actuator motor is energized while disconnected (such as during testing), it
must be recalibrated after it is reconnected. After reassembling the door and actuator, and reconnecting
the actuator electrical connector, initiate calibration procedure manually by following the actuator / door
position recalibration procedure page 149.

Cycling the ignition switch DOES NOT initiate the calibration procedure.

NOTE – Ignition key must be in ON position.

NOTE – HVAC control head must be ON.

Table 10 Blend Actuator Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Does control head Calibrate control head NO: Problem persists YES: Control works properly
setting match page 149. after recalibration. after recalibration.
1.
current position
of actuator? Continue to Step 2. Repair complete.
Is voltage being Check for voltage at NO: Voltage is not YES: 12 Vdc. ± 1.5
supplied by the HVAC control head, within specifications.
HVAC control pin B11. Operate Suspect faulty HVAC Voltage is within
2.
head? temperature switch control head. Refer specifications.
from full cold to full to HVAC Control
heat settings. Circuit Test. Continue to step 2.
Does the actuator Disconnect mode NO: Test light does YES: Test light illuminated.
operate in all actuator connector. not illuminate. Inspect
temperature Connect a test light A74B and A74C NOTE – It is important to
settings? between cavity circuits for open or physically verify actuator
B and cavity A. short. Repair and door operation in addition to
3.
Sweep temperature retest circuit. electrical troubleshooting.
switch through all
temperature settings,
testing for voltage in
all temp settings.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Fresh/Recirculate Door Actuator Checks

NOTE – To establish a known starting position, the control head runs the actuator and door through a
calibration procedure when battery voltage is first applied to the HVAC control head. Initiate calibration
procedure manually by following the actuator / door position recalibration procedure page 149.

Cycling the ignition switch DOES NOT initiate the calibration procedure.

NOTE – The HVAC control head will occasionally lose the position of the actuators or doors. If a
malfunction is caused by a lack of Mode or Temperature control, first perform the calibration procedure
page 149.

NOTE – Whenever the door actuator motor is energized while disconnected (such as during testing), it
must be recalibrated after it is reconnected. After reassembling the door and actuator, and reconnecting
the actuator electrical connector, initiate calibration procedure manually by following the actuator / door
position recalibration procedure page 149.

NOTE – Ignition must be in ON position.

NOTE – HVAC control head must be ON.

Table 11 Recirc Door Actuator Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Does control head Calibrate control head NO: Problem persists YES: Control works properly
setting match page 149. after recalibration. after recalibration.
1.
current position
of actuator? Continue to Step 2. Repair complete.
Is voltage being Mode Switch should NO: Voltage is not YES: 12 Vdc ± 1.5
supplied by the be in MAX air within specifications.
HVAC control conditioning mode. Suspect faulty HVAC Voltage is within specifications.
2.
head? Check for voltage control head. Refer
at HVAC control to HVAC Control Continue to step 2.
head, pin B1. Circuit Test.
Does the actuator Disconnect recirc. NO: Test light does YES: Test light Illuminated.
operate in all motor connector not illuminate. Inspect
positions? (4017). Connect a test A70D and A74E NOTE – It is important to
3.
light between cavity B circuits for open. physically verify actuator
and cavity A. Actuate Repair and retest door operation in addition to
mode actuator. circuit. electrical troubleshooting.

156
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Linear Power Module/Blower Motor Checks

Table 12 LPM / Blower Motor Circuit Test

NOTE – Ignition must be in ON position.

NOTE – HVAC control head must be ON.

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:
Does the linear Disconnect LPM (1220) NO: Voltage is not within YES: 12 Vdc ±
power module have connector. specifications. Inspect 1.5 Voltage is
battery voltage? for blown or loose fuse within specifications.
Check voltage between F6 - A (1015) or loose Continue to step 2.
1.
LPM connector, cavity wires at connector.
6, and ground. Inspect A75 circuit for
open or shorts. Repair
and retest circuit.
Does the linear Check voltage between NO: Voltage is not within YES: (See Table 13,
power module have LPM connector, cavity specifications. Inspect page 158)
2. voltage supplied by 4, and ground. A75A circuit for open
the HVAC control? or shorts. Repair and
retest circuit.
Does the linear Check resistance NO: Resistance is too YES: ≤1 ohm.
power module have between LPM connector, high or no continuity Resistance is within
continuity to ground? cavity 5, and ground is present. Inspect specifications.
3. plate. A75 - G ground circuit Connect LPM harness
for open, loose, or connector. Continue
damaged connections. to step 4.
Repair and retest circuit.
Is full power being Operate blower motor at NO: Voltage is not YES: (See Table 13,
supplied to the HIGHEST speed setting. within specifications. page 158)
blower motor? Check voltage between
LPM connector, cavity Inspect A75A circuit
4, and ground. for open or short from
4.
HVAC control to LPM.

If no problems are
evident, perform HVAC
Control Circuit Test.
Is power being Operate blower motor NO: Voltage is not YES: (See Table 13,
supplied to the at LOWEST speed within specifications. page 158)
blower motor on setting (20% duty cycle).
the lowest setting? Check voltage between Inspect A75A circuit HVAC control head is
LPM connector, cavity for open or short from operating properly.
5.
4, and ground. HVAC control to LPM.
Continue to Step 6.
If no problems are
evident, perform HVAC
Control Circuit Test.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 12 LPM / Blower Motor Circuit Test (cont.)

NOTE – Ignition must be in ON position.

NOTE – HVAC control head must be ON.

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

Operate blower motor

control switch in each
speed setting.

View voltages in each

speed setting, and
compare to Blower
Speed Voltage (See
Table 13, page 158).

