Service Manual: Service Manual Section Heat Ventilation Air Conditioning (Hvac) System

SERVICE MANUAL
SERVICE MANUAL SECTION
HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM
For 2007
Model: ProStar®
Model: LoneStar®
S16039
04/28/2009
S16039
Copyright © 04/28/2009 Navistar, Inc.
TABLE OF CONTENTS
TABLE OF CONTENTS
1. SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. GENERAL DESCRIPTION – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.1. SYSTEM DESCRIPTION – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Air Distribution (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Air Distribution (Air Conditioning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Air Distribution (Heat and Ventilation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Air Distribution (Defrost). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
A/C Refrigerant Flow – Front A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2. COMPONENTS – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Compressor and Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Thermostatic Expansion Valve (TXV) – Front A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Thermistors (Evaporator Inlet and Outlet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
A/C Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Heater Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HVAC Control Panel – Front HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.3. ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
General Operation Of The HVAC Electrical System – Front HVAC System. . . . . . . . . . . . . . . . . . . . . . . . . . .17
3. GENERAL DESCRIPTION – REAR HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.1. SYSTEM DESCRIPTION – REAR HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Air Distribution (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Air Distribution (Air Conditioning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Air Distribution (Heat). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
A/C Refrigerant Flow – Sleeper A/C System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.2. COMPONENTS – REAR HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Rear HVAC Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Heater Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Blower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Temperature Blend Air Door Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Rear HVAC Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Rear HVAC Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Rear HVAC Control Switches (Located in Instrument Panel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.3. ELECTRICAL SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
General Operation Of The Sleeper HVAC Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4. SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.1. CONTROL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.2. BLOWER FAN SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.3. TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.4. MODE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) i

TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

MAX Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
NORM Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
BI-Level Air Conditioning Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Vent Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Floor Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Mix Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.5. DEHUMIDIFYING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5. SYSTEM OPERATING CONTROLS – SLEEPER HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6. SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

6.1. PRE-SEASON SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
6.2. OFF-SEASON CARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.3. AIR FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7. DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

7.1. PRELIMINARY CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Check for Obvious Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Refrigerant Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Check for Non-Condensable Gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.2. DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
FAULT IDENTIFICATION PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
DIAGNOSTIC SYMPTOM CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7.3. PHYSICAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Physical Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Refrigerant Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pressure Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Filter-Drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Thermostatic Expansion Valve (TXV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Line Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
7.4. A/C SYSTEM PERFORMANCE TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
7.5. ABNORMAL GAUGE READINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
7.6. TROUBLESHOOTING TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8. REMOVE AND INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

8.1. PRESSURE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
8.2. THERMISTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
8.3. CONDENSER CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
8.4. A/C COMPRESSOR/CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
ii HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

TABLE OF CONTENTS

Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
8.5. AIR FILTER (LOCATED INSIDE EVAPORATOR HOUSING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.6. A/C REFRIGERANT HOSES (FRONT SYSTEM LONG LINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.7. FILTER-DRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
8.8. THERMOSTATIC EXPANSION VALVE – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
8.9. ACTUATOR, (FRESH/RECIRCULATE) AIR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
8.10. AIR CONDITIONER (EVAPORATOR) HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
8.11. FRESH/RECIRCULATE AIR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.12. EVAPORATOR CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
8.13. HEATER HOSES/LINES – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8.14. HEATER TRIM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
8.15. ACTUATOR, TEMPERATURE BLEND DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
8.16. ACTUATOR, MODE DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
8.17. BLOWER SCROLL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
8.18. LINEAR POWER MODULE AND BLOWER ASSEMBLY – FRONT HVAC SYSTEM. . . . . . . . . . . . . .104
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
8.19. HEATER CORE – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
8.20. HEATER HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
8.21. FRONT HVAC CONTROL PANEL ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) iii

TABLE OF CONTENTS

8.22. HVAC CONTROLS (SLEEPER). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Install, Rotary (Digital) Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Install, Rotary (Analog) Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
8.23. HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
8.24. A/C HOSE ASSEMBLY – TO REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
8.25. THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
8.26. BLOWER/FAN ASSEMBLY – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
8.27. FILTER ELEMENT – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
8.28. OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
8.29. LINEAR POWER MODULE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
8.30. BLEND DOOR ACTUATOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
8.31. SLEEPER HVAC CONTROLLER – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
8.32. HEATER CORE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
8.33. TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
8.34. EVAPORATOR CORE – REAR HVAC UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
8.35. REAR HVAC UNIT, COMPLETE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
9. SERVICE PROCEDURES FOR R-134A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

9.1. SERVICE WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
9.2. SERVICE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
9.3. REFRIGERANT IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
9.4. MANIFOLD GAUGE SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
iv HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

TABLE OF CONTENTS
Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
9.5. DISCHARGING THE SYSTEM (REFRIGERANT RECOVERY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
9.6. EVACUATING THE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
9.7. CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
9.8. ADDING REFRIGERANT TO THE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
9.9. PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Flushing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Purging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
9.10. OIL FILL GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Oil Separation During Refrigerant Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Excessive Oil Loss Due to Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
9.11. CHECKING COMPRESSOR OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
9.12. LEAK DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Electronic Leak Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Ultraviolet Lamp Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Ultrasonic Leak Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Soap Solution with Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Refrigerant Leak Testing with Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
10. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

10.1. TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
10.2. AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
11. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172

11.1. RECOVERY/RECYCLING/RECHARGING STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
11.2. MANIFOLD AND GAUGE SET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
11.3. ELECTRONIC VACUUM GAUGE AND MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
11.4. REFRIGERANT IDENTIFIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
11.5. ELECTRONIC LEAK DETECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
11.6. ULTRAVIOLET LAMP LEAK DETECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
11.7. FLUSH GUN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
11.8. DIGITAL THERMOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
11.9. BLOCK FITTING ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
11.10. ELECTRONIC SERVICE TOOL (EST), EZ-TECH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
12. GLOSSARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) v

vi HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM
S16039
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
To avoid property damage, personal injury, or death, park the vehicle on a flat level
surface, shift transmission to park or neutral, set parking brake, and block wheels before
performing diagnostic or service procedures.
WARNING
To avoid personal injury or death, refer to the manufacturer’s service information

before working on any high voltage equipment. By definition high voltage circuits and
components contain voltage levels that may cause equipment damage, electrical shock
and/or electrocution if handled incorrectly.
Only a trained technician may perform service inside high voltage components. If you
work around or maintain high voltage circuits, please seek high voltage training.
WARNING
Carbon monoxide is a colorless, odorless, and dangerous gas that is present in vehicle
exhaust. 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
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
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
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.
HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 1

WARNING
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
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
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
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
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
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 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
Do not install or remove A/C testing or charging equipment while the engine is running.
Serious injury may result from doing so.
2 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

WARNING
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
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.
WARNING
When purging the system or components, do not use nitrogen at pressures over 200 psi.
Personal injury or death may result from doing so.
WARNING
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.
CAUTION
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
Use only the specified PAG lubricant in the refrigerant system (International P/N
ZGGR725028). 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
Use only MINERAL BASED refrigerant oil (International P/N ZGGR6912) to lubricate
O-rings and fittings

GENERAL DESCRIPTION – FRONT HVAC SYSTEM
CAUTION
Disconnect battery ground cable during service to prevent possible damage to the
vehicle electrical system. If the battery must remain connected for a specific test, use
extreme caution when taking measurements.
CAUTION
When purging the system, or components of the system, use only dry nitrogen. The
introduction of compressed air into the A/C system may cause contamination of the
system.
CAUTION
After replacing a compressor verify that the pulley alignment and belt tension are correct.
CAUTION
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
When pressure cleaning the A/C components under the hood, do not direct the high
pressure stream directly at the actuator for the fresh air/recirculate air door.
2. GENERAL DESCRIPTION – FRONT 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 together of air from the
cooling and heating systems to produce a desired air temperature for the vehicle occupants. The front HVAC
system is used in both day cab and sleeper cab vehicles. The rear (sleeper) HVAC system is used only in
sleeper vehicles, and is described in separate sections of this manual.
The front HVAC system is comprised of two main modules, the heater module and evaporator module. These
modules are mounted on opposite sides of the dash panel on the passenger side of the vehicle (Figure 1).
NOTE – The electrical control systems for the HVAC system are covered in the applicable ELECTRICAL
CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM TROUBLESHOOTING guide listed in ISIS.

1. FRESH AIR 5. DRIVER FLOOR AIR

2. RECIRC AIR 6. DASH PANEL ASSEMBLY
3. VENT 7. ALL AIR
4. HEATER MODULE 8. EVAPORATOR MODULE
Figure 1 Heater Housing and Evaporator Housing Locations – Front HVAC System
The evaporator core, expansion valve, filter drier, thermistors, fresh/recirculate air door, air door actuator,
and air filter(s) are located on, or near, the dash mounted evaporator housing on the engine side of the
dash panel, under the hood (Figure 2).
The condenser, compressor, and a/c lines are also located under the hood.

1. PRESSURE TRANSDUCER 7. THERMISTOR (EVAPORATOR

2. CONDENSER TO EVAPORATOR OUTPUT)
LINE 8. EVAPORATOR HOUSING
3. LOW SIDE SERVICE PORT 9. SUCTION LINE
4. THERMISTOR (EVAPORATOR 10. DISCHARGE LINE
INLET) 11. COMPRESSOR
5. FILTER DRIER 12. CONDENSER
6. THERMOSTATIC EXPANSION 13. HIGH SIDE SERVICE PORT
VALVE (TXV)
Figure 2 Under the Hood HVAC Components (Typical Configuration Shown)
The front HVAC control panel (1, Figure 3) is located in the center section of the instrument panel. The heater
core, blower motor, blower motor speed control module, blower air scroll housing, passenger floor duct, and
air door actuators are located in (or on) the in-cab heater module and may be serviced without removing the
heater module housing. The heater module (2, Figure 1) is located behind the heater trim cover (4, Figure 3).

SYSTEM DESCRIPTION – FRONT HVAC SYSTEM GENERAL DESCRIPTION – FRONT HVAC SYSTEM
1. HVAC CONTROL PANEL 3. FUSE PANEL COVER

2. CENTER IP TRIM PANEL 4. HEATER TRIM COVER
(BEZEL)
Figure 3 In-Cab HVAC Components (Front HVAC System)
2.1. SYSTEM DESCRIPTION – FRONT HVAC SYSTEM

Air Distribution (General)
The following figure (Figure 4) is a cross-sectional view of the air-handling components of the front HVAC
system, as they are mounted in the vehicle. The figure shows the system’s four air doors and indicates
their range of travel.
The electrically actuated fresh/recirculate air door (14, Figure 4) is located in the evaporator housing (12), 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 upper rear of the
evaporator housing through the upper portion of the dash panel cutout (13). With the fresh/recirculate air door
in the fresh air position, fresh outside air enters the top of the evaporator housing via an air duct which is part
of the cowl drain tray (15). (The recirculate air is blocked by the fresh/recirculate air door.) In both cases the air
is pulled by the blower assembly (8) through the evaporator core (10) to exit the evaporator housing through
the lower portion of the dash panel cutout. The air entering the heater housing from the evaporator housing
enters the dual inlet, single scroll blower assembly and is pushed through the heater housing.

GENERAL DESCRIPTION – FRONT HVAC SYSTEM SYSTEM DESCRIPTION – FRONT HVAC SYSTEM
1. DEFROST DUCT (PART OF 10. A/C EVAPORATOR

INSTRUMENT PANEL) 11. AIR FILTER ELEMENT
2. FLOOR DUCT OUTLET FROM 12. A/C EVAPORATOR HOUSING
HEATER MODULE 13. RECIRCULATE AIR INLET
3. VENT DUCT FOR INSTRUMENT (OPEN TO CAB INTERIOR)
PANEL 14. FRESH/RECIRCULATION AIR
4. DEFROST/FLOOR DOOR DOOR
(MODE DOOR) 15. COWL TRAY
5. IP VENTS/FLOOR DOOR (MODE 16. HOOD
DOOR) 17. HVAC AIR INLET
6. HEATER CORE GRILLE/FILTER
7. TEMPERATURE BLEND DOOR 18. WINDSHIELD
8. BLOWER ASSEMBLY 19. FRONT OF VEHICLE
9. FLOOR (CAB INTERIOR)
Figure 4 Cross-Section of HVAC Air Handling Components – Front HVAC System

An air filter (11) is mounted vertically in front of the evaporator core, within the evaporator housing. On some
vehicles, a second air filter (17) is located at the air intake of the evaporator housing, and is accessible
from above the cowl drain tray.
The temperature blend door (7) 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 (8), either through
the heater core (6), 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.
The two mode doors, defrost/floor (4) and IP vent/floor (5), are controlled by the mode control (right knob) on
the HVAC control panel. The doors are located at the top of the heater housing and are controlled together via
a gear assembly and another 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 (3) and the defrost vents (1) is integrated into the instrument panel structure. The
upper surfaces of the heater housing 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
heater housing and a driver side floor duct (2) attached to the left side of the housing.
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.
Air Distribution (Air Conditioning)
Figure 5A 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 upper rear of the evaporator housing through the upper portion of the dash
panel cutout. (This air inlet is located behind the heater housing.) The air is pulled by the blower assembly,
through the evaporator core. The air entering the heater housing from the evaporator housing enters the
dual inlet, single scroll blower assembly and is pushed through the heater housing. The temperature blend
air door diverts air either through the heater core or past it depending on the temperature selected for the
outlet air. Although the temperature control is operational while in the A/C modes, the temperature control is
generally set to divert all air around the heater core. The air proceeds to the mode doors where all of the air is
directed to the instrument panel vents.
Figure 5B 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 evaporator
housing 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.
Figure 5C 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.

1. FRONT OF VEHICLE
Figure 5 System Airflow by Mode – Front HVAC System
Air Distribution (Heat and Ventilation)
Figure 5B 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 evaporator housing via an air duct which is part of the cowl drain tray. The air is pulled by the
blower assembly, through the evaporator core. The air entering the heater housing from the evaporator
housing enters the dual inlet, single scroll blower assembly and is pushed through the heater housing. The
temperature blend air door diverts air either through the heater core or past it depending on the temperature
selected for the outlet air. The temperature blended air proceeds to the mode doors where all of the air is
directed to the instrument panel vents.
Figure 5D 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.
Air Distribution (Defrost)
Figure 5E 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 evaporator housing via an air duct which is part of the cowl drain tray. The air is pulled by the
blower assembly, through the evaporator core. The air entering the heater housing from the evaporator
housing enters the dual inlet, single scroll blower assembly and is pushed through the heater housing. The
temperature blend air door diverts air either through the heater core or past it depending on the temperature
selected for the outlet air. The air proceeds to the mode doors where the doors direct the output air to both
the defrost ducts, and the floor ducts.
Figure 5F 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.
A/C Refrigerant Flow – Front A/C System
The refrigerant cycle (Figure 6) consists of four phases: compression, condensation, expansion, and
evaporation. Consider the starting point at the compressor.
When any air conditioning position is selected on the HVAC control panel, the clutch assembly mounted to 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.

1. DIRECTION OF RAM AIR 11. THERMISTOR (OUTLET)

2. CONDENSER 12. SERVICE PORT (LOW
3. SERVICE PORT (HIGH PRESSURE)
PRESSURE) 13. DIRECTION OF COLD AIR
4. DISCHARGE SIDE 14. EVAPORATOR
5. COMPRESSOR 15. DIRECTION OF WARM AIR
6. SUCTION SIDE 16. THERMISTOR (INLET)
7. HIGH PRESSURE GAS 17. EXPANSION VALVE
8. HIGH PRESSURE LIQUID 18. FILTER DRIER
9. LOW PRESSURE LIQUID 19. PRESSURE TRANSDUCER
10. LOW PRESSURE GAS
Figure 6 A/C Refrigerant Flow Diagram – Front A/C System Only
The suction side of the compressor draws low pressure refrigerant vapor (5 to 50 psi) 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)
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

COMPONENTS – FRONT HVAC SYSTEM GENERAL DESCRIPTION – FRONT HVAC SYSTEM
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, and that the condenser cooling fins
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 refrigerant control and diagnostic software within 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 evaporator housing 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.
Thermistors are located at the input and output of the evaporator to monitor the temperature or the refrigerant
at these points. The inputs from these sensors are used to control system operation by providing inputs
to the body controller.
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.
2.2. COMPONENTS – FRONT HVAC SYSTEM

Refer to Figure 2 for locations of the components described in the following paragraphs (See Figure 2, page 6).
Compressor and Clutch
The system uses a Sanden Model SD7 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.

GENERAL DESCRIPTION – FRONT HVAC SYSTEM COMPONENTS – FRONT HVAC SYSTEM
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.
Pressure Transducer
The pressure transducer (Figure 7) 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.
1. GROUND TERMINAL 3. OUTPUT TERMINAL

2. POWER TERMINAL
Figure 7 Pressure Transducer
Filter-Drier
The primary function of the filter-drier (Figure 8) 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 a 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.

COMPONENTS – FRONT HVAC SYSTEM GENERAL DESCRIPTION – FRONT HVAC SYSTEM
Figure 8 Filter-Drier
Thermostatic Expansion Valve (TXV) – Front A/C System
The expansion valve (Figure 9) 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 what amount of refrigerant is needed at the
evaporator input to keep the evaporator operating within operational parameters.
Figure 9 Thermostatic Expansion Valve – Front A/C System
Evaporator
The evaporator core (10, Figure 4) is located in the evaporator housing mounted on the engine side of the
dash 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 into the bottom of the
evaporator housing. Service access for the air filter is through the large fresh air inlet in the cowl tray and the
top surface of the evaporator housing.
Thermistors (Evaporator Inlet and Outlet)
The inlet thermistor (Figure 10) is mounted in the evaporator inlet line. This thermistor senses the temperature
of the refrigerant entering the evaporator. Another thermistor is mounted to the evaporator outlet line
immediately after the TXV to sense the refrigerant temperature at the evaporator outlet. The resistance
value of each thermistor is determined by the temperature of the refrigerant at its location. The resistance
values of these thermistors are monitored by the software in the Body Controller which is used to control A/C

GENERAL DESCRIPTION – FRONT HVAC SYSTEM COMPONENTS – FRONT HVAC SYSTEM
system operation and detect system faults. The refrigerant system must be discharged before removing
and replacing either thermistor.
Figure 10 Thermistor
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 into the block
fitting. The primary O-ring seal has a large cross section for improved sealing as well. 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.
Heater Core
The heater core is located in the heater housing 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 directly above the evaporator housing. 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.
Blower Assembly
The blower assembly is located in the blower scroll housing (part of the heater unit), 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.
Linear Power Module
The Linear Power Module (LPM) (Figure 11) is mounted to the blower scroll housing (part of the heater unit),
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.