Table 13 Cab LPM and Blower Speed Voltage Table

CONTROL SPEED CONTROL BLOWER SPEED

SETTING VOLTAGE TO LPM VOLTAGE
OFF 0 – 0.4 Vdc 0 Vdc.
1 (Lowest) 1.4 ± 0.2 Vdc 3.85 ± 0.5 Vdc.
2 1.8 ± 0.2 Vdc 4.95 ± 0.5 Vdc.
3 2.4 ± 0.2 Vdc 6.60 ± 0.5 Vdc.
4 2.75 ± 0.3 Vdc 7.7 ± 0.5 Vdc
5 3.35 ± 0.3 Vdc 9.35 ± 0.5 Vdc
6 3.9 ± 0.3 Vdc 10.73 ± 0.5 Vdc
7 (Highest) 3.35 ± 0.3 Vdc 12.10 ± 0.5 Vdc

158
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

A/C Compressor Checks

NOTE – Diagnose HVAC control head DTC's prior to circuit testing A/C compressor. Certain DTC's will
inhibit compressor operation.

NOTE – Ensure A/C System pressures are within specifications and system is fully charged.

NOTE – Utilizing the Diamond Logic Builder®, verify that the following signals are true:

• Ignition key is in the RUN position.

• A/C request is ON.
• Low pressure switch voltage is < 2 Vdc.
• Freeze probe thermistor (evaporator temperature) is above 38°F
• High pressure transducer pressure is < 400 psi.

Table 14 A/C Compressor Clutch Circuit Test.

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

Is voltage being Check voltage at the NO: Voltage is not YES: 12 Vdc. ± 1.5
supplied to the body controller #J1 within specifications.
A/C compressor (1603) connector, pin No A/C compressor Voltage is within
by the BC? C to ground. output voltage supplied specifications.
1.
by BC. Verify operation
of all compressor inputs Continue to step 2.
to BC. Suspect faulty
body controller.
Is voltage present Check voltage at IP/ENG NO: Voltage is not YES: 12 Vdc. ± 1.5
at the engine/IP 42 - way connector (1702 within specifications.
connector cavity 10? - 10) cavity 10 to ground. Open or shorted Voltage is within
A77A circuit. Inspect specifications.
2.
for damaged wires,
loose, or corroded Continue to step 3.
connections. Repair
and retest circuit.
Does the A/C Check voltage at A/C NO: Voltage is not YES: 12 Vdc. ± 1.5
compressor have compressor clutch within specifications.
voltage? (6200) connector, cavity Open or shorted K77 Voltage is within
B to ground. (IBB engine) or K77A (I6 specifications.
3. engine) circuit. Inspect
for damaged wires, Continue to step 4.
loose, or corroded
connections. Repair
and retest circuit.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 14 A/C Compressor Clutch Circuit Test. (cont.)

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:
Does the A/C Disconnect A/C NO: Resistance is out YES: ≤1 ohm.
compressor have compressor clutch of specifications or no Resistance is within
proper ground? (6200) connector. continuity is present. specifications.
Measure resistance Inspect K77 - G ground Continuity is present.
4.
between cavity A to circuit for open, loose, or A/C compressor clutch
ground. damaged connections. circuits are operable.
Repair and retest circuit. Suspect faulty A/C
compressor clutch coil.

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DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Pressure Transducer (IBB engine) Checks

NOTE – Refer to latest circuit diagram information related to vehicles equipped with transmission oil
temperature gauges and air restriction.

NOTE – Ensure A/C system pressures are within specifications and system is fully charged.

NOTE – Ensure ignition key is in the ON position

NOTE – A/C request is ON.

Table 15 Pressure Transducer Circuit Test (IBB engine)

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

Does the body Check voltage at body NO: Voltage is not within YES: 5 Vdc. Voltage
controller supply controller #J5 connector specifications. Verify is within specifications.
1. 5 Vdc. signal to (1602), pin E6 to ground. BC operation. Inspect Continue to step 2.
the A/C pressure J5 connector for loose
transducer? or damaged pins.
Is voltage present Check voltage at body NO: Voltage is not within YES: 0 Vdc. Voltage
at the pressure controller #J5 connector specifications. If voltage is within specifications.
transducer zero volt (1602), pin E3 to ground. is present, inspect circuit Continue to step 3.
2. reference circuit? A9Z and A9C for short
to voltage. Repair and
retest circuit.

Does the zero volt Disconnect A/C pressure NO: Resistance is not YES: ≤1 ohm. Continue
reference circuit transducer connector within specifications to step 4.
have low resistance? (6201). Disconnect BC OR no continuity is
#J5 connector (1602). present. Inspect A9Z
Measure resistance and A9C circuit for
3. between transducer open and source of high
connector, cavity A and resistance. Inspect zero
cavity E3 of the BC volt reference connector
#J5 connector. (1620) for loose or
damaged connections.
Repair and retest circuit.

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TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

STEP POSSIBLE CAUSE

TEST/CHECK (cont.) NO: (cont.) YES: (cont.)
(cont.) (cont.)
NO: Voltages do
not directly relate to
pressures (Refer to
Pressure Transducer
Voltage Table 17).
Measure voltage from
BC #J3 connector If voltage is 5 Vdc:
YES: Voltage is
(1600), pin B12 Inspect A77B and
Does the pressure directly related to A/C
to ground. Using K77B circuits for short
transducer signal pressures. As pressure
the Diamond Logic to voltage.
4. voltage correctly increases, voltage
Builder®, view the
relate to pressure increases. Refer to
A/C_High_Side_Pressure If voltage is 0 Vdc:
reading? Pressure Transducer
signal. Compare Inspect A77B and K77B
Voltage Table 17.
voltages to pressure circuits for open or
signal. short to ground.

If no problems are
evident with circuit(s):
Suspect faulty A/C
pressure transducer.

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DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Pressure Transducer (I6, V8 engine) Checks

NOTE – Refer to latest circuit diagram information related to vehicles equipped with transmission oil
temperature gauges and air restriction.

NOTE – Ensure A/C system pressures are within specifications and system is fully charged.

NOTE – Ensure ignition key is in the ON position

NOTE – A/C request is ON.

Table 17 Pressure Transducer Circuit Test (I6, V8 engine)

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

Does the body Check voltage at body NO: Voltage is not within YES: 5 Vdc. Voltage
controller supply controller #J5 connector specifications. Verify is within specifications.
1. 5 Vdc. signal to (1602), pin E6 to ground. BC operation. Inspect Continue to step 2.
the A/C pressure J5 connector for loose
transducer? or damaged pins.
Is 0 voltage present Check voltage at NO: Voltage is not within YES: 0 Vdc. Voltage
at the pressure pressure transducer specifications. If voltage is within specifications.
transducer ZVR connector (8602), pin is present, inspect circuit Continue to step 3.
2.
circuit? B to ground. A99AA, A9E, K9E, and
K9A for short to voltage.
Repair and retest circuit.
Does the 0 voltage Disconnect A/C NO: Resistance is not YES: ≤1 ohm. Continue
reference circuit pressure transducer within specifications OR to step 4.
have low resistance? connector (8602) and no continuity is present.
BC #J5 connector Inspect A99AA, A9E,
(1602). Measure K9E, and K9A circuits for
3. resistance between open or source of high
transducer connector, resistance. Inspect zero
cavity A and E6 at the volt reference connector
BC #J5 connector. (6747) for loose or
damaged connections.
Repair and retest circuit.

163
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

STEP POSSIBLE CAUSE TEST/CHECK NO: YES:

4. Does the pressure Measure voltage from NO: Voltages do YES: Voltage is
transducer signal BC #J3 connector not directly relate to directly related to A/C
voltage correctly (1600), pin B12 to pressures (Refer to pressures. As pressure
relate to pressure ground. Using the Pressure Transducer increases, voltage
reading? Diamond Logic Voltage Table 17) increases. Refer to
Builder®, view the Pressure Transducer
A/C_High_Side_Pressure If voltage is 5 Vdc Voltage Table 17.
signal. Compare Inspect A77B and K77B
voltages to pressure circuits for short to
signal. voltage.

If voltage is 0 Vdc.
Inspect A77B and K77B
circuits for open or short
to ground.

If no problems are
evident with circuit(s):
Suspect faulty A/C
pressure transducer.

Table 19 Pressure Transducer Voltage Table

Continues
PRESSURE (PSI) 0 20 25 40 50 75 100 150 185
in Row 3

NOMINAL Continues
0.25 0.42 0.48 0.62 0.71 0.92 1.15 1.59 1.90
VOLTAGE (VDC) in Row 4

PRESSURE (PSI)
200 250 285 300 350 400 420 450 475 500
Continued

NOMINAL
VOLTAGE (VDC) 2.03 2.48 2.80 2.92 3.38 3.81 3.99 4.26 4.48 4.71
Continued

164
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Freeze Thermistor Checks

NOTE – Ensure A/C system pressures are within specifications and system is fully charged.

NOTE – Verify ignition key state for individual test.

NOTE – Ensure A/C control head is ON.

NOTE – Perform test with freeze probe thermistor connector (4019) disconnected from thermistor.

Table 20 Freeze Thermistor Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage being Key in ON position. NO: Voltage is not within YES: 10 Vdc. ± 1.0
supplied to specifications. Inspect for
the HVAC unit Measure voltage at open or shorted circuit Voltage is within
1.
connector cavity HVAC unit connector between cavity G to BC specifications.
G? (1210) cavity G to #J3 connector. Repair
ground. and retest circuit. Continue to step 2.
Does the freeze Disconnect HVAC unit NO: No continuity is YES: < 1 ohm.
thermistor zero volt connector (1210) and present. Check for open
reference circuit BC #J5 connector(1602). circuits between HVAC unit Resistance is within
2. have continuity Measure continuity from connector (1210) cavity specifications.
to ground? cavity H to BC #J5 H and BC connector #J5
cavity E3. (1602) pin E3. If no open Continue to step 3.
exist, suspect faulty BC.
Does freeze Key in OFF position. NO: Resistance YES: Voltage is within
thermistor measurements do not specifications.
resistance Measure resistance agree with temperature:
measurement between thermistor Replace thermistor
correctly relate terminals A to B. (freeze probe)
3.
to temperature?
Refer to Thermistor Resistance
Cross Reference Table measurements agree
21 for specifications. with temperature:
Suspect faulty BC.

165
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Low Pressure Switch Checks

NOTE – Ensure A/C System pressures are within specifications and system is fully charged.

NOTE – Verify ignition key state for individual test.

NOTE – Ensure A/C control head is ON.

NOTE – Perform test with low pressure switch connector (4018) disconnected from thermistor.