ELECTRICAL SYSTEM OVERVIEW GENERAL DESCRIPTION – FRONT HVAC SYSTEM
Figure 11 Linear Power Module - Front HVAC System
HVAC Control Panel – Front HVAC System
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.
2.3. ELECTRICAL SYSTEM OVERVIEW

The heater/ventilation/air conditioning (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 the applicable ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM
TROUBLESHOOTING guide listed in ISIS.
Malfunctions in the HVAC system could be attributed to either mechanical or electrical failures in the system.
Diagnosis of a malfunctioning system should always begin by performing the procedures in the DIAGNOSIS
AND TROUBLESHOOTING section (See DIAGNOSIS AND TROUBLESHOOTING, page 34) to determine
what part of the system is malfunctioning.
General Operation Of The HVAC Electrical System – Front HVAC System
The controls on the front 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 air flow doors
located in the evaporator and heater modules. 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 contains the circuitry and the software program that controls the cycling of the air
conditioner compressor. In general the body controller monitors the refrigerant sensors (transducer and
thermistors) and other system parameters to determine if all parameters are within acceptable limits. If

GENERAL DESCRIPTION – REAR HVAC SYSTEM ELECTRICAL SYSTEM OVERVIEW
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.
3. GENERAL DESCRIPTION – REAR HVAC SYSTEM

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 12 and Figure 13).
NOTE – The electrical control systems for the sleeper HVAC system are covered in the applicable
ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM TROUBLESHOOTING guide
listed in ISIS.
1. OUTLET DUCT, REAR HVAC 3. AIR INLET

UNIT 4. AIR OUTLET VENT
2. REAR HVAC UNIT 5. FRONT OF VEHICLE
Figure 12 Location of Rear HVAC Unit

ELECTRICAL SYSTEM OVERVIEW GENERAL DESCRIPTION – REAR HVAC SYSTEM
1. FRONT OF VEHICLE
Figure 13 Rear HVAC Unit
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 14).

GENERAL DESCRIPTION – REAR HVAC SYSTEM ELECTRICAL SYSTEM OVERVIEW
1. Thermal Expansion Valve (TXV) 10. Rear HVAC Controller

2. Foam Seal (Air Inlet) 11. Cover, Heater Core
3. Rear HVAC Unit Lower Housing 12. Actuator, Blend Air Door
4. Blower Assembly 13. Discharge Duct Temperature
5. Upper Clamp Plate (TXV) Sensor
6. Evaporator Core 14. Blend Air Door
7. Rear HVAC Unit Upper Housing 15. Heater Core
8. Filter Element (Air Inlet) 16. Inlet/Outlet Tube for Heater Core
9. Linear Power Module 17. Foam Seal (Under Bunk Outlet)
Figure 14 Major Components of the Rear HVAC Unit

SYSTEM DESCRIPTION – REAR HVAC SYSTEM GENERAL DESCRIPTION – REAR HVAC SYSTEM
The rear HVAC control panel (Figure 15) 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 can also be used to control the blower
and temperature settings for the sleeper HVAC system.
1. DIGITAL CONTROL PANEL, 3. REAR PANEL

SLEEPER CONTROL PANEL 4. DASH CENTER PANEL
2. ANALOG CONTROL PANEL,
SLEEPER CONTROL PANEL
Figure 15 Sleeper HVAC Controls
3.1. SYSTEM DESCRIPTION – REAR HVAC SYSTEM

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).
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

GENERAL DESCRIPTION – REAR HVAC SYSTEM SYSTEM DESCRIPTION – REAR 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.
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.
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.
A/C Refrigerant Flow – Sleeper A/C System
The addition of the sleeper A/C system does not change the operation of the front (cab) A/C refrigerant
system. Refer to A/C REFRIGERANT FLOW – FRONT 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
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. The electrical control systems
are covered in the applicable ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM
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 16). 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.

SYSTEM DESCRIPTION – REAR HVAC SYSTEM GENERAL DESCRIPTION – REAR HVAC SYSTEM
1. DIRECTION OF RAM AIR 11. FRONT EVAPORATOR

2. CONDENSER 12. DIRECTION OF WARM AIR
3. SERVICE PORT (HIGH 13. THERMISTOR (INLET)
PRESSURE) 14. FRONT EXPANSION VALVE
4. DISCHARGE SIDE 15. FILTER-DRIER
5. COMPRESSOR 16. REAR EVAPORATOR
6. SUCTION SIDE 17. REAR EXPANSION VALVE
7. PRESSURE TRANSDUCER 18. HIGH PRESSURE GAS
8. THERMISTOR (OUTLET) 19. HIGH PRESSURE LIQUID
9. SERVICE PORT (LOW 20. LOW PRESSURE LIQUID
PRESSURE) 21. LOW PRESSURE GAS
10. DIRECTION OF COLD AIR
Figure 16 A/C Refrigerant Flow Diagram (with Sleeper System Shown)

GENERAL DESCRIPTION – REAR HVAC SYSTEM COMPONENTS – REAR HVAC SYSTEM
3.2. COMPONENTS – REAR HVAC SYSTEM

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 COMPONENTS – FRONT HVAC
SYSTEM. The electrical control systems are covered in the applicable ELECTRICAL CIRCUIT DIAGRAMS
manual and/or ELECTRICAL SYSTEM TROUBLESHOOTING guide listed in ISIS.
Refer to Figure 14 for locations of the components described in the following paragraphs.
Thermostatic Expansion Valve (TXV)
The rear expansion valve (1, Figure 14 and Figure 17) 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.
Figure 17 Rear Thermostatic Expansion Valve
Evaporator
The evaporator core (6, Figure 14) 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
Refer to Figure 18.
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.

COMPONENTS – REAR HVAC SYSTEM GENERAL DESCRIPTION – REAR HVAC SYSTEM
Figure 18 Under Cab HVAC Lines for Rear System
Heater Core
The rear heater core is located in the rear HVAC unit (15, Figure 14). 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.
Blower Assembly
The rear blower assembly is mounted to the rear HVAC unit (4, Figure 14). 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.
Linear Power Module
The rear Linear Power Module (LPM) (9, Figure 14 and Figure 19) 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). More information on the electrical control
systems can be found in the applicable ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL
SYSTEM TROUBLESHOOTING guide listed in ISIS.

GENERAL DESCRIPTION – REAR HVAC SYSTEM COMPONENTS – REAR HVAC SYSTEM
Figure 19 Rear Linear Power Module
Temperature Blend Air Door Actuator
The temperature blend air door actuator (12, Figure 14) 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 (10, Figure 14) 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 (Figure 15). 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. More information on the electrical control
systems can be found in the applicable ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL
SYSTEM TROUBLESHOOTING guide listed in ISIS.
Rear HVAC Control Panel
The rear HVAC control panel (Figure 15) 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.

ELECTRICAL SYSTEM OVERVIEW SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM
Rear HVAC Control Switches (Located in Instrument Panel)
Two rocker switches, located in the center console of the instrument panel (Figure 15), 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.
3.3. ELECTRICAL SYSTEM OVERVIEW

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 the applicable
ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM TROUBLESHOOTING guide
listed in ISIS.
Malfunctions in the HVAC system could be attributed to either mechanical or electrical failures in the system.
Diagnosis of a malfunctioning system should always begin by performing the procedures in the DIAGNOSIS
AND TROUBLESHOOTING section (See DIAGNOSIS AND TROUBLESHOOTING, page 34) to determine
what part of the system is malfunctioning.
General Operation Of The Sleeper HVAC Electrical System
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.
4. SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM

The operation of the front Blend-Air system is based on standard automotive air conditioning and heating
principles.
NOTE – The following paragraphs describe operation of the front 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.
4.1. CONTROL ASSEMBLY

All major functions of the front A/C-heater system are controlled from the control panel assembly (Figure 20). 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.

SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM BLOWER FAN SPEED CONTROL
1. BLOWER FAN SPEED CONTROL 3. MODE CONTROL

2. TEMPERATURE CONTROL
Figure 20 Front HVAC Control Panel Assembly
4.2. BLOWER FAN SPEED CONTROL

This control regulates the amount of air provided to the front cab 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. (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.
4.3. TEMPERATURE CONTROL

This control regulates the temperature of the air discharged from the front cab 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.
4.4. MODE CONTROL

This control selects the operating mode of the front HVAC 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, two air doors located in the in-cab heater housing. 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).
The air conditioning settings are indicated by icons with snowflakes.
MAX Air Conditioning Mode
In this mode all airflow is directed to the instrument panel air outlets and the air is recirculated inside the
vehicle. Use this mode to block out any outside odors, smoke, or dust and to cool the cab area rapidly upon
initial start up 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.

MODE CONTROL SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM
NORM Air Conditioning Mode
In this mode all airflow is directed to the instrument panel air outlets. Fresh (outside) air is used to cool the
cab area 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.
BI-Level Air Conditioning Mode
In this mode 75% of the airflow is directed to the instrument panel air outlets, 25% of the airflow is directed to
the floor air outlets, and fresh (outside) air is circulated inside the vehicle cab area.
Vent Mode
In this mode all airflow is directed to the instrument panel air outlets and fresh (outside) air is circulated
inside the vehicle cab area.
Floor Mode
In this mode all airflow is directed to the floor air outlets and fresh (outside) air is circulated inside the
vehicle cab area.
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 cab area. 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.
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 cab area. 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.
Table 1 Air Distribution Chart
CONTROL KNOB POSITION AIRFLOW

Front Air Conditioner Systems Panel Floor Windshield
MAX A/C 100%
NORM A/C 100%
DOT 1 50% 50%
BI-LEVEL 75% 25%
DOT 2 50% 50%
PANEL 100%
DOT 3 25% 75%

SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM DEHUMIDIFYING
Table 1 Air Distribution Chart (cont.)

CONTROL KNOB POSITION AIRFLOW
Front Air Conditioner Systems Panel Floor Windshield
FLOOR 100%
DOT 4 75% 25%
MIX 50% 50%
DOT 5 25% 75%
DEFROST 100%
4.5. 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.
5. SYSTEM OPERATING CONTROLS – SLEEPER 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. All
information covering the front HVAC system in these vehicles can be found in SYSTEM OPERATING
CONTROLS – FRONT HVAC SYSTEM. The electrical control systems for the sleeper HVAC system are
covered in the applicable ELECTRICAL CIRCUIT DIAGRAMS manual and/or ELECTRICAL SYSTEM
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 NOT be set to OFF.
For additional information, refer to the Section 3.1 (See SYSTEM DESCRIPTION – REAR HVAC SYSTEM,
page 21).

PRE-SEASON SERVICING SYSTEM MAINTENANCE
6. SYSTEM MAINTENANCE
6.1. PRE-SEASON SERVICING
Experience has shown that many unsatisfactory conditions incurred with heating and air conditioning systems
result from lack of regular maintenance. Preventive maintenance and cleanliness of all components within the
system are extremely important. A complete step-by-step pre-season checkout of the air conditioner/heater
system will substantially increase satisfactory operation during the operating season.
Perform the following procedures:
1. Check the mounting fasteners of each component for looseness.
2. Check condition, tension and alignment of all drive belts. Refer to GROUP 12– ENGINE section in the
Master Service Manual.
3. Check condition of heater hoses and engine cooling system hoses. Replace if necessary.
4. Verify that the vehicle coolant level is correct.
5. Check refrigerant hose retention and condition. Look for cracks, chafing, or other damage. Inspect all
tubing and hoses for dirty or loose connections. All connections must be clean and tight.
NOTE – If a patch of oily residue is found at or near a connection it may indicate a refrigerant leak. Note
its location in case a system operational test indicates a refrigerant leak or a low refrigerant condition.
NOTE – Cleanliness of the air conditioner components cannot be over-emphasized. Lack of proper
attention in this area is one of the major causes of costly and unsatisfactory unit operation.
CAUTION
Never force the fresh/recirculate air door open. If the door position must be changed;
turn on key, set mode control to FLOOR, turn off key. Forcing the door will result in a
broken door shaft and a costly repair.
6. Check the filter elements in the evaporator housing and the housing air intake. If the vehicle is equipped
with a sleeper HVAC system, check the rear system filter element. Clean or replace filter elements if
necessary. To access the filter in the front evaporator housing, refer to REMOVE AND INSTALL, AIR
FILTER (See AIR FILTER (LOCATED INSIDE EVAPORATOR HOUSING), page 83).
CAUTION
When using a pressure washer to clean any heat exchanger (radiator, condenser,
evaporator, or charge air cooler); use caution and maintain distance from the
component with the pressure washer. Do not spray the component fins at an angle as
fin damage may occur and reduce efficiency.
7. Clean all foreign material from condenser and radiator fins. As often as necessary, spray water through
the condenser towards the radiator and through the radiator towards the condenser to flush debris from
the fins. If necessary, spray the component with a cleaning solution, allow to soak 20 - 30 minutes,
then rinse with clean water.
8. Operate front air conditioner system and check operation of controls.

SYSTEM MAINTENANCE OFF-SEASON CARE
9. Check operation of front blower (airflow matches selected blower speed).
10. Verify that the front system is cooling properly in the A/C modes and heating properly in the heat modes.
11. If the vehicle is equipped with a sleeper HVAC system, proceed to step 14; otherwise, continue to the
next step.
12. Use Diamond Logic Builder (DLB) and the electronic service tool to verify that no HVAC Diagnostic Trouble
Codes (DTC’s) are currently stored in the system. For complete information on viewing DTC’s refer to the
applicable Electrical Troubleshooting Guide, on ISIS.
13. If no DTC’s are present and the system is operating correctly, the pre-season check is completed.
If the system appears to be malfunctioning refer to the DIAGNOSIS AND TROUBLESHOOTING section
(See DIAGNOSIS AND TROUBLESHOOTING, page 34).
14. Verify that the vehicle engine is running.
15. On the front HVAC control panel, set the blower speed control to midrange, and the mode control to a
non-A/C mode.
NOTE – In the following steps, bar graphs representing the set points of the blower speed and
temperature controls should be displayed in the message display area of the gauge cluster. The bar
graphs are displayed only during, and for several seconds after, actuation of the controls. If the vehicle
is equipped with a DIGITAL rear HVAC control panel, the bar graphs will also be displayed at that
location.
16. Operate the blower speed controls for the sleeper HVAC system (rear control panel and instrument panel
switches), and verify that the system responds correctly. Leave the rear blower speed set to mid-range.
17. Using the sleeper temperature rocker switch on the instrument panel, adjust the temperature set point to
its highest setting, and verify that warm air is output from the sleeper vents.
18. Using the sleeper temperature control on the rear control panel, adjust the temperature set point to its
lowest (coldest) setting. Verify that within 2 minutes the A/C compressor is energized and cool air is
output from the sleeper vents.
19. Use Diamond Logic Builder (DLB) and the electronic service tool to verify that no HVAC Diagnostic Trouble
Codes (DTC’s) are currently stored in the system. For complete information on viewing DTC’s refer to the
applicable Electrical Troubleshooting Guide, on ISIS.
20. If no DTC’s are present and the system is operating correctly, the pre-season check is completed.
If the system appears to be malfunctioning refer to the DIAGNOSIS AND TROUBLESHOOTING section
(See DIAGNOSIS AND TROUBLESHOOTING, page 34).
6.2. OFF-SEASON CARE

This system does not require any off-season maintenance. Do not remove compressor drive belt during the
off-season, as clutch and compressor bearings may become brinneled. It is not necessary to operate the A/C
system periodically during the off-season because the system uses the A/C compressor while in the defrost
mode, if the ambient temperature is above freezing.

AIR FILTERS SYSTEM MAINTENANCE
6.3. AIR FILTERS

CAUTION
Never force the fresh/recirculate air door open. If the door position must be changed,
follow the referenced procedures. Forcing the door will result in a broken door shaft and
a costly repair.
Inspect the HVAC inlet air filter elements for dust and road dirt at the beginning of each cooling season.
Clean or replace the elements as needed. More frequent cleaning and/or replacement may be required on
vehicles operated in severe conditions.
A filter/grille assembly is located at the top of the fresh air intake, above the front evaporator housing. This filter
is mounted to the air intake above the cowl drain tray. This filter assembly is secured with thumb screws and
does not require tools for removal and installation.
Another filter element is located inside the front evaporator housing, under the fresh/recirculate air door. To
replace this air filter refer to AIR FILTER, REMOVE AND INSTALL (See AIR FILTER (LOCATED INSIDE
EVAPORATOR HOUSING), page 83).
If the vehicle is equipped with a sleeper HVAC system, a filter element is located at the rear HVAC unit air
intake. Clean or replace with a new element if necessary. The filter element can be accessed by lifting the
lower bunk.