Table 21 Low Pressure Switch Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage present Key in ON position. NO: Voltage is not within YES: 10 Vdc. ± 1.0
at the HVAC Unit specifications Inspect
(1210) connector Measure voltage from for an open or shorted Voltage is within
cavity J? HVAC Unit (1210) circuit between harness specifications.
1. connector cavity J connector cavity J and
to ground. BC #J3 connector (1600) Continue to step 2.
pin B5. If no circuit
faults exist, suspect BC.
Repair and retest circuit.
Does the low Disconnect HVAC unit NO: No continuity is YES: < 1 ohm. Resistance
pressure switch 0 connector (1210) and present. Check for is within specifications.
voltage reference BC #J5 connector open circuits between Continue to step 3.
circuit have (1602). Measure HVAC unit connector
2.
continuity to continuity from cavity K (1210) cavity K and BC
ground? to BC #J5 cavity E3. connector #J5 (1602)
pin E3. If no open exist,
suspect faulty BC.
Does low Key in OFF position. NO: Resistance YES: Refer to Thermistor
pressure switch measurements do not Cross Reference Table 21
resistance Measure resistance agree with pressure: for specifications.
measurement between low pressure Replace thermistor (low
relate to switch (4018) terminals pressure switch).
3.
temperature? A to B.
Resistance
measurements agree
with pressure: Suspect
faulty BC.

166
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Table 22 Thermistor Cross Reference

TEMP. TEMP. MIN. RESISTANCE NOMINAL RESISTANCE MAX. RESISTANCE

(°C) (°F) (kohms) (kohms) (kohms)
-15 5 35.03 35.67 36.32
-10 14 26.65 27.06 27.48
-5 23 20.46 20.72 20.98
0 32 15.84 16.00 16.16
5 41 12.30 12.46 12.61
10 50 9.626 9.771 9.918
15 59 7.589 7.722 7.856
20 68 6.025 6.144 6.265
25 78 4.816 4.922 5.030
30 86 3.874 3.968 4.064

Auxiliary HVAC Controller Test

NOTE – Ensure no faults exist with front HVAC system, any faults may effect sleeper HVAC operation.

NOTE – Ignition key must be in the ON position while performing Auxiliary HVAC Controller Test.

NOTE – Bench testing of the sleeper accessory relay (5001–H3) is necessary prior to performing
Auxiliary HVAC Controller Test.

Table 23 Auxiliary HVAC Controller Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is switched voltage Check power to NO: Voltage is not within YES: 12 Vdc ± 1.5
being supplied sleeper accessory specifications.
to the sleeper relay (5001–H3). Voltage is within
accessory relay? Inspect H12B circuit for specifications.
Check voltage at cavity open or short.
1. 86 to ground of the Continue to step 2.
sleeper accessory relay Verify ignition switch
(5001–H3). operation.

Repair and retest

circuit(s).
Does the sleeper With the sleeper relay NO: Voltage is not within YES: 12 Vdc.± 1.5
accessory relay removed, check for specifications.
have battery voltage at cavity 30 of Voltage is within
power? the sleeper relay. Inspect for blown sleeper specifications.
2. fuse (5001–H2) and
fuse F7–H (1016). Continue to step 3.
Inspect H75BV circuit
for open or short.

167
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 23 Auxiliary HVAC Controller Circuit Test (cont.)

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE

Repair and retest

circuit(s).
Does the sleeper With sleeper relay NO: Continuity is not YES: ≤ 1 ohm.
accessory relay removed, check present or resistance
have proper continuity to ground is too high. Resistance is within
ground? between cavity 85 of specifications.
relay and ground. Inspect H11–GS and
3. H11–GSK circuits Continue to step 4.
for open, loose, or
damaged connections.

Repair and retest

circuit(s).
Is battery feed Check power to NO: Voltage is not within YES: 12 Vdc ± 1.5
voltage being the auxiliary HVAC specifications.
supplied to controller (5210). Voltage is within
auxiliary HVAC Inspect H75V circuit for specifications.
controller? Check voltage from open or short.
4. cavity 3 to ground. Continue to step 5.
Inspect H75–GBB circuit
for open or short.

Repair and retest

circuit(s).
Does the auxiliary Check auxiliary HVAC NO: Excessive YES: ≤1 ohm.
HVAC controller controller ground. resistance is found or no
have proper continuity is present. Resistance is within
ground? Check continuity specifications.
between the auxiliary Inspect auxiliary HVAC
HVAC controller (5210) controller ground circuit Continue to step 6.
5.
and cavity 4 to ground. H75–GBB for open,
loose, or damaged
connections.

Repair and retest

circuit(s)

168
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Is the auxiliary Check auxiliary HVAC NO: Blower motor speed YES: Blower Motor speed
HVAC controller controller multiplex signal does not relate to signal directly relates to
communicating on operation. switch operation. switch operation.
the Data Link?
6. Utilizing the DLB, view Verify operation of other Controller is operable and
auxiliary HVAC blower controller output signals. communicating on the
motor speed signal while J1939 Bus circuit.
operating blower motor. Suspect faulty controller.
Continue to step 7.
Can the auxiliary Using the DLB, view NO: Signals did not YES: Signals followed all
HVAC controller signals while operating follow switch request on individual switch requests.
operate outputs? sleeper HVAC controls. one or more controls.
Auxiliary HVAC controller
Actuate the following Perform test on specific is operational, power
controls while viewing failed controls and and grounds are
DLB signals: (Trim circuits. present. Controller is
3 LED controls) communicating on the
temperature setting, Suspect faulty auxiliary J1939 Bus. All outputs
7.
blower setting, HVAC controller. are operational.
temperature switches
up/down, blower speed Repair and retest. No problems evident with
switch up/down, dimmer auxiliary HVAC controller.
switch
Problem may be
(Trim 1 and 2 analog intermittent.
controls) blower speed
control, temp control.

169
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Auxiliary HVAC (Analog) Control Checks

NOTE – Ignition key must be in the ON position while performing Auxiliary HVAC (Analog) Control
Checks.