DIAGNOSIS AND TROUBLESHOOTING AIR FILTERS
7. DIAGNOSIS AND TROUBLESHOOTING

Diagnosis and troubleshooting of the HVAC system consists of the following steps:
• Preliminary Checks — checking for physical damage and verifying the contents of the refrigerant system.
• Diagnosis — identifying the probable causes of the system malfunction by observing diagnostic trouble
codes, making physical checks, operating the system, and identifying fault symptoms during operation.
• Troubleshooting — Isolating the fault by use of the troubleshooting tables.
• A/C System Performance Test — Using test equipment to monitor A/C system parameters during operation.
This is done to help identify faults during troubleshooting and to verify correct operation after repairs.
The following steps provide an overview for diagnostic and troubleshooting customer HVAC complaints.
1. Perform fault identification procedure (check diagnostic trouble code display).
a. If diagnostic codes are displayed, record diagnostic codes and refer to the applicable electrical
system troubleshooting guide on ISIS.
b. If no diagnostic codes are displayed, refer to the diagnostic symptom chart in this manual.
2. Perform indicated troubleshooting procedures or repairs. Refer to the remove and install procedures
contained in this manual as needed.
3. Was diagnostic trouble code in the A/C refrigerant system?
a. Yes, verify the repairs by performing the A/C SYSTEM PERFORMANCE TEST PROCEDURE .
b. No, verify the repairs by performing the FAULT IDENTIFICATION PROCEDURE .
4. If customer HVAC complaint is no longer present, system repairs are complete. If customer HVAC complaint
is still present return to step 1.

PRELIMINARY CHECKS DIAGNOSIS AND TROUBLESHOOTING
7.1. PRELIMINARY CHECKS

The following preliminary checks should be performed to check for 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 (including sleeper HVAC connections, if so equipped)
• condenser mounting
• condenser fins (and blockage by debris)
• receiver-drier mounting
• expansion valve (TXV) mounting (front and rear, if vehicle is equipped with a sleeper HVAC system)
• filter elements
• evaporator housing drains (including sleeper, if so equipped)
• evaporator housing mounting and overall condition
• electrical connections to pressure transducer and thermistors
• electrical connections to actuators for air flow doors: recirculate, temperature, and mode doors (front
HVAC system)
• electrical connections to the rear HVAC unit: blower, controller, LPM, temperature door actuator, and
temperature sensor (if vehicle is equipped with a sleeper HVAC system)
• rear HVAC unit mounting and overall condition (if vehicle is equipped with a sleeper HVAC system)
• connection of sleeper duct work to rear HVAC unit (if vehicle is equipped with a sleeper HVAC system)
Refrigerant Identification
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 (See REFRIGERANT
IDENTIFICATION, page 143).
Check for Non-Condensable Gases
Verify that the system does not contain air or some other non-condensable gas. A common cause of poor
system operation. When a Refrigerant Identifier is not available, this check of the system contents should
be performed (Table 2). This check 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.

DIAGNOSIS AND TROUBLESHOOTING DIAGNOSIS
Table 2 Check for Non-Condensable Gases
NOTE – The engine must not be running, and A/C system must be at ambient temperature for this step.
1. Connect recovery station to A/C system. Refer • If gauges are >10 psig higher than the
to Figure 65 (See Figure 64, page 147). table listings, system contains air or
some non-condensable gas. Discharge,
2. Using a thermometer determine ambient
evacuate, and recharge the system. Refer to
temperature within a degree or two.
SECTION 9 (See SERVICE PROCEDURES
3. Record system pressures indicated on recovery FOR R-134a, page 138).
station gauges.
• If gauges are >10 psig lower than the table
4. Compare gauge readings to table 3. listings, system is undercharged.
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). Refer
to SERVICE PROCEDURES FOR R-134a
(See SERVICE PROCEDURES FOR
R-134a, page 138).
Table 3 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
7.2. DIAGNOSIS
An HVAC system is received for service because the operator feels that the system is not operating correctly.
Usually, the operator will provide a symptom describing the operation of the system. In the following procedure,
diagnosis begins by observing any Diagnostic Trouble Codes logged by the body controller. If no diagnostic
trouble codes are displayed, the reported fault is verified by operating the system and observing the symptoms.
Because the Fault Identification Procedure, Diagnostic Symptom Chart, and Troubleshooting Tables are
organized in order of increasing confidence; any fault symptom must be resolved at its first appearance.
Diagnostic Trouble Codes
The body controller monitors parameters throughout the A/C system and generates Diagnostic Trouble Codes
(DTC’s) whenever a monitored parameter falls outside of its specified range. When any DTC is generated it is
stored in memory. Observing DTC’s is one of the first steps in diagnosing a malfunctioning A/C system, as
indicated in the following procedure. Always resolve active DTC’s before troubleshooting symptoms.

DIAGNOSIS DIAGNOSIS AND TROUBLESHOOTING
FAULT IDENTIFICATION PROCEDURE
NOTE – The following test may not perform correctly if the ambient temperature is too cold. If the
A/C compressor does not turn on when first attempted, allow the engine to warm up to operating
temperature, and try again. If the A/C compressor still will not turn on, a fault probably exists.
NOTE – The cycling rate of the A/C compressor will vary with the ambient temperature. In cooler ambient
temperatures the compressor may cycle up to four times a minute.
NOTE – Unless specifically identified as “sleeper” controls, assume that the controls described in this
procedure are located on the front (instrument panel) HVAC control panel.
Perform the following steps to determine if any HVAC related DTC’s are being generated and/or to verify a
reported symptom. Resolve each fault (DTC or symptom) at its first appearance. If a DTC is present when
checked, follow the instructions provided in the Electrical Troubleshooting Guide. If no DTC’s are displayed,
perform the remainder of the procedure and note any symptoms observed. When a symptom is noted without
a DTC, proceed to the DIAGNOSTIC SYMPTOM CHART (See DIAGNOSTIC SYMPTOM CHART, page 40).
1. Check for HVAC related DTC’s. Refer to the applicable Electrical Troubleshooting Guide, on ISIS.
2. If no DTC’s were displayed, start the engine and set the air conditioning controls for maximum cooling,
as follows.
A. Set blower speed control to highest speed, full cw.

B. Set temperature control for maximum cooling, full ccw.
C. Set mode control to MAX A/C, full ccw.
D. Set sleeper blower control to OFF (vehicles equipped with sleeper HVAC system)
E. Set sleeper temperature control to midrange (vehicles equipped with sleeper HVAC system)
3. Set the engine speed at 1500 RPM or above.
4. While performing the following steps, run the air conditioning system for at least five minutes even if it
appears that the system is not operating correctly.
NOTE – In the following step, verify only that the blower is operating and air flow is present at some
instrument panel or floor outlet. The air distribution system will be checked in a later step.
5. Cycle the blower speed control through each of its settings and verify correct blower operation. (Air flow
stops in the OFF position and increases as the control is rotated in a clockwise direction.)
6. Set the blower speed control to the highest setting (full cw).
NOTE – In the following step verify that the main forced air flow is through the indicated outlets. However,
it is normal for a very slight amount of bleed-through air to be present at other outlets.
7. Slowly cycle the mode control through each of its settings and verify correct air distribution at the various
air outlets as indicated. Also note the strength of the air flow.
a. MAX, NORM, and Vent Only settings direct air flow through the instrument panel vents ONLY.
b. Bi-level setting directs air flow through the instrument panel vents and the floor ducts ONLY.
c. Floor setting directs air flow through the floor ducts ONLY.

d. Floor/Defrost setting directs air flow through the floor ducts and the defrost ducts ONLY.
e. Defrost setting directs air flow through the defrost ducts ONLY.
8. Set the mode control to the Floor setting.
NOTE – The engine coolant must be at operating temperature before the next step will work correctly.
9. Set the temperature control to the maximum heat setting (full cw), and verify that the temperature of the air
flow at the floor ducts is warm to hot.
10. Set the temperature control to the maximum cooling setting (full ccw).
11. Set the mode control to the MAX air conditioning setting (full ccw), and verify that within five minutes
cold air is present at the instrument panel vents.
12. Set the mode control to the Defrost setting, and verify that the compressor remains energized or cycles
on within two minutes.
13. Repeat the previous step with the mode control set to the Floor/Defrost setting; the compressor should
continue to operate.
14. With the engine still running, check again for DTC’s. Refer to the applicable Electrical Troubleshooting
Guide for complete procedures. If a DTC is present when checked, follow the instructions provided in the
Electrical Troubleshooting Guide; otherwise, proceed to the next step.
15. If no diagnostic trouble codes are present, and the system is not operating correctly, find the fault symptom
in the DIAGNOSTIC SYMPTOM CHART (See DIAGNOSTIC SYMPTOM CHART, page 40). If vehicle is
equipped with a sleeper HVAC system, proceed to step 17, otherwise, proceed to the next step.
16. The HVAC system is operating correctly. If you are performing this test after making repairs; the fault
has been repaired. Before returning the vehicle to service, perform a physical inspection of the HVAC
system including a refrigerant leak test.
NOTE – The remaining steps in this procedure pertain only to vehicles equipped with a sleeper HVAC
system.
17. Verify that the engine is running and set the front (instrument panel) HVAC control panel as follows.
A. Set blower speed control to OFF, full ccw.

B. Set temperature control to any temperature.
C. Set mode control to direct air from the instrument panel vents (no A/C).
18. Verify that the engine speed is set at 1500 RPM or above.
19. Using the ’SLPR TEMP’ rocker switch, located on the instrument panel, adjust the sleeper temperature
to several settings. Verify that a bar graph corresponding to the temperature setting is displayed in the
message display on the gauge cluster for several seconds after each setting change.
20. Using the ’SLPR FAN’ rocker switch, located on the instrument panel, cycle the sleeper blower through its
settings. Verify that a bar graph corresponding to the blower speed setting is displayed in the message
display on the gauge cluster for several seconds after each setting change.

21. If the vehicle is equipped with a digital sleeper HVAC control panel, proceed to step 35; otherwise,
proceed to the next step.
22. On the analog sleeper HVAC control panel, adjust the temperature control through several settings.
Verify that a bar graph corresponding to the temperature setting is displayed in the message display on
the gauge cluster for several seconds after adjusting the control. Leave the sleeper temperature set
to its maximum heat setting (full cw).
23. On the analog sleeper HVAC control panel, cycle the blower speed control through its settings. Verify that
a bar graph corresponding to the blower control setting is displayed in the message display on the gauge
cluster for several seconds after adjusting the control.
24. Verify that the air flow through the sleeper vents corresponds to the setting of the blower speed control.
(Air flow stops in the OFF position and increases as the control is rotated in a clockwise direction.)
25. Leave the sleeper blower speed control set to a midrange speed.
26. Verify that the air from the outlet vents is warm to hot (as the engine warms up).
27. On the analog sleeper HVAC control panel, set the temperature control to its maximum cooling setting (full
ccw), and verify that the temperature of the air from the outlet vents is reduced to near ambient temperature.
28. Verify that the following message is displayed in the message display on the gauge cluster: “Activate
HVAC front blower.”
29. Verify that the A/C compressor does not energize.
30. On the front (instrument panel) HVAC control panel, set the blower control to the slowest speed above
OFF.
31. Verify that the A/C compressor energizes within 2 minutes.
32. Verify that the temperature of the air from the sleeper outlet vents begins to cool.
33. Verify that within five minutes cold air is present at the sleeper vents.
34. Proceed to step 48.
35. On the digital sleeper HVAC control panel, press the temperature up button several times. Verify that a bar
graph corresponding to the sleeper temperature setting is displayed on the sleeper control panel display.
36. Repeatedly press the temperature up button until the temperature set point is at its warmest setting.
37. On the digital sleeper HVAC control panel, press the blower speed up and down buttons to cycle the
blower through its speed settings. Verify that a bar graph corresponding to the sleeper blower speed
setting is displayed on the sleeper control panel display.
38. Verify that the air flow through the sleeper vents corresponds to the blower speed set point. Leave the
sleeper blower set to a midrange speed.
39. Verify that the air from the outlet vents is warm to hot (as the engine warms up).

40. On the digital sleeper HVAC control panel, repeatedly press the temperature down button until the
temperature set point is at its coolest setting, and verify that a bar graph corresponding to the sleeper
temperature setting is displayed on the sleeper control panel display.
41. Verify that the temperature of the air from the outlet vents is reduced to near ambient temperature.
42. Verify that the following message is displayed in the message display on the gauge cluster: “Activate
HVAC front blower.”
43. Verify that the A/C compressor does not energize.
44. On the front (instrument panel) HVAC control panel, set the blower control to the slowest speed above
OFF.
45. Verify that the A/C compressor energizes within 2 minutes.
46. Verify that the temperature of the air from the outlet vents begins to cool.
47. Verify that within five minutes cold air is present at the sleeper vents.
48. With the engine still running, check again for DTC’s. Refer to the applicable Electrical Troubleshooting
Guide for complete procedures. If a DTC is present when checked, follow the instructions provided in the
Electrical Troubleshooting Guide; otherwise, proceed to the next step.
49. If no DTC’s are present, and the system is not operating correctly, find the fault symptom in the
DIAGNOSTIC SYMPTOM CHART; otherwise, proceed to the next step.
50. The HVAC system is operating correctly. If you are performing this test after making repairs; the fault
has been repaired. Before returning the vehicle to service, perform a physical inspection of the HVAC
system including a refrigerant leak test.
DIAGNOSTIC SYMPTOM CHART
This chart is used to determine what action is required when a fault symptom exists but no diagnostic trouble
code has been logged. After locating the fault symptom in the chart, service the system as instructed in the
ACTION column.
Once the system has been serviced, it should be tested to verify correct operation. If the fault was refrigerant
based, verify the repairs by performing the A/C SYSTEM PERFORMANCE TEST PROCEDURE (See
A/C SYSTEM PERFORMANCE TEST PROCEDURE, page 45). If the fault was not refrigerant based,
verify the repairs by performing the FAULT IDENTIFICATION PROCEDURE (See FAULT IDENTIFICATION
PROCEDURE, page 37).

Table 4 Diagnostic Symptom Chart
Symptom Action
NOTE – This table is designed to be used after completing the FAULT IDENTIFICATION PROCEDURE
and resolving any HVAC related Diagnostic Trouble Codes that were set.
NOTE – Resolve any HVAC related symptoms in the order that they occurred during the performance
of the FAULT IDENTIFICATION PROCEDURE.
No Air Flow (in Cab Area) This is an electrical problem related to the cab
(front) blower circuit. Refer to the Electrical
Troubleshooting Guide on ISIS.
Wrong Air Distribution (in Cab Area) Refer to MODE SELECTION TROUBLESHOOTING
table (See Table 8, page 51).
Low Air Flow (in Cab Area) Refer to LOW AIR FLOW IN CAB
TROUBLESHOOTING table (See Table 12,
page 58).
Insufficient Heat in Cab Area (Heater Mode) Refer to INSUFFICIENT CAB HEAT
page 60).
Insufficient Cooling in Cab Area (A/C Mode) Refer to INSUFFICIENT CAB COOLING
(Compressor may be operable or inoperable) TROUBLESHOOTING table (See Table 14, page
61).
NOTE – If any diagnostic codes are set, refer to the
Electrical Troubleshooting Guide on ISIS.
Insufficient Defrost (Defrost Mode) Refer to INSUFFICIENT DEFROST
page 65).
Compressor Has Excessive Vibration or Noise Refer to NOISY COMPRESSOR
page 68).
NOTE – The following symptoms pertain only to vehicles equipped with sleeper HVAC systems.
Sleeper HVAC System Control (Fan Speed or This is an electrical problem related to the control
Temperature) Inoperative. circuit. Refer to the Electrical Troubleshooting
Guide on ISIS.
(Instrument panel bar graph NOT displayed when
sleeper HVAC control is actuated.)
Sleeper HVAC System Blower not Operating Correctly.
(Instrument panel bar graph IS displayed when control

is actuated; but fan speed, or system air flow, does not
respond correctly to control setting.)
No Air Flow from Sleeper Vents Refer to NO SLEEPER AIR FLOW
page 70).
Low Air Flow from Sleeper Vents Refer to LOW SLEEPER AIR FLOW
page 71).

DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS
Table 4 Diagnostic Symptom Chart (cont.)

Symptom Action
Insufficient Sleeper Heat (Heater Mode) Refer to INSUFFICIENT SLEEPER HEAT
TROUBLESHOOTING table (See Table 19, page
72).
Insufficient Sleeper Cooling (A/C Mode) (Compressor Refer to INSUFFICIENT SLEEPER COOLING
may be operable or inoperable) TROUBLESHOOTING table (See Table 20, page
73).
NOTE – If any diagnostic codes are set, refer to the
Electrical Troubleshooting Guide on ISIS.
Sleeper system temperature does not correctly track Verify that the discharge duct temperature sensor is
the temperature control setting. Temperature control correctly installed in the rear HVAC unit.
requires constant adjustment.
Refer to the temperature blend door information in
the Electrical Troubleshooting Guide on ISIS.
7.3. 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
A/C refrigerant system. Perform these checks when referenced from the troubleshooting tables.
Physical Check Procedure
1. Start the engine and set the front (instrument panel) HVAC control panel for maximum cooling, as follows:
A. Set blower speed control to highest speed, full cw.

B. Set temperature control for maximum cooling, full ccw.
C. Set mode control to MAX A/C, full ccw.
2. If the vehicle is equipped with a sleeper HVAC system, set the sleeper HVAC control panel as follows:
A. Set blower speed to any midrange speed.

B. Set sleeper temperature set point for maximum cooling.
3. Set the engine speed at 1500 RPM or above, and run the air conditioning system for at least five minutes.
WARNING
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.
4. 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

PHYSICAL CHECKS DIAGNOSIS AND TROUBLESHOOTING
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 A/C compressor. After warmup, underhood heat will allow
the compressor to cycle on at very low ambient temperatures.
Compressor problems are usually revealed in one of five ways: abnormal noise, seizure, leakage, high
suction pressure, or low discharge pressure.
CAUTION
In the following step, the A/C 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 won’t 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 buildup) cakes up, airflow over the condenser fins is reduced and the
air is not able to absorb enough heat to turn the hot refrigerant gas into a liquid. High discharge pressure
will result. In these cases, carefully clean off the outer surface of the condenser with soap and water and
compressed air; be careful not to bend the fins.
High discharge pressure will also occur if the condenser’s tubing is abnormally bent, restricting or blocking the
flow of refrigerant. Frost will appear at the point where the flow of refrigerant is restricted.
Less common internal blockage (foreign material or metallic grit buildup) 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.