Table 25 Analog Temperature and Blower Speed Control Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage being Check for voltage NO: Voltage is NOT YES: 12 Vdc ± 1.5 Voltage
supplied to the between pin 18 of within specifications. is within specifications.
temperature and the auxiliary HVAC
blower speed controller connector Suspect faulty controller. Continue to step 2.
1. controls? and ground.
Perform Auxiliary HVAC
Controller Test.

Repair and retest.

Is voltage present Check for voltage NO: Voltage is NOT YES: 12 Vdc ± 1.5
at both the at cavity A at the within specifications.
temperature temperature control and Voltage is within
control and blower blower speed control Inspect for open or specifications.
speed control switches to ground. short circuit on H77TVT,
2.
switches? H77TVB, and H77TV Continue to step 3.
circuits.

Repair and retest

circuit(s).
Does circuit Disconnect auxiliary NO: No continuity is YES: 0 to 10K ohms.
resistance follow HVAC controller present.
temperature connector (5210). Resistance varied with
control switch Inspect ground circuit switch position and is
position? Measure resistance H77TZ and signal circuit within specifications.
between cavity 21 H77TT for open.
and cavity 19 of Continue to step 4.
3.
the auxiliary HVAC Resistance is not within
controller connector. specifications and did
not vary with switch
Change temperature position. Replace
control switch position temperature control
and observe voltage switch and retest circuit.
reading.

170
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Does circuit Disconnect auxiliary NO: No continuity is YES: 0 to 10k ohms.

resistance follow HVAC controller present.
blower speed connector (5210). Resistance varied with
control switch Inspect signal circuit switch position and is
position? Measure resistance H77TB for open. within specifications.
between cavity 23
and cavity 19 of Resistance is not within No faults evident at
4.
the auxiliary HVAC specifications and did not this time.
controller connector. vary with switch position.
Perform Auxiliary HVAC
Change blower speed Replace blower speed Controller Test.
control switch position control switch and
and observe voltage retest circuit.
reading.

171
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Sleeper HVAC (LED) Control Checks

NOTE – Ignition key must be in the ON position while performing the Sleeper HVAC (LED) Control
Checks.

Table 27 HVAC LED Control Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is the HVAC LED Disconnect HVAC NO: Voltage is NOT YES: 12 Vdc ± 1.5 Voltage
control being LED Control (5200) within specifications. is within specifications.
supplied power connector.
by the auxiliary Inspect circuit H75F for Continue to step 2.
HVAC controller? Check voltage between open or short.
cavity 7 of the HVAC
LED control connector Inspect main sleeper or
and ground. sleeper control panel
connector (5130/5134)
1.
for loose, damaged or
pushed out terminals.

If no problems are
evident, suspect internal
controller fault.

Repair and retest

circuit(s)
Is the HVAC LED Disconnect HVAC NO: No continuity is YES: ≤1 ohm.
control grounded LED control (5200) present or resistance
to the auxiliary connector. is too high. Resistance is within
HVAC controller? specifications.
Measure continuity from Inspect H75–GA circuit
cavity 8 of the HVAC for open. NOTE – If power and
LED control (5200) ground are present and
connector and ground. Inspect for loose or HVAC LED Control and
damaged terminals display is inoperative,
at the main sleeper suspect internal LED
2.
connector (5130/5134) control fault.

Verify auxiliary HVAC Continue to step 3.

controller ground circuit.

If no problems are
evident, suspect internal
controller fault.

Repair and retest circuit.

172
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Are all controls Utilizing the Diamond NO: If more than one YES: All controls are
operable on Logic Builder® circuit has failed, suspect operable, the auxiliary
the HVAC LED (DLB) software, view faulty HVAC LED control. HVAC controller is
control? appropriate rear HVAC receiving the input signal.
signals. Test individual failed
circuit(s) for open NOTE – If output
Operate the following or short. fault exist, perform
3.
controls: troubleshooting on
Repair and retest circuit. specific failed output.
blower setting, blower
switch up/down, No faults evident at
temperature setting, this time.
temp switch up/down,
dimmer switch.

173
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Rear HVAC Blend Door Actuator Checks

NOTE – To establish a known starting position, the auxiliary HVAC controller runs the actuator and door
through a calibration procedure when battery voltage is first applied to the controller, such as cycling
the key. Cycling key during diagnostic troubleshooting can cause false circuit information.

Initiate calibration procedure manually by following the actuator / door position recalibration procedure
page 149.

NOTE – Ignition key must be in the ON position while performing the Rear HVAC Blend Door Actuator
Checks.

Table 29 Rear HVAC Blend Door Actuator Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage being Check for voltage at NO: Voltage is not within YES: 12 Vdc. ± 1.5
supplied by the the auxiliary HVAC specifications.
auxiliary HVAC controller (5210), pin 11. or -12 Vdc ± 1.5
controller? Suspect faulty auxiliary
1.
Operate blend switch, HVAC controller. Voltage is within
test all switch positions. specifications.
Refer to Auxiliary HVAC
Controller Test. Continue to step 2.
Does the actuator Disconnect blend NO: Test light does YES: Test light
function in all actuator connector. not illuminate. illuminated.
temperature
settings? Connect a test light Inspect H75TMA and Circuits are functioning
between cavity 7 H77TFB circuits for properly, replace blend
and cavity 5. open or short. door actuator and retest
2. system.
Sweep temperature Suspect faulty auxiliary
switch through all HVAC controller. NOTE – It is important
settings, testing to physically verify
for voltage in all Repair and retest circuit. actuator door operation
temperature modes. in addition to electrical
troubleshooting.

174
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Rear HVAC Blower Motor/LPM Checks

NOTE – Ignition key must be in the ON position while performing the Rear Blower Motor/LPM Checks.

Table 30 Rear Blower Motor/LPM Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is the linear power Disconnect LPM 3 way NO: Voltage is not within YES: 12 Vdc ± 1.5
module being connector (5214). specifications.
supplied battery Voltage is within
voltage? Check voltage at the Inspect for blown 30A specifications.
LPM connector, cavity fuse F7 - E (1016).
6 to ground. Continue to step 2.
Inspect H75C and A75C
circuit for open or shorts.
1.
Inspect auxiliary heater
connector (5009) for
loose, damaged or
pushed out terminals.

Verify battery feed circuit

operation.

Repair and retest circuit.

Does the linear Check resistance NO: Resistance is too YES: ≤1 ohm.
power module between cavity 5 of the high or no continuity
have continuity LPM connector (5214) is present. Resistance is within
to ground? and ground plate. specifications.
Inspect H11 - GSM
ground circuit for open or Reconnect LPM harness
source of high resistance. connector.
2.
Inspect auxiliary heater Continue to step 3.
connector (5009) for
loose, damaged or
pushed out terminals.

Repair and retest circuit.

Is the LPM being Check voltage at the NO: Voltage is not Yes: 5.0 Vdc
supplied voltage LPM connector, cavity within specifications.
by the auxiliary 4 to ground. Inspect H75CB circuit Voltage is within
HVAC controller? for open or short. specifications.
Place blower motor
3.
control switch on Perform Auxiliary HVAC Continue to step 4.
highest setting. Controller Test. Verify
blower control operation.

Repair and retest circuit.

175
TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING

Table 30 Rear Blower Motor/LPM Circuit Test (cont.)

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is the LPM being Check voltages at the NO: Voltages did not YES: Voltage decreased
supplied voltage LPM connector, cavity decrease with speed with speed setting.
by the HVAC 4 to ground. setting.
controller on all Control circuit working
4.
blower speed Decrease blower speed Suspect faulty auxiliary properly.
settings? one setting at a time. HVAC controller.
Continue to step 5.
Observe voltages. Repair and retest system.
Is the blower Disconnect blower NO: YES: Voltages are within
motor operating motor harness specifications.
on all switch connector from LPM. Voltages are not within
positions? specifications. If blower motor is still
Check for voltage at the inoperative, replace and
LPM. pin A to pin B. Suspect faulty LPM. retest blower motor.

5. Operate blower motor

control switch in each
speed setting.

View voltages in each

speed setting, and
compare to blower
speed voltage table 12.

176
DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES

Rear HVAC Temperature Sensor Checks

NOTE – Ignition key must be in the ON position while performing Rear HVAC Temperature Sensor
Checks.

Table 31 Auxiliary HVAC Temperature Sensor Circuit Test

POSSIBLE
STEP TEST/CHECK NO: YES:
CAUSE
Is voltage Disconnect auxiliary NO: Voltage is not within YES: 12 Vdc. ± 1.5
present at the HVAC temperature specifications. Inspect
auxiliary HVAC sensor connector for an open or shorted Voltage is within
temperature (5213). H77TSA circuit between specifications. Continue
sensor? temperature sensor to step 2.
Check voltage from connector and auxiliary
auxiliary HVAC HVAC controller.
1.
temperature sensor
(5213), cavity 1 to If no circuit faults are
ground. present, perform auxiliary
HVAC controller test.

Suspect faulty auxiliary

HVAC controller.
Does the Disconnect auxiliary NO: No continuity or high YES: ≤1 ohm.
auxiliary HVAC HVAC temperature resistance is present.
temperature sensor connector (5213) Check for an open Resistance is within
sensor have and auxiliary HVAC H77TSB circuit. Inspect specifications.
proper ground? controller connector connectors for loose,
(5210). corroded, or pushed Continue to step 3.
out terminals.
Measure resistance
2. between auxiliary HVAC Repair and retest circuit.
temp sensor connector,
cavity 2 and auxiliary If no circuit faults
HVAC controller (5210) are present, perform
connector, cavity 12. Auxiliary HVAC
Controller Test.

Suspect faulty auxiliary

HVAC controller.
Does the Utilizing the Diamond NO: Temperature sensor YES: Temperature
auxiliary HVAC Logic Builder® resistance does not sensor resistance agrees
temperature software, view the agree with actual with actual discharge
sensor read Rear_HVAC_Discharge_ discharge temperatures. temperatures.
correct Temp_Setting Signal.
3.
temperature? Check resistance Replace temperature No faults evident with
between cavities 12 sensor. auxiliary temperature
and 13 of the auxiliary sensor.
HVAC controller Repair and retest system.
connector (5210).