DIAGNOSIS AND TROUBLESHOOTING PHYSICAL CHECKS
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.
Thermistors
Verify that the wires to the thermistors are in good condition and have not become disconnected.
Inspect the thermistor 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 in the cab area. If the vehicle
is equipped with a sleeper HVAC system, the rise in head pressure will be reduced, and the sleeper A/C
may operate normally.
Thermostatic Expansion Valve (TXV)
NOTE – If the vehicle is equipped with a sleeper HVAC system, a second TXV (and evaporator) circuit
is connected in parallel with the TXV/evaporator circuit that cools the cab area. Because of the parallel
arrangement, the following conditions/symptoms could exist in the front, rear, or both A/C systems. If
one system is cooling normally while the other system is not cooling, a TXV problem is indicated. If the
problem is intermittent, moisture may be present in the refrigerant system.
Problems that start in the expansion valve show up as follows.
• When stuck closed, the evaporator core and expansion valve will be at outside temperature, and the
system will not cool.
• When stuck open, both the evaporator core and the valve will be extremely cold with possible frost or ice
buildup. If the vehicle is equipped with a second A/C system (front/sleeper), that system’s performance
may be degraded.
Because the expansion valve channels are very small, blockage in the system is usually found here (the valve
is very sensitive to contamination). Usually the contamination is water. Less that a drop of water is all it takes
to make the valve inoperative. When water reaches the valve, the extreme cold that results from the pressure
drop freezes the water, forming an ice blockage. After the system shuts down and the valve warms up, the
valve operates again, only to freeze up when the moisture returns and the temperature drops.
Intermittent expansion valve freeze up indicates that the filter-drier is not removing the moisture from the
system.
Evaporator
The evaporator core is basically trouble-free when air flow over the fins is not blocked. Normally, the
evaporator outlet tube will feel cool to cold. External or, less often, internal blockage of an evaporator core will
cause low suction pressure in the system, as well as little or no cooling.
NOTE – If the vehicle is equipped with a sleeper HVAC system, a second TXV/evaporator circuit is
connected in parallel with the TXV/evaporator circuit that cools the cab area. Because of the parallel
arrangement, the described symptoms could exist in the front, rear, or both A/C systems.

A/C SYSTEM PERFORMANCE TEST PROCEDURE DIAGNOSIS AND TROUBLESHOOTING
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 air flow through the evaporator and stops the
cooling until the ice melts. Evaporator freeze-up may be caused by a faulty TXV or a problem with the sensing
circuitry that controls the cycling of the A/C compressor (input thermistor circuit or output thermistor circuit).
A flooded evaporator occurs when there is too much refrigerant flowing into the evaporator, and is generally
caused by a faulty TXV. A starved evaporator occurs when there is not enough refrigerant flowing into the
evaporator. Starvation can be caused by a faulty TXV or a low refrigerant charge. A starved evaporator may
cause the evaporator outlet tube to feel warmer than usual: at or near ambient temperature.
If a leak exists in the system, and it cannot be traced to other parts or fittings, suspect damage to the
evaporator core.
The evaporator is the most difficult of all the components to inspect visually because of its enclosed location.
To detect airflow blockage due to debris, bent fins, and/or refrigerant leaks (oil smudges) inspect the inlet
side of the evaporator.
CAUTION
To inspect the cowl mounted evaporator, the fresh air/recirculate air door must be in the open (fresh air)
position (the mode control must not be set to the MAX A/C position). Remove the grille from the cowl tray
air inlet, and remove the internal air filter. Using a flashlight and inspection mirror, inspect the inlet side
of the evaporator core.
For vehicles equipped with a sleeper HVAC system, the inlet side of the evaporator can be inspected after
removing the blower assembly from the rear HVAC unit. Through the hole left by the blower, use a flashlight
and inspection mirror to inspect the evaporator core.
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 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.
NOTE – If the vehicle is equipped with a sleeper HVAC system, the sleeper TXV/evaporator circuit is
arrangement, a restriction in only one of the parallel circuits may cause only a slight change in the
pressure readings. The system with the restricted A/C line will experience a loss of cooling, while the
other system will operate normally.
If a restriction occurs in one of the lines common to both A/C systems, pressure readings will be affected,
and both systems will experience a loss of cooling.
7.4. A/C SYSTEM PERFORMANCE TEST PROCEDURE

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.

DIAGNOSIS AND TROUBLESHOOTING A/C SYSTEM PERFORMANCE TEST PROCEDURE
The test is performed using a recovery/recycling/charging station (recovery station) or a manifold gauge set,
two thermometers and an electronic leak detector. When a fault is detected perform the repairs indicated.
After making repairs involving the refrigerant system, repeat this test to verify correct A/C operation.
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 air flow comparable to normal ram air
flow.
1. If the system has not yet been diagnosed, perform step 2 with the engine and A/C system at ambient
temperature. The engine and A/C system must NOT have been run within the last 30 minutes.
If this test is being performed to verify a repair, skip step 2 and proceed to step 3.
2. With the engine off, connect a recovery station (with an internal gauge set) to the low and high side A/C
service ports. A known good manifold gauge set may also be used. Refer to FIGURE 64 (See Figure 63,
page 145) and/or FIGURE 65 (See Figure 64, page 147).
a. Determine (and record) the ambient temperature (within a degree or two).
b. Record the system pressures indicated on the high and low gauges connected to the A/C system.
Both gauges should read close to the same value when the truck is not running.
c. Compare the pressure readings recorded in the last step to the pressures shown in TABLE 3 (See
Table 3, page 36).
d. If the pressure on the gauges is more than 10 psig higher than the pressure listed in the chart, the
A/C system contains air or some non-condensable gas in the refrigerant system. The system needs
to be discharged, evacuated, and recharged using a recovery system. Refer to SECTION 9 (See
SERVICE PROCEDURES FOR R-134a, page 138).
EXAMPLE: If the ambient is 75°F, the A/C 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 non-condensable gas in the system.
NOTE – A refrigerant identifier can also be used to verify the contents of the A/C system. Refer
to SECTION 9.3 (See REFRIGERANT IDENTIFICATION, page 143).
e. If the pressure on the gauges 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

A/C SYSTEM PERFORMANCE TEST PROCEDURE DIAGNOSIS AND TROUBLESHOOTING
a recovery system. Undercharged systems should be inspected for a possible leak before being
discharged. Refer to SECTION 9 (See SERVICE PROCEDURES FOR R-134a, page 138).
f. If no faults have been noted, proceed to step 3.
3. Run the remainder of the test under the following conditions:
• Park the vehicle so there is no solar loading and no wind.

• Position a thermometer approximately 30 to 60 cm (12 to 24 inches) in front of the vehicle grille to
measure ambient temperature of air entering the condenser.
• If not connected previously, connect a recovery station (with an internal gauge set) to the low and high
side A/C service ports. A known good manifold gauge set may also be used. Refer to Figure 64 (See
Figure 63, page 145) and/or Figure 65 (See Figure 64, page 147).
• Engage the engine cooling fan (unless the vehicle is equipped with a viscous fan drive).
• Slowly close the hood, being careful not to damage test equipment connections.
• Insert a thermometer into the passenger side, left instrument panel vent. Do not allow thermometer to
touch the side of the duct. (NOTE When testing the sleeper A/C system, place the thermometer
into the lower passenger side bunk vent.)
• Run the engine at 1500 RPM.
• Open the windows and close both cab doors.
• Set the controls on the front HVAC control panel as follows: mode control to NORM A/C, blower control
to high (full cw), and temperature control to maximum cooling (full ccw).
• (Sleeper Cabs) Set the controls on the sleeper HVAC control panel as follows: blower control to high,
and temperature control to maximum cooling.
• Operate the system for at least five minutes, or until the gauge readings settle. Check the gauge
readings on the recovery station. If the A/C system is operating properly, the high and low pressure
readings will be within the listed pressure ranges in the applicable SYSTEM PRESSURE TEST
CHART. Day cab vehicles refer to Table 5 and sleeper vehicles refer to Table 6. If the gauges are not
reading within the System Pressure Test Chart ranges, refer to ABNORMAL GAUGE READINGS (See
ABNORMAL GAUGE READINGS, page 48).
Table 5 System Pressure Test Chart (Day Cabs)

Ambient Air Relative Vent Air Temperature Refrigerant Refrigerant Compressor
Temperature Humidity Left Passenger Pressure Pressure Cycling ?
High Side Low Side
Service Port Service Port
(°F) (°C) (% RH) (°F) (°C) (psig) (psig)
70 21.1 30-50 45-51 7.2-10.5 126-146 27-32 Yes
70 21.1 70-90 45-58 7.2-14.4 133-153 31-36 Yes
80 26.7 30-50 46-56 7.8-13.3 146-166 26-31 Yes
80 26.7 70-90 44-54 6.7-12.2 153-173 32-37 Yes
90 32.2 30-50 45-53 7.2-11.7 175-195 32-37 Yes
90 32.2 70 57-62 13.9-16.7 189-209 39-44 Yes
100 37.8 30-50 54-60 12.2-15.6 209-229 38-43 Yes
100 37.8 70 67-72 19.4-22.2 232-252 47-52 Yes

DIAGNOSIS AND TROUBLESHOOTING ABNORMAL GAUGE READINGS
Table 6 System Pressure Test Chart (Sleepers)

Ambient Air Relative Vent Air Temperature Vent Air Temperature Refrigerant Refrigerant Compressor
Temperature Humidity Instrument Panel Lower Passenger Pressure Pressure Cycling ?
Left Passenger Bunk Vent High Side Low Side
Service Port Service Port
(°F) (°C) (% RH) (°F) (°C) (°F) (°C) (psig) (psig)
70 21.1 30-50 41-47 5-8.3 34-40 1.1-4.4 135-155 33-38 No
70 21.1 70-90 41-54 5-12.2 30-40 –1.1 to 4.4 132-152 35-40 No
80 26.7 30-50 43-53 6.1-11.7 32-39 0-3.9 158-178 33-38 No
80 26.7 70-90 50-60 10-16.6 36-44 2.2-6.7 153-173 36-41 No
90 32.2 30-50 54-62 12.2-16.7 40-46 4.4-7.8 197-217 39-44 No
90 32.2 70 62-68 16.7-20 47-52 8.3-11.1 214-234 46-51 No
100 37.8 30-50 61-69 16.1-20.6 45-51 7.2-10.6 230-250 48-53 No
100 37.8 70 75-79 23.9-26.1 55-57 12.8-13.9 252-272 56-61 No
7.5. ABNORMAL GAUGE READINGS
WARNING
During system pressure tests, DO NOT open either hand valve on the 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 – In rare conditions, vehicles using a viscous fan drive, and being operated with no load may need
to set a fan in front of the condenser large enough to develop air flow comparable to normal ram air flow.
NOTE – On vehicles equipped with a sleeper HVAC system, the sleeper TXV/evaporator circuit is
arrangement, a malfunction in only one of the parallel circuits may cause only a slight change in the
pressure readings. The system with the restricted A/C line will experience a loss of cooling, while the
other system may operate normally, or be only slightly degraded.
If a restriction (or other malfunction) occurs in one of the lines or components common to both A/C
systems, pressure readings will be affected, and both systems will experience a loss of cooling.
If abnormal pressure readings are indicated during the System Performance Test Procedure, and no HVAC
related Diagnostic Trouble Codes have been set, refer to the following table and review the PHYSICAL
CHECKS section. For complete information on checking for Diagnostic Trouble Codes, and resolving those
codes, refer to the Electrical Troubleshooting Guide on ISIS.

ABNORMAL GAUGE READINGS DIAGNOSIS AND TROUBLESHOOTING
Table 7 Abnormal Pressure Troubleshooting Chart
SYMPTOM POSSIBLE CAUSES ACTION

Low Suction - High (1) Restriction in system between Reference:
Discharge Pressure compressor discharge port and inlet of
the filter-drier. • HIGH HEAD PRESSURE
TROUBLESHOOTING table
NOTE – On sleeper vehicles this (See Table 10, page 54).
symptom would occur only if the
restriction occurs in the section of
discharge line common to both front
and rear A/C systems.
Extremely Low Suction (1) Restriction in system between outlet Reference:
- Normal to Low of the filter-drier and the compressor
Discharge Pressure suction port, usually at expansion valve. • PHYSICAL CHECKS section (See
PHYSICAL CHECKS, page 42).
NOTE – On sleeper vehicles this
• REFRIGERANT CHARGE
symptom would occur only if the
restriction occurs in the section of
(See Table 9, page 52).
suction line common to both front
and rear A/C systems. • INSUFFICIENT CAB COOLING
TROUBLESHOOTING table (See
(2) Low refrigerant charge. Table 14, page 61).
(3) Intermittent condition may indicate

freezing of expansion valve due to
moisture in system.
NOTE – On sleeper vehicles this

symptom would occur only if BOTH
expansion valves freeze up.
High Suction - Normal (1) Expansion valve stuck open. (TXV Reference:
to Slightly Low would be very cold.)
Discharge Pressure • PHYSICAL CHECKS section (See
(2) Compressor not functioning (suction PHYSICAL CHECKS, page 42).
side).
• INSUFFICIENT CAB COOLING
TROUBLESHOOTING table (See
Table 14, page 61).
• COMPRESSOR

DIAGNOSIS AND TROUBLESHOOTING ABNORMAL GAUGE READINGS
Table 7 Abnormal Pressure Troubleshooting Chart (cont.)

SYMPTOM POSSIBLE CAUSES ACTION
High Suction - High NOTE – These readings may indicate Reference:
Discharge Pressure normal operation for a stationary
vehicle. Operate a large fan in front of • PHYSICAL CHECKS section (See
the condenser and recheck readings. PHYSICAL CHECKS, page 42).
• REFRIGERANT CHARGE
(1) Condenser plugged with debris.
(2) Excessive air, water or oil in system.
• HIGH HEAD PRESSURE
(3) Overcharged system. TROUBLESHOOTING table
(4) Engine fan not operating properly.
High Suction - Normal (1) Heater core shutoff valves not shut NOTE – Verify all heater assembly
to Slightly High off completely (if equipped with valves). seals and gaskets are installed
Discharge Pressure correctly.
(2) Temperature blend door not closing
completely. • Verify heater shut off valves are
completely shut off.
(3) Intrusion of outside air. Open vent
• Isolate fault to temperature door
or window.
or temperature door actuator
circuit. Refer to the Electrical
Troubleshooting Guide on ISIS.
• Repair cab fresh air leaks as
required.
Refer to GROUP 16 – CAB section

in the Master Service Manual.
Low Suction - Low (1) Low refrigerant charge. Reference:
Discharge Pressure
(2) Compressor not functioning properly. • REFRIGERANT CHARGE
• COMPRESSOR

TROUBLESHOOTING TABLES DIAGNOSIS AND TROUBLESHOOTING
7.6. TROUBLESHOOTING TABLES

Table 8 Mode Selection Troubleshooting
STEP KEY ACTION TEST SPEC. YES- IN SPEC. NO-OUT OF

POINTS SPEC.
Possible Causes: • Jammed/Damaged Mode Doors or Door Gear Drive
• Defective Actuator or Control Circuit
• Internal Actuator Slippage
1. ON Remove actuator from Gear Rotating the Go to next step. Isolate and clear
gear train that drives train for gear train input cause of door
the mode doors. Set mode shaft through jam or gear train
blower speed to full cw. doors. its full range jam.
Grasp the gear drive should move
input shaft (normally the mode doors (If the jam
mates to actuator) and to direct the air cannot be
manually rotate the flow as follows: cleared, replace
shaft through its full Full ccw = heater housing
range of movement. dash vents assembly.)
Full cw =
defrost vents
Mid position =
floor ducts
2. OFF Inspect the gear Gear Shaft and gear Isolate to Replace
train input shaft and train for train should defective mode heater housing
mechanism for wear mode be free of actuator or assembly.
or damage that may doors. excessive wear. related control
cause slippage. circuit.
Refer to the
Electrical
Troubleshooting
Guide on ISIS.

DIAGNOSIS AND TROUBLESHOOTING TROUBLESHOOTING TABLES
Table 9 Refrigerant Charge Troubleshooting

POINTS SPEC.
Possible Causes: • Faulty Thermistor Circuit
• System Leak
• Improperly Charged System
1. ON Review diagnostic Diagnostic No trouble Go to next Troubleshoot the
trouble codes to trouble codes were step. diagnostic trouble
Do not determine if any codes. logged code as indicated
start thermistor codes were for the in the Electrical
engine. logged. thermistors. Troubleshooting
Guide.
For complete
information on
viewing diagnostic
trouble codes refer
to the Electrical
Troubleshooting Guide
on ISIS.
2. OFF Connect recovery Go to next
station to A/C system. step.
3. OFF NOTE – The engine ThermometerGauge Problem is not If gauges are >10
must not be running, and readings a refrigerant psig higher than
and A/C system must recovery must be charge the table listings,
be near ambient station within 10 problem. system contains
temperature for this gauges psig of Review air or some
step. the table Diagnostic non-condensable
values. Trouble Codes, gas. Discharge,
A. Determine and/or table 4 evacuate, and
ambient (See Table 4, recharge the
temp. page 41) for a system. Refer
within a more accurate to SECTION 9
degree or symptom. (See SERVICE
two. PROCEDURES
For complete FOR R-134a, page
B. Record
information 138).
system
on viewing
pressures
diagnostic If gauges are
indicated
trouble >10 psig lower
on
codes refer than the table
recovery
to the Electrical listings, system
station
is undercharged.
gauges.

Table 9 Refrigerant Charge Troubleshooting (cont.)

POINTS SPEC.
C. Compare Troubleshooting Proceed to the

gauge Guide on ISIS. next step.
readings
to table
3 (See
Table 3,
page 36).
CAUTION
Do not direct a high pressure stream at the actuator located on the evaporator housing.
4. OFF Visually inspect all All Joints and Go to next Clean area around
joints and seals in refrigerant seals clean step. dirty joint or seal,
the air conditioning system and free of then go to next
system. joints and oil leakage. step.
seals.
5. OFF Inspect all joints and All No System was Refer to SECTION
seals using a leak refrigerant refrigerant improperly 9 (See SERVICE
detector (electronic or system leaks charged. PROCEDURES
UV style). Refer to joints and detected. Discharge, FOR R-134a, page
LEAK DETECTION. seals. evacuate, 138).
Concentrate on joints and recharge
that were dirty in the system. Refer Discharge system
previous step. to SECTION 9 and repair leak.
(See SERVICE
PROCEDURES Re-torque all
FOR R-134a, fittings to specified
page 138). levels (refer to
Torque table).
Evacuate and
recharge the
system.

Table 10 High Head Pressure Troubleshooting
STEP KEY ACTION TEST SPEC. YES- IN NO-OUT OF

POINTS SPEC. SPEC.
NOTE – Trucks may temporarily cycle the A/C system off during stationary operation, without setting
a ’High Head Pressure’ trouble code. This may be normal operation. Refer to the description of the
System Pressure Diagnostics located in the applicable Electrical Troubleshooting Guide on ISIS.
Possible Causes: • Blocked Condenser
• Restriction in High Pressure Side of System
• Air/Moisture in System
• Too Much Refrigerant Oil in System
• Faulty Pressure Transducer
• Faulty Fan or Fan Drive
1. OFF Visually inspect Condenser, Air flow Go to next Remove debris
for debris blocking grille, and through step. and re-establish
air flow through radiator condenser airflow through
condenser. should be condenser.
unrestricted.
2. OFF Inspect condenser Condenser Condenser Go to next Straighten fins.
for bent fins. fins must not step. If fins cannot
be crushed be repaired
together. Fins condenser core
should be must be replaced.
reasonably
straight and
separated,
allowing air
flow between
the fins.
3. OFF Inspect refrigerant Refrigerant Lines and Go to next Correct hose
hoses for kinks or lines and hoses must step. routing or replace
pinched areas. hoses. be free of damaged line or
kinks, pinched NOTE – If hose.
areas, and Refrigerant
tight bends. Identification
and the
check for
Non-Condensable
Gases were
already
performed,
skip to step
6.

Table 10 High Head Pressure Troubleshooting (cont.)

POINTS SPEC. SPEC.
4. OFF If a Refrigerant Connect the A/C system Go to next The system must
Identifier is not Refrigerant contents step. be discharged,
available, proceed Identifier as must be evacuated, and
to the next step. directed in R-134a at a recharged with
SECTION concentration the correct type
If a Refrigerant 9.3 (See of ≥98%. and amount of
Identifier is REFRIGERANT refrigerant. Refer
available, verify the IDENTIFICATION, to SECTION 9
contents of the A/C page 143). (See SERVICE
system. Follow PROCEDURES
the instructions FOR R-134a, page
in SECTION 138).
9.3, and those
provided with
the Refrigerant
Identifier.
5. ON NOTE – Do not Thermometer Gauge Proceed to If gauges are >10
or start engine. A/C and recovery readings must next step. psig higher than
OFF system must station be within 10 the table listings,
be OFF and gauges psig of the system contains
close to ambient table values. air or some
temperature. non-condensable
gas. Discharge,
Connect recovery evacuate, and
station to A/C recharge the
system. system.
A. Determine Refer to SECTION

ambient temp. 9 (See SERVICE
within a degree or PROCEDURES
two. FOR R-134a, page
138).
B. Record
system pressures If gauges are
indicated on >10 psig lower
recovery station than the table
gauges. listings, system
is undercharged.
C. Compare gauge Check for leaks,
readings to table 3 then discharge,
(See Table 3, page evacuate, and
36). recharge the
system.

Table 10 High Head Pressure Troubleshooting (cont.)

POINTS SPEC. SPEC.
6. ON Start engine. Condenser Condenser Go to next Repair or replace
tubes. tubes should step. condenser.
Set controls be free of
for NORM A/C damage and
operation. should be
free of cold
Inspect condenser spots. (Refer
tubing for visual to PHYSICAL
damage, frost, or CHECKS.)
cold spot.
7. ON Inspect Compressor A/C lines Go to next Replace defective
compressor -to- -to- should be step. component.
condenser line, condenser uniform in
condenser -to- line, temperature.
filter drier line, and condenser Compressor
filter drier body -to- filter drier -to-
for frost or a cold line, and condenser
spot, indicating a filter drier line may be
restriction. assembly. warmer than
others. There
should be
no frosty or
cold patches.
Refer to
PHYSICAL
CHECKS.
8. See Check the Pressure Pressure Too much Repair pressure
procedure.
operation of Transducer Transducer moisture or transducer circuit,
the pressure Circuit, Circuit, oil in system. cooling fan, or fan
transducer circuit, Cooling fan, Cooling fan, Discharge drive as indicated
the engine cooling and fan drive. and fan drive and purge in the applicable
fan, and the fan are operating system. Electrical
drive. correctly. Replace Troubleshooting
filter-drier, Guide.
For complete then
information refer recharge
to the Electrical system.
Troubleshooting Refer to
Guide on ISIS. SERVICE
PROCEDURES
FOR R-134a
(See
SERVICE
PROCEDURES
FOR R-134a,
page 138).

Table 11 Compressor Troubleshooting

STEP KEY ACTION TEST SPEC. YES- IN SPEC. NO-OUT OF SPEC.
POINTS
NOTE – A thorough understanding of the body controller’s refrigerant control and diagnostics program
is necessary to understand the interaction of the inputs required by the compressor circuit. The control
and diagnostics program is designed to control the compressor; including removing power from the
compressor when a fault is detected.
Before troubleshooting this circuit using this table, resolve any HVAC related DTC’s currently in the
system and insure that all previously active DTC’s have been cleared. For complete information on
viewing DTC’s refer to the Electrical Troubleshooting Guide on ISIS.
If no HVAC related DTC’s have been logged and the system compressor AND refrigerant charge are
believed to be ok, refer to INSUFFICIENT CAB COOLING TROUBLESHOOTING table (See Table 14, page
61).
Possible Causes: • Faulty Compressor
• Faulty Compressor Control Circuit (Thermistors, Transducer, A/C
Control Head, Body Controller, Clutch)
CAUTION
In the following step, the A/C clutch should only be turned in a CW direction, as viewed
from the front.
1. OFF Verify that the A/C Drive plate Go to next step. Replace A/C
compressor has compressor should compressor.
not seized by clutch drive turn using
attempting to turn plate. a clutch
the compressor wrench.
clutch drive plate
in a cw direction,
using a clutch
wrench.
2. OFF Recover refrigerant A/C system System was Replace A/C Locate and repair
from A/C system and adequately compressor. leak, refer to LEAK
using recovery Recovery charged. DETECTION.
station. Station.
Re-torque all fittings
Note quantity to levels specified in
of refrigerant TORQUE CHART (See
recovered. Table 22, page 168).
Charge the A/C

system. Refer to
CHARGING THE
AIR CONDITIONING
SYSTEM (See
CHARGING THE
AIR CONDITIONING
SYSTEM (FULL
CHARGE), page 151).

Table 12 Low Air Flow In Cab Troubleshooting

POINTS SPEC. SPEC.
NOTE – This table pertains to the cab (front) A/C system only. If the vehicle is equipped with a sleeper
HVAC system, set the sleeper system blower to OFF.
Possible Causes: • Blocked Recirc Air (in cab) Inlet (MAX A/C only)
• Blocked Heater Core (Heat Mode only)
• Dirty Air Inlet Filter Element
• Blocked Evaporator Core
• Faulty Blower or Blower Speed Control Circuit
1. ON Check air flow with the Various Airflow is weak Recirculate Go to next step.
mode control set to air outlets only in the air inlets
each mode position for depending MAX A/C are blocked.
about 30 seconds. on mode mode. (Located in
selected. cab behind
heater
housing.)
2. ON Check air flow with the Various Airflow is weak Heater core Go to next step.
mode control set to air outlets only when is blocked
each mode position for depending the TEMPER- by debris.
about 30 seconds. on mode ATURE control With the key
selected. is set from its OFF, clean
midrange to its heater core.
full cw position.
Disassemble
the heater
housing only
as far as
necessary
to clean the
heater core.
It is not
necessary
to remove
the core or
disconnect
the heater
hoses to
clean the
core. Refer
to HEATER
CORE,
REMOVE
AND
INSTALL
(See
HEATER
CORE –

Table 12 Low Air Flow In Cab Troubleshooting (cont.)

POINTS SPEC. SPEC.
FRONT
HVAC
SYSTEM,
page 104).
CAUTION
3. ON Remove grille from Evaporator Remove filter Replace Go to next step.
evaporator inlet on cowl air inlet. and check for filter with
tray. Remove air filter normal air flow a new filter
from within evaporator at high blower element.
housing. speed, in all
modes.
4. OFF Using a small flashlight Evaporator Verify that the Troubleshoot Clean the
and an angled mirror, inlet. evaporator the blower debris from the
check for debris core is free of and blower evaporator inlet.
blocking the evaporator debris. control
core in the evaporator circuit. Check airflow.
housing. If not improved,
Refer to the troubleshoot
Electrical the blower and
Troubleshooting
blower control
Guide on circuit.
ISIS.
Refer to the
Electrical
Troubleshooting
Guide on ISIS.
If the problem is intermittent, or occurs only after a period of A/C operation the evaporator core could be
icing up due to a restriction in the evaporator core or a defective component in the thermistor control circuit.

Table 13 Insufficient Cab Heat Troubleshooting

POINTS SPEC. SPEC.
NOTE – On vehicles equipped with heater shut off valves, verify that the valves are open.
Possible Causes: • Low Coolant Level or Coolant Flow
• Blocked Air Flow through Heater Core
• Defective Temperature Door, Door Actuator, or Control
Circuit
1. ON Check for correct Coolant Verify Go to next Troubleshoot
coolant level, coolant system correct step. coolant system
temperature, and and heater coolant problem as
coolant flow through core. level, indicated in
heater core. coolant the applicable
temperature, COOLING
Refer to the applicable and coolant section in
COOLING section in flow GROUP 12–
GROUP 12– ENGINE through ENGINE in the
in the Master Service heater Master Service
Manual. core. Manual.
If heater
core must be
removed, refer to
HEATER CORE,
REMOVE AND
INSTALL (See
HEATER CORE
– FRONT HVAC
SYSTEM, page
104).
2. OFF Check for blockage of air Heater Verify Fault is in the Heater core
flow through heater core. core. airflow Temperature is blocked
through Door, Door by debris.
Disassemble the heater the heater Actuator, or Clean debris
housing only as far as core is Control Circuit. from heater
necessary to clean the unrestricted. Refer to the core, before
heater core. It is not Electrical reassembling
necessary to remove the Troubleshooting heater housing.
core or disconnect the Guide on ISIS.
heater hoses to clean the
core. Refer to HEATER
CORE, REMOVE AND
INSTALL (See HEATER
CORE – FRONT HVAC
SYSTEM, page 104).

Table 14 Insufficient Cab Cooling Troubleshooting
STEP KEY ACTION TEST SPEC. YES- IN NO-OUT OF SPEC.

POINTS SPEC.
NOTE – On vehicles equipped with heater shut off valves, closing the shut off valves will improve
the performance of the A/C system.
a ’High Head Pressure’ trouble code. This is normal operation.
NOTE – A thorough understanding of the body controller’s refrigerant control and diagnostics
program is necessary to understand the interaction of the inputs required by the compressor
circuit. The control and diagnostics program is designed to control the compressor; including
removing power from the compressor when a fault is detected.
NOTE – Do not start the engine until instructed to do so. Some steps in this procedure require that
the engine and A/C system are at ambient temperature
Possible Causes: • Loose Drive Belt
• Excessive Engine Temperature
• Malfunctioning On/Off Fan Drive Circuit (Some Vehicles)
• Fresh Air Leaking into Cab
• Defective Temperature Blend Door, Door Actuator/Circuit
• Defective A/C Control Head
• Defective A/C Thermistor
• Defective A/C Pressure Transducer
• Defective Body Controller
• Defective Compressor
• Incorrect Refrigerant Charge
1. OFF Check compressor Compressor Drive belt Go to next Replace drive belt
drive belt condition drive belt must be step. if required and/or
and tension. in good set belt tension to
condition specified level.
Refer to COOLING and tension
section in GROUP must be
12– ENGINE in within
the Master Service specified
Manual. levels.

Table 14 Insufficient Cab Cooling Troubleshooting (cont.)

POINTS SPEC.
2. OFF Verify that the A/C Drive plate Go to next Replace A/C
compressor has compressor should step. compressor.
not seized by clutch turn using
attempting to turn the drive plate. a clutch NOTE – If
compressor clutch wrench. Refrigerant
drive plate in a cw Identification
direction, using a and the
clutch wrench. check for
Non-Condensable
Gases were
already
performed,
skip to step
5.
3. OFF If a Refrigerant Connect A/C system Go to next The system must
Identifier is not the contents step. be discharged,
available, proceed Refrigerant must be evacuated, and
to the next step. Identifier R-134a at a recharged with the
as concentration correct type and
If a Refrigerant directed in of ≥98%. amount of refrigerant.
Identifier is available, SECTION Refer to SECTION
verify the contents of 9.3 (See 9 (See SERVICE
the A/C refrigerant REFRIGERANT PROCEDURES FOR
system. Follow IDENTIFICATION, R-134a, page 138).
the instructions page 143).
in SECTION 9.3,
and those provided
with the Refrigerant
Identifier.
4. OFF NOTE – A/C system ThermometerGauge Go to next If gauges are >10
should be OFF for and readings step. psig higher than the
at least 30 minutes recovery must be table listings, system
prior to test. A/C station within 10 contains air or some
system must be gauges psig of the non-condensable
close to ambient table values. gas. Discharge,
temperature. evacuate, and
recharge the system.
Connect recovery
station to A/C system. If gauges are >10
psig lower than the
A. Determine table listings, system
ambient temp. within is undercharged.
a degree or two. Check for leaks, then
discharge, evacuate,
B. Record system and recharge the
pressures indicated system.
on recovery station
gauges. Refer to SECTION
9 (See SERVICE

POINTS SPEC.
PROCEDURES FOR
C. Compare gauge R-134a, page 138).
readings to table 3
(See Table 3, page
36).
5. OFF If not previously Go to next
connected, connect step.
recovery station to
A/C system.
6. OFF Connect EZ-Tech Go to next
service tool to step.
diagnostic connector,
to check HVAC
system signals.
NOTE – After
connecting
EZ-Tech, turn key
on but do not start
engine. A/C system
must be OFF and
close to ambient
temperature.
7. ON Compare transducer EZ-Tech Pressure Go to next Repair transducer
signal value on (pressure values step. circuit. Refer
EZ-Tech to recovery transducer should be to the Electrical
station high side signal) within 20 psi. Troubleshooting
gauge. Guide on ISIS.
Recovery
station
(high side
gauge)
8. ON NOTE – The Inlet and The Go to next Based on the
engine must not outlet difference step. ambient temperature,
be running, and thermistor between determine which
A/C system must signals signal values thermistor circuit
be near ambient must be ≤5°, appears to be reading
temperature for this AND should incorrectly.
step. indicate the
approximate Repair thermistor
Use EZ-Tech ambient circuit. Refer
to observe both temp. to the Electrical
thermistor signals. Troubleshooting
Guide on ISIS.


POINTS SPEC.
9. ON Start engine. After Engine Engine Go to next If engine is running
initial warmup, verify temperature temperature step. hot, determine cause
engine operating gauge gauge must of excessive engine
temperature is indicate temperature. Repair
normal. Continue to engine is not if necessary.
monitor throughout running hot.
test.
10. ON Select A/C NORM A/C A/C Go to next Review conditions
mode on HVAC Compressor compressor step. required for
control head. must cycle compressor
on and operation. Isolate
Set fan control to off, or run component
mid-range. continuously, preventing
when in A/C compressor
Verify A/C modes. operation. Refer
compressor cycles to the Electrical
ON. Troubleshooting
Guide on ISIS.
11. ON Verify that recovery Recovery Gauge Go to next If vehicle is equipped
station gauge station readings step. with an On/Off fan
readings are within pressure are within drive, verify fan drive
ranges shown in the gauges ranges is operating correctly.
applicable SYSTEM shown in the Refer to the Electrical
PRESSURE TEST applicable Troubleshooting
CHART. SYSTEM Guide on ISIS.
PRESSURE
Day cab vehicles TEST Otherwise, refer to
refer to Table 5 (See CHART. the ABNORMAL
Table 5, page 47). PRESSURE
TROUBLE-
Sleeper vehicles SHOOTING CHART
refer to Table 6 (See (See Table 7, page
Table 6, page 48). 49), and perform


POINTS SPEC.
action listed for
NOTE – In some observed symptom.
conditions a
stationary vehicle
may temporarily
shut down the A/C
system as part of
normal operation.
Refer to the
description of the
System Pressure
Diagnostics located
in the Electrical
Troubleshooting
Guide on ISIS.
12. ON Verify air temp at ThermometerVent air Repair cab NOTE – Verify all
passenger vent is in temp must fresh air heater assembly
within normal range. passenger be within leaks as seals and gaskets
air vent normal required. are installed
range. correctly.
Refer to
GROUP Isolate fault to
16 – CAB temperature door
section in or temperature door
the Master actuator circuit. Refer
Service to the Electrical
Manual. Troubleshooting
Guide on ISIS.
If the cab takes a long time to cool down using the MAX A/C mode, the fresh air/recirc air door may be
malfunctioning. Verify fresh air/recirc air door is closed when in MAX A/C mode with blower set to any
position except OFF. If door is open, refer to the Electrical Troubleshooting Guide on ISIS.
icing up due to a restriction in the evaporator core or a defective component in the thermistor control circuit.
Table 15 Insufficient Defrost Troubleshooting

POINTS SPEC. SPEC.
Possible Causes: • Insufficient Heat
• Compressor or Compressor Control Circuit Failure
• Defective Fresh Air/Recirc Door Actuator Circuit
• Defective Mode Doors and/or Actuator Circuit

Table 15 Insufficient Defrost Troubleshooting (cont.)