177
TORQUE CHART SPECIFICATIONS

7. SPECIFICATIONS
7.1. TORQUE CHART
Table 32 Torque Chart

Figure No. (Item Item Description Torque Value

No.) N•m Lbf-ft Lbf-in
Figure 30 (Item 3) C-plate Nuts 19 to 20 14 to 15 168 to 180
Figure 31 (Item 5) C-plate Nuts 19 to 20 14 to 15 168 to 180
Figure 31 (Item 1) Pressure Transducer 7 to 14 5 to 10 60 to 120
Figure 27 (Item 2) Low Pressure Switch 7 to 14 5 to 10 60 to 120
Figure 32 (Item 9) Filter-Drier Cover Screws 2.3 2.26 20
Figure 32 (Item 2) Front Lock Plate Screw 9 to 10 7 80 to 90
Figure 33 (Item 3) Expansion Valve Screws 4 to 4.3 3 to 4 35.4 to 38
Figure 34 (Item
2) and Figure 35 Fresh Air Module Nuts 7 5 58
(Item 1)
Figure 36 (Item 1) Interior Module Trim Screws 5.7 2.26 20
Figure 37 (Item 6) Fresh/Recirc Door Actuator Screws 5.7 2.26 20
Figure 38 (Item 3) Blend Door Actuator Screws 5.7 2.26 20
Figure 39 (Item 1) Mode Door Actuator Screws 5.7 2.26 20
Figure 61 (Item 7) Blower Scroll Housing Screws 5.7 2.26 20
Figure 54 (Item 3) LPM Screws 5.7 2.26 20
Figure 55 (Item 5) Blower Assembly Screws 5.7 2.26 20
Figure 67 (Item 1) Interior Module Mounting Nuts 7 5 58
Figure 67 (Item 3) Front C-plate Nuts 19 to 20 14 to 15 168 to 180
Figure 58 (Item 3) Front HVAC Control Panel Screws 2 to 3 20 to 27 20 to 27
Figure 45 (Item 3) Compressor Mounting Bolts 23 to 29 17 to 21 204 to 252

178
SPECIFICATIONS AIR CONDITIONING SYSTEM

7.2. AIR CONDITIONING SYSTEM

Table 33 Air Conditioning System Specifications

ITEM SPECIFICATION
Refrigerant Type R-134a
Refrigerant Quantity (Full Charge)

• ProStar®/LoneStar® (Day Cab) • 40 oz.

(2.5 lbs)

(1.13 kg)
• ProStar®/LoneStar® (Sleeper Cab) • 48 oz.

(3 lbs)

(1.36 kg)
Compressor Oil Type PAG Oil

International® P/N ZGGR725028

Compressor Oil Capacity (All Models) 300 cc (10.14 fl.oz.)
Lubricating Oil Type (O-rings, threads, etc.) Do NOT International® P/N ZGGR6912
use as compressor refrigerant oil.
(Mineral Oil)
Compressor Belt Drive Tension Controlled by auto-tensioner.

179
AIR CONDITIONING SYSTEM SPECIAL TOOLS

8. SPECIAL TOOLS
CAUTION

The servicing tools recommended for this system were designed specifically for use
with R-134a systems. Servicing tools designed and/or used for R-12 systems must not
be used when servicing R-134a systems unless they are specifically identified as being
compatible with both systems.

Servicing air conditioning efficiently and effectively requires proper tools and equipment. The recommended
tools, as well as alternate service tools are shown and discussed below.

The tools listed in the following table can be ordered through the International® tool supplier. For special tools
that are obtained locally refer to TOOLS OBTAINED LOCALLY.

Table 34 Special Service Tools

DESCRIPTION PART NO.

Air Conditioning Recovery, Recycling, and Recharge Machine: the

International® Machine
RHS980C-NAV
D440A-NAV Refrigerant Leak Detector D440A-NAV
D400A Refrigerant Leak Detector D400A
Electronic Service Tool (EST), EZ-Tech
and Interface Communications Cable

Table 35 Frequently Used International® A/C Servicing System Consumable Items

ISN PART NUMBER REFERENCE RTI P/N ITEM DESCRIPTION

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

180
SPECIAL TOOLS AIR CONDITIONING SYSTEM

Table 35 Frequently Used International® A/C Servicing System Consumable Items (cont.)
ISN PART NUMBER REFERENCE RTI P/N ITEM DESCRIPTION
IRTI3608001200 360 80012 00 OIL VACUUM PUMP (12 QT CASE)
REPLACEMENT BATTERY FOR CIRCUIT
IRTI3608229200 360 82292 00
BOARD CR1025

All consumable items can be ordered through Navistar parts.

181
INTERNATIONAL® SERVICING SYSTEM (RHS980C-NAV) SPECIAL TOOLS

8.1. INTERNATIONAL® SERVICING SYSTEM (RHS980C-NAV)

Figure 93 International® Servicing System (RHS980C-NAV)

The International® Servicing System (RHS980C-NAV) is the recommended air conditioning service machine,
meeting SAE J2788 standards. If other recovery tools (meeting SAE J2788) are used, refer to the instructions
provided by the tool manufacturer (this includes the current Robinair machine).

The RHS980C-NAV can be used to perform a fully automatic service. The technician will be prompted for
entry of data such as charge amount and given options like vacuum leak test. Once the necessary data has
been entered, the RHS980C-NAV will automatically perform the complete service and alert the technician for
interaction or that the service is complete.

The RHS980C-NAV can also be used to perform individual functions like recycle, vacuum, or charge. The
keypad has dedicated buttons (AUTOMATIC, RECYCLE, VACUUM, and CHARGE) to allow the technician to
jump directly to any one of these functions.

Units of measure displayed can be changed at any time by repeatedly pressing the U/M key.

A setup routine can be used to select options, set default values, perform maintenance operations, and
manage fluid capacities processed.

For any additional operating instructions refer to the operators manual supplied with the RHS980CNAV.

182
SPECIAL TOOLS INTERNATIONAL® SERVICING SYSTEM (RHS980C-NAV)

CAUTION

Sealants and leak stop chemicals in A/C systems may cause serious damage to the
RHS980C-NAV if they are present in the refrigerant recovered intended for recovery.
Detection devices are readily available to check for the presence of these chemicals
and are highly recommended to protect the RHS980C-NAV.

NOTE – The new SAE Standard J2788 dictates that the filter must be changed at set intervals to ensure
that recycled refrigerant is pure.