POINTS SPEC. SPEC.
1. ON Check for normal heater Floor ducts Verify that Go to next Refer to the
operation. With the the air at step. INSUFFICIENT
engine running at the floor CAB HEAT
operating temperature, ducts is TROUBLE-
set the blower speed hot. SHOOTING table
control to high speed (full (See Table 13,
cw), set the temperature page 60).
control to maximum heat
(full cw), and set the
mode control to the floor
setting.
2. ON NOTE – If the Air outlet Verify that Go to next Refer to the
ambient temperature vents. the A/C step. INSUFFICIENT
is very low, the system is CAB COOLING
engine may have to cooling the TROUBLE-
raise the underhood air at the SHOOTING table
temperature before the air outlet (See Table 14,
A/C compressor can vents. page 61).
be energized.
Check for normal A/C

operation.
Set the mode control

to NORM A/C, blower
speed to high, and
temperature to full ccw.
3. ON Check for compressor A/C Verify that Go to next The compressor is
operation while in the Compressor compressor step. not being enabled
defrost mode. cycles in the Defrost
regularly mode.
Set the mode control to while in
Defrost and the blower the Defrost Troubleshoot the
speed control to high mode. HVAC control head
speed. circuit. Refer
to the Electrical
Troubleshooting
Guide on ISIS.
4. ON While in the defrost Fresh Verify Go to next Troubleshoot the
mode, check the position Air/Recirc that fresh step. fresh air/recirc
of the fresh air/recirc Door air/recirc door control
door in the evaporator door is circuit. Refer
housing. open while to the Electrical
in the Troubleshooting
Defrost Guide on ISIS.
mode.

Table 15 Insufficient Defrost Troubleshooting (cont.)

POINTS SPEC. SPEC.
5. ON Remove actuator from Gear train Rotating Go to next Isolate and clear
gear train that drives for mode the gear step. cause of door jam
the mode doors. Set doors. train input or gear train jam.
blower speed to full cw. shaft
Grasp the gear train through its (If the jam cannot
input shaft (normally full range be cleared, replace
mates to actuator) and should heater housing
manually rotate the shaft move the assembly.)
through its full range of mode
movement. doors to
direct the
air flow
as follows:
Full ccw =
dash vents
Full cw
= defrost
vents
Mid
position =
floor ducts
6. OFF Inspect the gear Gear train Shaft and Isolate to Replace heater
train input shaft and for mode gear train defective housing assembly.
mechanism for wear or doors. should be mode
damage that may cause free of actuator
slippage. excessive or related
wear. control
circuit.
Refer to the
Electrical
Troubleshooting
Guide on
ISIS.
7. ON Check for an obstruction Defrost Verify that Mode Clear obstruction
in the defrost ducts. ducts there is no actuator from defrost ducts.
It may be necessary obstruction is slipping
to remove the heater in the internally.
housing. defrost Replace
ducts. actuator.

Table 16 Noisy Compressor Troubleshooting

POINTS SPEC.
Possible Causes: • Missing or Loose Compressor Mounting Bolts
• Broken or Cracked Brackets or Braces
• Drive Belt Idler or Pulley Loose or Damaged
• Drive Belt Misadjusted, Misaligned, or Worn
• Compressor Clutch Slipping
• Defective Compressor/Clutch
• Excessive Refrigerant Charge
1. OFF Check torque on Compressor Verify all Go to next Replace missing
compressor mounting mounting compressor step. mounting bolts.
bolts. bolts. mounting bolts Tighten all mounting
are present bolts to the correct
and torqued value.
to the correct
value: 23 to 29
N.m (17 to 21.4
lbf-ft).
2. OFF Check for broken or Compressor Verify that Go to next Replace broken
cracked compressor mounting compressor step. or cracked
mounting brackets or system. mounting components.
braces. brackets and
braces are
complete and
free of cracks.
3. OFF Check compressor Compressor Pulleys and Go to next Tighten or replace
drive belt pulleys and drive belt idlers must be step loose or damaged
idlers for damage, pulleys and damage free pulleys and/or
looseness or worn idlers. and tight. idlers as indicated
bearings. in GROUP 12–
ENGINE section in
the Master Service
Manual.
4. OFF Check compressor Compressor Belt wear, Go to next Replace belt, or
drive belt for wear, drive belt. alignment and step. align and adjusts
misalignment or adjustment the belt as indicated
misadjustment. must be within in the GROUP 12–
acceptable ENGINE section in
limits as the Master Service
indicated in Manual.
the GROUP
12– ENGINE
section in the
Master Service
Manual.

Table 16 Noisy Compressor Troubleshooting (cont.)

POINTS SPEC.
5. ON Check for compressor Compressor/ The clutch Go to next Cycle clutch several
clutch slippage. Clutch should engage step. times to burnish
assembly and run with face. Recheck
no slipping. operation; if
(A slipping scrapping sound
clutch makes is no longer present,
a scraping no further repairs
noise.) are necessary.
6. ON Run A/C SYSTEM A/C system, Pressure Replace the Service the A/C
PERFORMANCE gauge set readings must compressor/ system (discharge,
TEST PROCEDURE or recovery be within clutch evacuate, and
(See A/C SYSTEM station. the limits assembly. recharge the
PERFORMANCE indicated in system). Refer
TEST PROCEDURE, test procedure to SERVICE
page 45). table. PROCEDURES
FOR R-134a
Check for high (See SERVICE
discharge pressure PROCEDURES
readings, indicating an FOR R-134a, page
excessive refrigerant 138).
charge.

Table 17 No Sleeper Air Flow Troubleshooting

POINTS SPEC. SPEC.
NOTE – This table pertains to the sleeper (rear) A/C system only.
Possible Causes: • Disconnected Sleeper Blower
• Stuck Blower/Fan Assembly
• Broken Fan
• Faulty Sleeper Blower or Blower Speed Control Circuit
1. OFF Verify that the blower LPM on Connector Go to next Seat connector
motor electrical the rear must be firmly step. and check
connector is plugged HVAC unit seated. for normal
into the LPM on the rear operation.
HVAC unit.
2. OFF Remove blower Blower/fan Fan wheel must Go to next Replace
assembly and check assembly rotate freely step. blower/fan
condition of fan wheel. and be free of assembly.
damage. Refer to
BLOWER/FAN
ASSEMBLY,
REMOVE AND
INSTALL (See
BLOWER/FAN
ASSEMBLY –
REAR HVAC
UNIT, page
121).
3. OFF Check for obstructions Rear Rear HVAC unit Troubleshoot Remove
within the fan mounting HVAC unit housing must the blower obstructions in
cavity of the rear HVAC housing be free of fan and LPM rear HVAC unit
unit housing. obstructions. output to allow normal
circuit. operation of
blower/fan
Refer to the assembly.
Electrical
Troubleshooting
Guide on
ISIS.

Table 18 Low Sleeper Air Flow Troubleshooting

POINTS SPEC. SPEC.
NOTE – This table pertains to the sleeper (rear) HVAC system only. Set the blower control on the cab
HVAC control panel (on instrument panel) to OFF.
Possible Causes: • Blocked Air Inlet
• Dirty Air Inlet Filter Element
• Damaged/missing Foam Seals in Rear HVAC Unit
• Blocked Evaporator Core
• Faulty Blower or LPM Output Circuit
1. OFF Verify that the air intake Rear Area in front Go to next Clear area in
for the rear HVAC unit HVAC unit of air intake step. front of rear
is not blocked. air intake must be HVAC unit air
relatively clear intake.
of obstructions.
2. OFF Check condition of filter Filter Filter element Go to next Clean or
element in rear HVAC element for should be free step. replace filter
unit. rear HVAC of heavy dirt element.
unit deposits.
Filter element
should be
cleaned or
replaced
at regular
intervals,
depending
on operating
conditions.
3. ON With rear blower Rear Little or no air Go to next Replace foam
operating at maximum HVAC unit should escape step. seals as
speed, check for air from the necessary
leaking from damaged components to correct
or missing foam seals mounted to the reduced air flow
on rear HVAC unit rear HVAC unit, problem.
components (LPM, including the
blower, heater core discharge duct.
cover) and duct work.

Table 18 Low Sleeper Air Flow Troubleshooting (cont.)

POINTS SPEC. SPEC.
4. OFF Remove blower Evaporator Verify that Troubleshoot Clean the
assembly from rear core in rear evaporator the blower debris from
HVAC unit. HVAC unit core is free of and LPM the evaporator
debris. output core.
Using a small flashlight circuit.
and an angled mirror, Check airflow.
check for debris Refer to the If not improved,
blocking the evaporator Electrical troubleshoot the
core. Troubleshooting
blower and LPM
Guide on output circuit.
ISIS.
Refer to the
Electrical
Troubleshooting
Guide on ISIS.
icing up due to a malfunctioning rear TXV or a restriction in the evaporator core.
Table 19 Insufficient Sleeper Heat Troubleshooting

POINTS SPEC.
NOTE – This table pertains to the sleeper (rear) HVAC system only. Set the blower control on the cab
HVAC control panel (on instrument panel) to OFF.
NOTE – On vehicles equipped with a heater shut off valve, verify that the valve is open.
Possible Causes: • Low Coolant Level or Coolant Flow
• Defective Temperature Door
1. ON Check for correct Coolant Verify Repair or Troubleshoot
coolant level, coolant system correct replace coolant system
temperature, and and rear coolant the sleeper problem as
coolant flow through heater level, temperature indicated in
rear heater core. lines. coolant door. Refer to the applicable
temperature, TEMPERATURE COOLING
Refer to the applicable and coolant BLEND AIR section in
COOLING section in flow DOOR, GROUP 12–
GROUP 12– ENGINE through REMOVE AND ENGINE in the
in the Master Service rear heater INSTALL (See Master Service
Manual. core. TEMPERATURE Manual.
BLEND AIR
DOOR – If rear heater
REAR HVAC core must be
UNIT, page removed, refer to
128). HEATER CORE,
REMOVE AND
INSTALL (See

Table 19 Insufficient Sleeper Heat Troubleshooting (cont.)

POINTS SPEC.
HEATER CORE
– REAR HVAC
UNIT, page 125).
If heater
lines must be
removed, refer to
HEATER HOSE
ASSEMBLY,
REMOVE AND
INSTALL (See
HEATER HOSE
ASSEMBLY –
TO REAR HVAC
UNIT, page 115).
Table 20 Insufficient Sleeper Cooling Troubleshooting

POINTS SPEC. SPEC.
NOTE – This table pertains to the sleeper (rear) HVAC system only.
NOTE – It is assumed that all DTC’s related to the front and rear A/C systems have been noted and
resolved before reaching this table. This table pertains only to cooling problems involving the sleeper
HVAC system, that do NOT set a DTC.
NOTE – It is assumed that all fault symptoms related to the front A/C system have been noted and
resolved before reaching this table.
NOTE – On vehicles equipped with a heater shut off valve, closing the shut off valve will improve the
performance of the A/C system.
a ’High Head Pressure’ trouble code. This is normal operation.
NOTE – A thorough understanding of the body controller’s refrigerant control and diagnostics
program is necessary to understand the interaction of the inputs required by the compressor circuit.
The control and diagnostics program is designed to control the compressor; including removing
power from the compressor when a fault is detected.
NOTE – Do not start the engine until instructed to do so. Some steps in this procedure require the
engine and A/C system are at ambient temperature

Table 20 Insufficient Sleeper Cooling Troubleshooting (cont.)

POINTS SPEC. SPEC.
Possible Causes: • Malfunctioning Rear A/C Request Circuit
• Fresh Air Leaks in Cab/Sleeper
• Defective Temperature Blend Door, Door Actuator/Circuit
• Incorrect Refrigerant Flow Through Rear Evaporator Core
Circuit
1. OFF Connect recovery station Go to next
to A/C system. step.
2. ON Start engine. A/C A/C Go to next Refer to the
Compressor compressor step. applicable
On front HVAC control must cycle Electrical
panel: on within Troubleshooting
2 minutes Guide on ISIS.
• Set fan control to of setting
mid-range. controls. Review conditions
required for
• Set temperature
compressor
control to minimum
operation (A/C
(full ccw).
Request). Isolate
• Set mode control to component
the VENT (non-A/C) preventing
mode. compressor
operation.
On rear HVAC control
panel:
• Set fan speed control

to mid-range.
• Set temperature
control to the lowest
temperature setting
(maximum cooling).
Verify A/C compressor

cycles ON within 2
minutes.


POINTS SPEC. SPEC.
3. ON Run A/C SYSTEM Recovery Verify gauge A/C Go to next step.
PERFORMANCE TEST station readings (and system is
PROCEDURE, (starting pressure sleeper vent operating
at step 3). gauges temperatures) correctly.
and are within Repair cab
Verify that recovery thermometer ranges shown fresh air
station gauge readings in sleeper in SYSTEM leaks as
(and sleeper vent vent. PRESSURE required.
temperatures) TEST CHART
are within ranges (SLEEPERS). Refer to
shown in SYSTEM GROUP
PRESSURE TEST 16 – CAB
CHART (SLEEPERS), section in
(See Table 6, page 48). the Master
Service
NOTE – In some Manual.
conditions a stationary
vehicle may temporarily
shut down the A/C
system as part of
normal operation. Refer
to the description of
the System Pressure
Diagnostics located
in the Electrical
Troubleshooting Guide
on ISIS.
4. ON Remove coolant flow to ThermometerVerify Isolate Isolate fault to
rear heater core. Either in sleeper sleeper vent fault to rear rear TXV, rear
close heater shut off vent. temperature is temperature evaporator core, or
valve or pinch rear heater within range door rear A/C lines.
lines with clamping pliers shown in or rear
(Figure 45). SYSTEM temperature Refer to the
PRESSURE door PHYSICAL
After several minutes, TEST CHART actuator CHECKS section
verify that sleeper vent (SLEEPERS). circuit. (See PHYSICAL

REMOVE AND INSTALL TROUBLESHOOTING TABLES

POINTS SPEC. SPEC.
temperature is within Refer CHECKS, page
range shown in SYSTEM to the 42).
PRESSURE TEST Electrical
CHART (SLEEPERS), Troubleshooting
(See Table 6, page 48). Guide on
ISIS.
NOTE
– While
performing
checks,
verify all
seals and
gaskets
of the rear
HVAC unit
(and duct
work) are
installed
correctly,
and are
undamaged.
icing up due to a malfunctioning rear TXV or a restriction in the evaporator core.
8. REMOVE AND INSTALL

WARNING
WARNING
To prevent damage to the equipment and/or personal injury, always turn the vehicle
ignition key OFF before performing Removal and Installation procedures.

TROUBLESHOOTING TABLES REMOVE AND INSTALL
WARNING
To avoid personal injury or death, refer to the manufacturer’s service information

before working on any high voltage equipment. By definition high voltage circuits and
components contain voltage levels that may cause equipment damage, electrical shock
and/or electrocution if handled incorrectly.
Only a trained technician may perform service inside high voltage components. If you
work around or maintain high voltage circuits, please seek high voltage training.
CAUTION
To prevent contamination of the HVAC system as well as continued leakage from an open
line, always cap or plug all open tubes or ports after disconnecting components.
NOTE – Cleanliness of the air conditioner components cannot be over-emphasized. Lack of proper
attention in this area is one of the major causes of costly and unsatisfactory unit operation.
NOTE – Special attention to the following, during component remove and install, will aid in avoiding
unnecessary and time-consuming problems.
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 21). 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 22).
I. All fittings must be tightened as specified in the TORQUE CHART (See Table 22, page 168). Use
only a torque wrench known to be accurate.

REMOVE AND INSTALL PRESSURE TRANSDUCER
1. O-RING 2. C-PLATE
Figure 21 A/C Fitting C-Plate and O-Ring
Figure 22 Use a Back-Up Wrench When Loosening or Tightening Fittings
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.
The removal and installation procedures for this heating – air conditioning system are organized in the following
order. Under hood components are covered first, followed by the in-cab components, then sleeper components.
8.1. PRESSURE TRANSDUCER

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

damage to the A/C system replace a defective transducer only with the recommended
part.
NOTE – The pressure transducer can be removed and installed without removing the refrigerant from
the A/C system.
NOTE – Refer to Figure 24 while performing the following Remove and Install procedures.

THERMISTORS REMOVE AND INSTALL
The pressure transducer is located on the condenser-to-evaporator refrigerant line.
Remove
1. Disconnect electrical connection to pressure transducer (2, Figure 23).
2. Unscrew pressure transducer from condenser-to-evaporator refrigerant line and cap open fitting.
1. CONDENSER 3. SERVICE PORT (HIGH SIDE)

2. PRESSURE TRANSDUCER
Figure 23 A/C Condenser and Pressure Transducer
Install
1. Install a new O-ring on transducer fitting and lubricate O-ring and threads with mineral-based oil.
2. Screw pressure transducer onto A/C line fitting and tighten to 6.8 to 13.6 N•m. (5 to 10 lbf-ft).
3. Connect electrical connector to pressure transducer (2).
8.2. THERMISTORS
WARNING
The AC thermistors CANNOT be removed and installed without removing the refrigerant
from the AC system. The procedures are the same for either thermistor.
Remove
1. Discharge A/C system. Refer to DISCHARGING THE SYSTEM (See DISCHARGING THE SYSTEM
(REFRIGERANT RECOVERY), page 146).
2. Disconnect electrical connection to thermistor being removed.

REMOVE AND INSTALL CONDENSER CORE
3. Unscrew thermistor from its fitting and cap open fitting.
1. EVAPORATOR OUTPUT 2. EVAPORATOR INPUT

THERMISTOR THERMISTOR
Figure 24 A/C Thermistor Locations
Install
1. Ensure a new O-ring is installed on the new thermistor, and lubricate O-ring and threads with mineral-based
oil.
2. Screw thermistor into its fitting and tighten to 5.0 to 9.5 N.m (44.3 to 84.1 lbf-in).
NOTE – The thermistor connector is not polarized. It may be connected in either orientation.
3. Connect electrical connection to replaced thermistor.
4. Recharge A/C system. Refer to CHARGING THE AIR CONDITIONING SYSTEM (See CHARGING THE
AIR CONDITIONING SYSTEM (FULL CHARGE), page 151).
8.3. CONDENSER CORE

Depending on the vehicle model/engine combination, replacement of certain components may require the
removal of nearby assemblies to gain access to fittings, components, or mounting hardware. Refer to the
appropriate section(s) in the Master Service Manual for additional procedures.
Remove
2. If necessary, unclip or unbolt condenser line support clamps and disconnect pressure transducer wiring
connector to allow A/C lines to be moved out of the way.

A/C COMPRESSOR/CLUTCH REMOVE AND INSTALL
3. Disconnect A/C line fittings from condenser and position the A/C lines out of the way.
4. Remove two bolts securing top mounting hangers to radiator frame.
5. Lift mounting hangers from top of condenser. Insure that rubber isolators remain in hanger sockets.
6. Lift condenser from sockets in bottom rail. Insure that rubber isolators remain in rail.
Install
1. Verify that rubber isolators are installed in bottom condenser support rail.
2. Insert posts on bottom of condenser into sockets until condenser is fully seated.
3. Insure that rubber isolators are installed in top hanger sockets.
4. Install top mounting hangers onto posts on top of condenser. Verify that posts are fully seated into sockets.
5. Secure top mounting hangers to radiator frame using two bolts removed earlier.
6. If the system is to be flushed or purged, perform that operation before completing reassembly. Refer to
PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM (See PURGING OR FLUSHING THE AIR
CONDITIONING SYSTEM, page 153).
NOTE – Always lubricate A/C fitting O-rings with mineral-based oil during installation.
7. Using new O-rings and C-plates connect A/C line fittings to condenser. Tighten to 19,000 to 21,000
N.mm (170 to 190 lbf-in).
8. If removed earlier, install any condenser line support clamps in their original location and orientation.
Connect wiring to pressure transducer.
9. Install any assemblies that were removed to gain access to the condenser.
8.4. A/C COMPRESSOR/CLUTCH

Depending on the vehicle model/engine combination, replacement of certain components may require the
removal of nearby assemblies to gain access to compressor mounting bolts and A/C lines. Refer to the
Remove
2. Remove or loosen compressor belt.
3. Disconnect compressor clutch wiring connector (4, Figure 25) from engine wire harness.

REMOVE AND INSTALL A/C COMPRESSOR/CLUTCH
4. Disconnect both refrigerant line fittings at compressor.
CAUTION
When removing mounting bolts from side mounted compressors, support compressor
to prevent possible damage to mounting bolts and/or compressor.
5. Remove four compressor mounting bolts (5), noting location and orientation of any brackets secured by
mounting bolts.
6. Remove compressor assembly (1) from engine.
1. A/C COMPRESSOR REAR VIEW 5. MOUNTING BOLT (QTY 4)

2. DISCHARGE PORT/LINE 6. TOP VIEW
3. SUCTION PORT/LINE 7. WITH TOP PORTS
4. ELECTRICAL CONNECTOR 8. WITH REAR PORTS
Figure 25 A/C Compressor (Typical Installation)
Install
NOTE – Verify that the clutch is installed on the compressor before performing the following installation
procedure.
1. If system is to be flushed or purged, perform that operation before reassembling system. Refer to
2. Before installing compressor, refer to OIL FILL GUIDELINES (See OIL FILL GUIDELINES, page 158).
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. Tighten to 23 to 29 N.m (16.9 to 21.4 lbf-ft).
NOTE – Always lubricate O-rings with mineral-based oil during installation.
4. Using new O-rings and C-plates connect refrigerant line fittings at compressor.
5. Connect compressor clutch wiring connector to engine harness.
6. Install and align compressor belt.

AIR FILTER (LOCATED INSIDE EVAPORATOR HOUSING) REMOVE AND INSTALL
8. Install any assemblies that were removed to gain access to the compressor.
8.5. AIR FILTER (LOCATED INSIDE EVAPORATOR HOUSING)

Remove
CAUTION
Never force the fresh/recirculate air door open. If door position must be changed,
perform the following procedures. Forcing the door will result in a broken door shaft
and a costly repair.
1. Remove grille or filter/grille covering HVAC air inlet (1, Figure 26), located in cab cowl tray at base of
windshield.
2. Verify that fresh/recirculate air door is open (4, Figure 27). This can be done by looking into cowl tray
air inlet.
3. If door is open proceed to next step. If door is closed, proceed as follows:
A. Turn ignition key to ON position (it’s not necessary to start engine),

B. Set blower speed control on HVAC control panel to OFF, (the fresh/recirculate air door will
open),
C. Turn ignition key to OFF position.
4. Reaching into the HVAC air inlet, located in evaporator housing (3, Figure 27), remove air filter (5) by
compressing top of filter, tipping it to the front, and lifting it straight up.

REMOVE AND INSTALL AIR FILTER (LOCATED INSIDE EVAPORATOR HOUSING)
1. AIR INLET FILTER/GRILLE 2. CAB COWL TRAY

Figure 26 Location of Air Inlet Filter/Grille
1. AIR INLET FILTER/GRILLE 5. AIR FILTER ELEMENT

2. CAB COWL TRAY 6. EVAPORATOR CORE
3. EVAPORATOR HOUSING 7. FRONT OF VEHICLE
4. FRESH/RECIRCULATE DOOR
(SHOWN IN OPEN/FRESH AIR
POSITION)
Figure 27 Cutaway View of Evaporator Housing
A/C REFRIGERANT HOSES (FRONT SYSTEM LONG LINES) REMOVE AND INSTALL
Install
1. With the filter pleats vertical, place filter (5, Figure 27) into evaporator housing (3) through air inlet.
2. Position bottom of filter as far to the rear as possible (behind the positioning rib in the housing); then
compress top of filter and push it to the rear until it is behind top positioning ribs. The filter is in place when
it is set behind the positioning ribs at all four corners.
3. Fit can be verified by grasping a central pleat and gently pulling forward. The filter should be retained
by the ribs.
4. Install grille or filter/grille covering HVAC air inlet (1, Figure 26).
8.6. A/C REFRIGERANT HOSES (FRONT SYSTEM LONG LINES)

The three A/C refrigerant hoses/lines (1, 2, and 4, Figure 28) 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 to gain access to the fittings, or to remove the A/C lines. Refer to the
Remove
NOTE – When removing Condenser-to-Evaporator Hose (4, Figure 28) disconnect electrical connection
to pressure transducer (5).
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 (4) remove pressure transducer (5) from old line
for transfer to new line.
Install
NOTE – Before installing a new Condenser-to-Evaporator line (4, Figure 28) it may be necessary to
transfer pressure transducer (5) from the old line to the new line.
1. If A/C system is to be flushed or purged, perform that operation before reassembling the system. Refer to
2. Place new A/C hose/line in its approximate location.

REMOVE AND INSTALL A/C REFRIGERANT HOSES (FRONT SYSTEM LONG LINES)
NOTE – Always lubricate O-rings with mineral-based oil during installation.
3. Using new O-rings and C-plates connect fittings at each end of the A/C hose/line. Tighten to 19,000 to
21,000 N.mm (170 to 190 lbf-in).
4. Secure the hose/line using all support clamps and strap locks removed during removal.
NOTE – After installing Evaporator-to-Compressor line (1) the cab cowl tray must be installed. Refer to
the appropriate CAB Section in Group 16 of the Master Service Manual for procedures covering all cab
cowl trays.
1. EVAPORATOR-TO-COMPRESSOR 8. EVAPORATOR OUTPUT LINE

LINE 9. INPUT THERMISTOR
2. COMPRESSOR-TO-CONDENSER 10. THERMOSTATIC EXPANSION
LINE VALVE
3. EVAPORATOR HOUSING 11. EXPANSION VALVE OUTPUT
4. CONDENSER-TO-EVAPORATOR LINE
LINE 12. OUTPUT THERMISTOR
5. PRESSURE TRANSDUCER 13. SERVICE PORT (LOW
6. FILTER-DRIER PRESSURE)
7. EVAPORATOR INPUT LINE
Figure 28 A/C System Components and Refrigerant Lines

FILTER-DRIER REMOVE AND INSTALL
8.7. FILTER-DRIER
The filter-drier inlet and outlet lines are part of the filter-drier assembly (Figure 29).
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.
Figure 29 Filter-Drier
Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components may
require the removal of nearby assemblies to gain access to the components or related A/C lines. Refer to the
Remove
2. To allow movement of condenser-to-evaporator line (4, Figure 28), remove or loosen hose support clamps
and/or strap locks used to secure line at evaporator housing (3).
3. Disconnect condenser-to-evaporator line (4) from filter-drier inlet line.
4. Remove screw securing filter-drier inlet line clamp to evaporator housing (3).
5. Remove T30 Torx head screw from locking plate on top of expansion valve (10).
6. Remove locking plate from top of expansion valve.
7. While supporting filter-drier (6), remove two mounting bolts securing filter-drier to evaporator housing.
8. Remove filter-drier by lifting it free of expansion valve.
Install

REMOVE AND INSTALL THERMOSTATIC EXPANSION VALVE – FRONT HVAC SYSTEM
NOTE – Always lubricate O-rings on fittings with mineral-based oil during installation.
2. With a new lubricated O-ring on the filter-drier outlet tube, carefully insert tube into expansion valve
(10, Figure 28) while securing filter-drier (6) to evaporator housing (3) with two mounting bolts. Tighten
to 11.0 to 11.6 N.m (8.1 to 8.5 lbf-ft).
3. Position locking plate on top of expansion valve and secure with T30 Torx head (M6) screw. Tighten to
9,000 to 10,000 N.mm (80 to 90 lbf-in).
4. Install screw securing filter-drier inlet tube clamp to evaporator housing.
5. Using a new O-ring and C-plate connect condenser-to-evaporator line (4) to filter drier inlet tube. Tighten
to 19,000 to 21,000 N.mm (170 to 190 lbf-in).
6. Secure condenser-to-evaporator line at evaporator housing using hose support clamps and/or strap
locks removed earlier.
8. Install cab cowl tray, if previously raised or removed.
8.8. THERMOSTATIC EXPANSION VALVE – FRONT HVAC SYSTEM

Depending on the vehicle model/engine combination, replacement of specific A/C refrigerant components may
require the removal of nearby assemblies to gain access to the components or related A/C lines. Refer to the
CAUTION
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.
Remove
2. Remove filter-drier. Refer to FILTER-DRIER.
3. With top locking plate removed from expansion valve, remove two 3mm Allen head capscrews from
expansion valve body. Remove and retain bottom locking plate.
4. Lift output thermistor line (11, Figure 28) from top of expansion valve. If necessary loosen or remove
cowl clamp(s) securing evaporator-to-compressor line (1) to allow removal of line from expansion valve.
(This requires removal or raising of cab cowl tray.)
5. Remove expansion valve.

ACTUATOR, (FRESH/RECIRCULATE) AIR DOOR REMOVE AND INSTALL
Install
NOTE – Before installing new O-rings in the following steps, insure that the old O-rings have been
removed.
2. Insure that new lubricated O-rings are installed on all lines being connected to expansion valve.
3. Position expansion valve on top of evaporator inlet and outlet lines.
4. Install bottom locking plate and secure to expansion valve with two 3mm Allen head (M5) capscrews.
Tighten to 4,000 to 4300 N.mm (35.4 to 38.0 lbf-in).
5. Insert outlet thermistor line (11, Figure 28) into top of expansion valve (10).
6. Install filter-drier. Refer to FILTER-DRIER.
7. Install top locking plate and secure to expansion valve with T30 Torx head (M6) screw. Tighten to 9,000 to
10,000 N.mm (80 to 90 lbf-in).
8. Insure that all clamps securing condenser-to-evaporator line (4) to evaporator housing (3) have been
installed and tightened.
9. Install and/or tighten clamp(s) securing evaporator-to-compressor line (1) to cowl.
11. Install cab cowl tray, if previously raised or removed.
8.9. ACTUATOR, (FRESH/RECIRCULATE) AIR DOOR

Depending on the vehicle model/engine combination, replacement of certain components may require
the removal of nearby assemblies to gain access to the components or mounting hardware. Refer to the
Remove
1. Disconnect wiring connector to actuator (1, Figure 30) for fresh/recirc air door.

REMOVE AND INSTALL ACTUATOR, (FRESH/RECIRCULATE) AIR DOOR
1. FRESH/RECIRC AIR DOOR 2. EVAPORATOR HOUSING

ACTUATOR
Figure 30 Actuator for Fresh/Recirc Air Door
2. Remove two screws securing actuator (1) to evaporator housing (2).
3. Remove actuator.
Install
CAUTION
In the following step, never force the actuator drive collar into position. If the drive collar
position must be changed, perform the following procedures. 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 (1, Figure 30) onto end of door shaft so that mounting holes are properly aligned, if possible. If
actuator drive collar must be moved to allow alignment:
a. Place the actuator into its approximate position.
b. Connect a 9 Volt battery across pins A and F of the actuator connector, to rotate the drive collar.
(Reverse the connection to rotate the drive collar in the opposite direction.)
c. Allow the drive collar to rotate until it is aligned with the door shaft, and the actuator mounting screws
can be inserted. Then, disconnect battery.
2. Secure actuator to evaporator housing (2) using two screws.
3. Connect wiring connector to actuator for fresh/recirc air door.
NOTE – In the following step the actuator may also be recalibrated by disconnecting the vehicle battery
for 15 seconds; however, this method may result in disrupting other electrical equipment (radio presets,
etc.).
4. Recalibrate the fresh/recirc air door by disconnecting the HVAC control panel assembly for at least 15
seconds. Refer to HVAC CONTROL PANEL ASSEMBLY, REMOVE AND INSTALL (See FRONT HVAC
CONTROL PANEL ASSEMBLY, page 112).

AIR CONDITIONER (EVAPORATOR) HOUSING REMOVE AND INSTALL
8.10. AIR CONDITIONER (EVAPORATOR) HOUSING

Removal and installation of the evaporator housing requires the removal of other assemblies (such as cab
cowl tray). The assemblies that must be removed vary by vehicle model and engine combinations. Refer to
the appropriate section(s) in the Master Service Manual for additional procedures.
NOTE – If you were referenced to this procedure from the heater housing removal procedure; note that
on some vehicles it may be possible to unmount the evaporator housing and move it away from the
cowl enough to remove the heater housing mounting nuts (located behind the evaporator housing),
WITHOUT disconnecting the A/C lines. Inspect the vehicle being serviced and review the following
procedure to determine if complete removal of the evaporator housing is necessary. If it is determined
that disconnection of the A/C lines is unnecessary, review the following procedures and perform only
the steps required to remove the evaporator housing from the cowl. If this method is followed, it will
still be necessary to unclamp A/C lines to allow movement. When positioning the evaporator housing
out of the way DO NOT kink the A/C lines.
Remove
1. Remove cab cowl tray.
3. Disconnect wiring to thermistors (2 and 5, Figure 31) and remove strap locks, as necessary, to allow
connectors to be moved out of the way.
4. Unclip or remove clamps securing condenser-to-evaporator line (10) to evaporator housing (9).
5. Disconnect end of condenser-to-evaporator line from filter-drier (6).
6. Unclip clamps and/or strap locks securing evaporator-to-compressor line (7) to cowl.
7. Disconnect end of evaporator-to-compressor line from outlet thermistor line (5).

REMOVE AND INSTALL AIR CONDITIONER (EVAPORATOR) HOUSING
1. EVAPORATOR INLET 6. FILTER-DRIER

LINE (INCLUDES INPUT 7. EVAPORATOR-TO-COMPRESSOR
THERMISTOR) LINE
2. INPUT THERMISTOR 8. HEATER HOSES
3. EVAPORATOR OUTLET LINE 9. EVAPORATOR HOUSING
(INCLUDES LOW SIDE SERVICE 10. CONDENSER-TO-EVAPORATOR
PORT) LINE
4. THERMOSTATIC EXPANSION
VALVE
5. OUTPUT THERMISTOR
LINE (INCLUDES OUTPUT
THERMISTOR)
Figure 31 Evaporator Housing (Shown with Cowl Tray Removed)
8. Disconnect wiring connector to actuator motor for fresh/recirc air door (16, Figure 32).

1. EVAPORATOR INLET LINE 11. FILTER-DRIER

2. INPUT THERMISTOR 12. EVAPORATOR HOUSING
3. BOTTOM LOCKING PLATE 13. GASKET/SEAL, AIR INTAKE
4. THERMOSTATIC EXPANSION 14. GASKET, EVAPORATOR
VALVE HOUSING
5. TOP LOCKING PLATE 15. RECIRCULATE/FRESH AIR
6. T30 TORX HEAD SCREW DOOR
7. OUTPUT THERMISTOR LINE 16. ACTUATOR, RECIRC DOOR
8. OUTPUT THERMISTOR 17. DRAIN TUBES
9. 3 MM ALLEN HEAD CAPSCREW 18. EVAPORATOR CORE
(2) 19. BOLTS, FILTER-DRIER MTG
10. EVAPORATOR OUTLET LINE
Figure 32 Evaporator Housing Mounting and Components
9. Remove four nuts securing evaporator housing (12, Figure 32) to mounting studs on cowl.