The RHS980C-NAV has one filter, which must be changed after recycling every 150 lbs. of refrigerant.

The technician will be alerted when the filter life is at 100 lbs (45 KG). This allows time to order a
replacement filter kit.

When the filter has purified 150 lbs (68 KG) of refrigerant, the RHS980CNAV will shut down and not
perform any function.

A new filter must be installed to re-activate the RHS980C-NAV controller.

183
RHS980C-NAV TEMPERATURE PROBES SPECIAL TOOLS

8.2. RHS980C-NAV TEMPERATURE PROBES

Three temperature probes are used with the RHS980C-NAV for testing and diagnostics. Temperature probes
provide a simple, accurate way to read relative humidity, pressures, and ambient air temperature.

8.3. REFRIGERANT IDENTIFIER

Figure 94 Refrigerant Identifier Hose (Found On The Rear Of The RHS980C-NAV)

In today's environment, there are a lot of alternative and blended refrigerants; International® only recognizes
R-134a for this system. The only way to know for sure if you can safely recover the refrigerant in a system is
through the use of a refrigerant identifier. If the RHS980C-NAV has a refrigerant identifier installed, the
refrigerant identifier samples the refrigerant, then displays the type and purity of the refrigerant in the system.
The refrigerant identifier hose is found on the rear of the RHS980C-NAV and connects to the vehicle low side
service port. The refrigerant identifier is supplied as part of a kit which includes the necessary hoses and
fittings. The refrigerant identifier is an optional item and can be installed in the field.

184
SPECIAL TOOLS D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS

8.4. D-400A AND D440A-NAV REFRIGERANT LEAK DETECTORS

1. D400A LEAK DETECTOR 2. D440A-NAV LEAK DETECTOR

Figure 95 Refrigerant Leak Detectors

The D400A and D440A-NAV features a long life heated sensor technology that is designed to detect the more
current and difficult HFC refrigerants, such as R-134a, in addition to all HCFC and CFC refrigerants including
hydrocarbon “blends”. The D400A and D440A-NAV’s unique digital leak size indicator takes the guesswork
out of whether or not to repair a small leak. The digital display equipped on the D440A-NAV is independent
of the audio alarm and sensitivity level, allowing the precise pinpointing of the leak source. The D400A and
D440A-NAV do not require rechargeable batteries. The D400A and D440A-NAV are SAE J2791 compliant.

185
AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT SPECIAL TOOLS

8.5. AIR CONDITIONING OIL AND DYE INJECTION EQUIPMENT

Figure 96 125401NAV Air Conditioning Oil And Dye Injection Equipment

Replacing the proper amount of oil during service is critical to compressor survival and extended customer
satisfaction. During service, additional lubrication is required to replace lubricant removed during component
replacement. The traditional method of replacing lubrication has several short-falls.

With the objective of making a tech’s job easier and ensuring the highest quality repairs, Navistar decided
to transition to the cartridge oil injection method. At any point in the service, the tech could add the lube to
the component or the system, whether under a vacuum, or charged. The tool also has check valves, which
means no mess.

For additional information refer to the documentation supplied with the 125401NAV Air Conditioning Oil
and Dye Injection Equipment.

8.6. FLUSH/PURGE FITTING ADAPTERS

Navistar flush/purge fitting adapters (RTI P/N 560 80533 00) are available to convert existing Navistar A/C
solvent flush/purge fittings to liquid refrigerant flush fittings. When the fittings are used in conjunction with the
RHS980C-NAV a liquid refrigerant flush can be performed. For more information on Navistar flush/purge fitting
adapters, refer to the instructions provided with the kit.

186
SPECIAL TOOLS TOOLS OBTAINED LOCALLY

8.7. TOOLS OBTAINED LOCALLY

1. NITROGEN CYLINDER, 3. DRAIN HOSE WITH

REGULATOR AND CART COMPRESSION FITTING
2. FLUSH GUN AND ADAPTERS
Figure 97 Service Tools that may be Obtained Locally

WARNING

The nitrogen supplied to the flush gun must not exceed 75 psi.

If the refrigerant system has been contaminated, such as due to an internal compressor failure, it must be
flushed and purged before it can be repaired and recharged. A flush gun (Figure 97, Item 2) is used, along
with compressed dry nitrogen, to force a flushing agent through the hoses and components of the refrigerant
system. The flush gun and drain hose with compression fitting/adapter can be obtained locally.

1. MALE ADAPTER (1/2 INCH), 3. FEMALE ADAPTER (1/2 INCH),

ZTSE4503 ZTSE4504
2. MALE ADAPTER (3/4 INCH), 4. FEMALE ADAPTER (3/4 INCH),
ZTSE4501 ZTSE4502
Figure 98 Block Fitting Adapters

When performing flushing and/or purging operations, adapters are required to connect the service equipment
to the HVAC system components.

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ELECTRONIC SERVICE TOOL (EST), EZ-TECH SPECIAL TOOLS

8.8. ELECTRONIC SERVICE TOOL (EST), EZ-TECH

Figure 99 Electronic Service Tool, EZ-Tech

The EZ-Tech electronic service tool (refer to Figure 99), running Diamond Logic Builder® (DLB) allows the
servicer to monitor the HVAC electrical circuits. The EZ-Tech is connected to the vehicle diagnostic connector
through an interface communications cable. When used in conjunction with the electrical troubleshooting,
the EZ-Tech allows the servicer to isolate electrical faults efficiently. See the Diamond Logic Builder® site at
https://evalueb.internationaldelivers.com/dlb/dlb/ for details on using the software.

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