10. Carefully remove evaporator housing from cowl.
NOTE – The need to perform additional steps is determined by the specific repair being performed.
Perform only the following steps that are required to transfer parts to a replacement housing or to replace
parts within the removed housing.
11. To remove recirc door actuator (16, Figure 32), remove two screws securing actuator to evaporator
housing (12).
12. Remove drain tubes (17, Figure 32) from evaporator housing.
13. Remove filter-drier, expansion valve, and associated a/c lines, as an assembly (Figure 33), as follows.
a. Remove screw securing filter-drier inlet line clamp to evaporator housing.
b. Remove nuts securing evaporator inlet and outlet lines (1 and 10, Figure 32) to the evaporator core
inlet and outlet fittings.
c. While supporting filter-drier (11, Figure 32), remove two mounting bolts (19) securing filter-drier to
evaporator housing.
CAUTION
While separating evaporator housing be careful not to damage fins or fittings on

evaporator core.
NOTE – The housing halves normally snap together and are secured with one screw (hi-lo thread);
however, mounting tabs are provided to allow assembling the halves with additional hi-lo thread screws
if the plastic snaps are damaged during disassembly. The mounting tabs are designed specifically to
use only hi-lo thread screws.
14. Separate housing halves by removing one or more hi-lo thread screws, releasing snap tabs, and pulling
halves straight away from each other.
15. Remove and discard mounting gaskets (13 and 14, Figure 32) if they are damaged during separation.
16. With housing separated, the evaporator core and/or fresh/recirculate air door may be removed.
NOTE – When replacing a damaged fresh/recirc air door verify that no parts remain lodged in the housing
or evaporator core.
17. When replacing a damaged evaporator housing (or housing half), transfer all good components (evaporator
core, fresh/recirculate door, door actuator, and drain tubes) from the damaged housing to the new housing.

Figure 33 Filter-Drier, Expansion Valve, and Associated A/C Lines
Install
NOTE – Depending on the level of disassembly required for the repair, some of the following steps may
not be necessary for each installation.
1. If refrigerant system is to be flushed or purged, perform that operation before reassembling the system.
Refer to PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM (See PURGING OR FLUSHING
THE AIR CONDITIONING SYSTEM, page 153).
2. When installing a new evaporator housing or reinstalling a housing that was removed for service, verify
that all internal components (evaporator core and fresh/recirculate door) are installed in the housing
before joining the housing halves.
NOTE – The housing halves normally snap together and are secured with one screw (hi-lo thread);
however, mounting tabs are provided to allow assembling the halves with additional hi-lo thread screws
if the plastic snaps are damaged during disassembly. The mounting tabs are designed specifically to
use only hi-lo thread screws.
3. Join housing halves by using snap tabs and one screw. If any snap tabs have been damaged, use
additional hi-lo thread screws in the molded joining tabs to securely join housing halves.
CAUTION
position must be changed, perform the following procedures. Forcing the drive collar
may result in a broken actuator.
4. If fresh/recirculate air door actuator (16, Figure 32), was previously removed, install actuator by rotating
door until flats on door shaft align with actuator hub, if possible. If actuator drive collar must be moved to
allow alignment:
a. Place actuator into its approximate position.
b. Connect a 9 Volt battery across pins A and F of actuator connector, to rotate drive collar. (Reverse
connection to rotate drive collar in opposite direction.)

c. Allow drive collar to rotate until it is aligned with door shaft, and actuator mounting screws can be
inserted. Then, disconnect battery.
5. Secure actuator to evaporator housing with two screws.
6. Install drain tubes (17, Figure 32).
7. Using a new gasket/seal (14, Figure 32), install evaporator housing (12) onto mounting studs located on
cowl using four nuts. Tighten to 5,400 to 7,600 N.mm (47.5 to 67.5 lbf-in).
CAUTION
In the following steps the filter-drier, expansion valve, and their associated a/c lines
are treated as an assembly. When installing this assembly care must be taken to align
connections properly and to not place undue stress on a/c line connections. Once
the filter-drier mounting bolts are loosely installed to support the assembly, the a/c
line connections should be torqued to provide proper joining and alignment, before
tightening the filter-drier mounting bolts.
8. Place new O-rings and C-plates on evaporator inlet and outlet lines (1 and 10, Figure 32).
9. Place filter-drier/expansion valve assembly (Figure 33) into its approximate position by inserting evaporator
inlet and outlet lines into evaporator core inlet and outlet fittings; AND loosely installing the two filter-drier
mounting bolts (19, Figure 33). (Filter-drier mounting bolts must be loose enough to allow proper alignment
of evaporator inlet and outlet fittings while supporting the weight of the filter-drier.)
10. Install nuts securing evaporator inlet and outlet lines to the evaporator core inlet and outlet fittings. Tighten
to 19,000 to 21,000 N.mm (170 to 190 lbf-in).
11. Tighten two mounting bolts securing filter-drier to evaporator housing. Tighten to 11,000 to 11,600 N.mm
(97 to 103 lbf-in).
12. Secure filter-drier inlet line clamp to evaporator housing using one screw.
13. Using a new O-ring and C-plate connect end of evaporator-to-compressor line (7, Figure 31) to outlet
thermistor line (5). Tighten to 19,000 to 21,000 N.mm (170 to 190 lbf-in).
14. Secure evaporator-to-compressor line to cowl using existing clamp(s).
15. Using a new O-ring and C-plate connect end of condenser-to-evaporator line (10, Figure 31) to filter-drier
inlet fitting. Tighten to 19,000 to 21,000 N.mm (170 to 190 lbf-in).
16. Secure condenser-to-evaporator line to evaporator housing (9, Figure 31) using existing clamps.
17. Connect wiring to thermistors (2 and 5, Figure 31) and secure wires in original position using strap locks.
18. Connect wiring connector to actuator motor (16, Figure 32) for fresh/recirc air door.
etc.).

FRESH/RECIRCULATE AIR DOOR REMOVE AND INSTALL
19. Recalibrate fresh/recirc air door by disconnecting HVAC control panel assembly for at least 15 seconds.
Refer to HVAC CONTROL PANEL ASSEMBLY, REMOVE AND INSTALL (See FRONT HVAC CONTROL
PANEL ASSEMBLY, page 112).
21. Install cab cowl tray/HVAC air inlet.
8.11. FRESH/RECIRCULATE AIR DOOR

The fresh/recirculate air door can be replaced after removing and separating the evaporator housing. Refer
to AIR CONDITIONER (EVAPORATOR) HOUSING, REMOVE AND INSTALL (See AIR CONDITIONER
(EVAPORATOR) HOUSING, page 91).
8.12. EVAPORATOR CORE

The evaporator core can be replaced after removing and separating the evaporator housing. Refer to
AIR CONDITIONER (EVAPORATOR) HOUSING, REMOVE AND INSTALL (See AIR CONDITIONER
(EVAPORATOR) HOUSING, page 91).
8.13. HEATER HOSES/LINES – FRONT HVAC SYSTEM
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
possible injury 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.
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 manor as the original equipment. Additional information for
the coolant system may be found in the appropriate section(s) in GROUP 12 of the Master Service Manual.
Some heater line connections now employ a peanut fitting (1, Figure 34) that is sealed with an O-ring (2) and
secured with one nut. Before installing a peanut fitting always verify that a new O-ring is in place.
Some engine options require a flow restrictor (3, Figure 35) in the top (inlet) heater hose where it connects to
the heater core at the cowl. When replacing this hose note whether the original hose contained a restrictor. If
necessary, install a new restrictor into the replacement hose before installing the hose onto the vehicle.
Depending on the vehicle model/engine combination, replacement of specific heater lines may require the
removal of nearby assemblies to gain access to the hoses/lines. Refer to the appropriate section(s) in the
Master Service Manual for additional procedures. For information on draining and filling engine coolant, refer
to the appropriate COOLING section in GROUP 12 of the Master Service Manual.

REMOVE AND INSTALL HEATER TRIM COVER
1. PEANUT FITTING 2. O-RING

Figure 34 Typical Coolant Line Peanut Fitting
1. EVAPORATOR HOUSING 3. FLOW RESTRICTOR

2. HEATER CORE TUBES 4. HEATER HOSES
Figure 35 Flow Restrictor in Heater Hose
8.14. HEATER TRIM COVER

The heater 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 heater trim cover may require the
removal of other trim panels. Refer to the appropriate CAB section(s) in GROUP 16 of the Master Service
Manual for additional procedures.

HEATER TRIM COVER REMOVE AND INSTALL
1. HEATER TRIM COVER 2. FRONT VIEW

Figure 36 Heater Trim Cover
Remove
1. Remove fuse panel cover from passenger side instrument panel by pulling top of cover away from IP to
release spring clips, then lift cover up.
2. Remove trim panels, as necessary, to gain access to mounting screws for heater trim cover (1, Figure 36).
3. Remove nine screws from heater trim cover.
4. Remove cover by pulling it straight back.

REMOVE AND INSTALL ACTUATOR, TEMPERATURE BLEND DOOR
Install
1. Secure heater trim cover (1, Figure 36) to heater housing with nine screws.
2. Install all additional trim panels removed to gain access to heater 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.
8.15. ACTUATOR, TEMPERATURE BLEND DOOR

Accessing the temperature blend door actuator may require the removal of trim panels not described in this
manual. Refer to the appropriate CAB section(s) in Group 16 of the Master Service Manual for additional
procedures.
Remove
2. Remove trim panels, as necessary, to gain access to mounting screws for heater trim cover (4, Figure 37).
4. Remove heater trim cover by pulling it straight back.
5. Disconnect electrical plug connected to temperature blend door actuator (6).
6. Remove two screws securing actuator to blower scroll housing (3), and pull actuator straight off of
temperature blend door shaft.
Install
CAUTION
position must be changed, follow the following procedures. 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, if possible, then
carefully slip the actuator onto end of door shaft so that mounting holes are properly aligned. If actuator
drive collar must be moved to allow alignment:
b. To rotate drive collar, connect a 9 Volt battery across the active pins of the actuator connector (check
mating connector if necessary). (Reverse connection to rotate drive collar in opposite direction.)
2. Secure actuator to blower scroll housing (3, Figure 37) using two screws.
3. Connect electrical control plug to temperature blend door actuator (6).

ACTUATOR, TEMPERATURE BLEND DOOR REMOVE AND INSTALL
4. Secure heater trim cover (4) to heater housing with nine screws.
1. HEATER HOUSING 7. LINEAR POWER MODULE

2. HEATER CORE (BLOWER SPEED CONTROL)
3. BLOWER SCROLL HOUSING 8. BLOWER ASSEMBLY
4. HEATER TRIM COVER 9. ACTUATOR, MODE CONTROL
5. BLOWER WIRE HARNESS DOOR
6. ACTUATOR, TEMPERATURE 10. LINEAR POWER MODULE
BLEND DOOR COVER
Figure 37 Heater Unit Exploded View
etc.).
7. Recalibrate temperature blend door by disconnecting HVAC control panel assembly for at least 15
seconds. Refer to HVAC CONTROL PANEL ASSEMBLY, REMOVE AND INSTALL (See FRONT HVAC
CONTROL PANEL ASSEMBLY, page 112).

REMOVE AND INSTALL ACTUATOR, MODE DOOR
8.16. ACTUATOR, MODE DOOR

Accessing the mode door actuator may require the removal of trim panels not described in this manual. Refer
to the appropriate CAB section(s) in Group 16 of the Master Service Manual for additional procedures.
Remove
2. Remove trim panels, as necessary, to gain access to heater trim cover (4, Figure 37) mounting screws.
4. Remove heater trim cover by pulling it straight back.
5. Disconnect electrical plug connected to mode door actuator (9).
6. Remove two screws securing actuator (9) to heater housing (1), and pull actuator straight off of mode
door shaft.
Install
CAUTION
position must be changed, follow the following procedures. Forcing the drive collar may
result in a broken actuator.
1. Carefully slip actuator (9, Figure 37) onto end of mode door shaft so that mounting holes are properly
aligned, if possible. If actuator drive collar must be moved to allow alignment:
2. Secure actuator to heater housing (1) using two screws.
3. Connect electrical control plug to mode door actuator motor (9).
4. Secure heater trim cover (4) to heater housing with nine screws.
etc.).

BLOWER SCROLL HOUSING REMOVE AND INSTALL
7. Recalibrate mode door by disconnecting HVAC control panel assembly for at least 15 seconds. Refer
to HVAC CONTROL PANEL ASSEMBLY, REMOVE AND INSTALL (See FRONT HVAC CONTROL
PANEL ASSEMBLY, page 112).
8.17. BLOWER SCROLL HOUSING

The blower scroll housing must be removed prior to removing the heater core, the heater core housing, or
any of the components within the blower scroll housing. Accessing the blower scroll housing may require the
removal of trim panels not described in this manual.
Remove
1. Remove fuse panel cover, other trim covers (as necessary), and heater trim cover. Refer to HEATER TRIM
COVER, REMOVE AND INSTALL (See HEATER TRIM COVER, page 98).
NOTE – Refer to Figure 37 while performing the following steps.
2. Disconnect electrical plug connected to the temperature door actuator (6, Figure 37).
3. Remove four screws securing blower scroll housing (3) to heater housing assembly (1).
NOTE – In the following step wiring connections to linear power module and blower motor must be
disconnected once blower scroll housing is partially separated from heater housing.
4. Carefully separate blower scroll housing (3) from heater housing (1).
5. With blower scroll housing removed, blower assembly (8), linear power module (7), and heater core
(2) are accessible for service.
6. When replacing a damaged scroll housing, transfer all good components: blower assembly, linear power
module, and temperature door actuator (6), from damaged housing to new housing. Refer to appropriate
procedures in this manual for additional information.
Install
NOTE – Depending on the level of disassembly required for the repair, some of the following steps may
not be necessary for each installation.
1. If removed previously, install blower assembly (8, Figure 37), using three screws.
2. If removed previously, install linear power module (7) and LPM cover (10), using two screws.
3. If temperature door actuator was removed previously, install actuator by rotating door until flats on door
shaft align with actuator drive collar, if possible; then carefully slip the actuator (6) onto end of door shaft so
that mounting holes are properly aligned. If actuator drive collar must be moved to allow alignment:

REMOVE AND INSTALL LINEAR POWER MODULE AND BLOWER ASSEMBLY – FRONT HVAC SYSTEM
4. Secure actuator to blower scroll housing (3) using two screws.
5. Before installing blower scroll housing, verify that heater core (2) is installed in heater housing (1). To
install the heater core refer to HEATER CORE, REMOVE AND INSTALL (See HEATER CORE – FRONT
HVAC SYSTEM, page 104).
6. Position blower scroll housing so that electrical connections to linear power module and blower motor
can be connected. After making connection, secure any excess wire so that it will not interfere with
installation of blower scroll housing.
NOTE – When installing the blower scroll housing in the following step, pay close attention to how the
edges of the housing walls mate up with the walls of the heater housing.
7. Carefully install blower scroll housing so that housing walls interlock with walls of heater housing, and
mounting holes line up.
8. Secure blower scroll housing (3) to heater housing using four screws.
9. Connect electrical control plug to temperature blend door actuator (6).
10. Install heater trim cover, other trim covers (as necessary), and fuse panel cover. Refer to HEATER TRIM
COVER, REMOVE AND INSTALL (See HEATER TRIM COVER, page 98).
8.18. LINEAR POWER MODULE AND BLOWER ASSEMBLY – FRONT HVAC SYSTEM
Remove
1. Remove blower scroll housing (3, Figure 37), refer to BLOWER SCROLL HOUSING, REMOVE AND
INSTALL (See BLOWER SCROLL HOUSING, page 103).
2. Detach linear power module (7) and LPM cover (10) from blower scroll housing (3) by removing two
mounting screws.
3. Remove blower assembly (8) by removing the three screws securing it to the scroll housing (3).
Install
1. Install blower assembly (8, Figure 37) by securing it to the scroll housing (3) with three screws.
2. Secure linear power module (7) and LPM cover (10) to blower scroll housing (3) with two screws.
3. Install blower scroll housing, refer to BLOWER SCROLL HOUSING, REMOVE AND INSTALL (See
BLOWER SCROLL HOUSING, page 103).
8.19. HEATER CORE – FRONT HVAC SYSTEM

Access to the heater hoses may require the removal of nearby assemblies. The assemblies that must be
removed vary by vehicle model and engine combinations. Refer to the appropriate section(s) in the Master
Service Manual for additional procedures.

HEATER CORE – FRONT HVAC SYSTEM REMOVE AND INSTALL
Remove
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
possible injury 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
section in GROUP 12 of the Master Service Manual.
2. Remove cab cowl tray.
NOTE – Before removing heater hoses in the following step, label hoses to insure correct installation.
3. Disconnect both heater hoses (2, Figure 38) from heater core tubes on engine side of cowl.
4. From inside cab, remove blower scroll housing. Refer to BLOWER SCROLL HOUSING, REMOVE AND
INSTALL (See BLOWER SCROLL HOUSING, page 103).
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.
5. Pull heater core (5) out of heater housing (6).

REMOVE AND INSTALL HEATER CORE – FRONT HVAC SYSTEM
1. VIEW OF COWL (UNDER HOOD) 5. HEATER CORE

2. HEATER HOSES 6. HEATER HOUSING
3. HEATER TRIM PANEL 7. SEAL, HEATER CORE TUBES
4. BLOWER SCROLL HOUSING 8. FLOW RESTRICTOR
Figure 38 Heater Component Locations
Install
NOTE – In the following step insure that the heater housing seal that surrounds the heater core tubes
does not become dislodged while installing the heater core.
1. From inside cab, carefully position heater core (5, Figure 38) in heater housing (6) so that tube ends of
core protrude through dash panel seal (7).
2. Install blower scroll housing (4) and heater trim panel. Refer to BLOWER SCROLL HOUSING, REMOVE
AND INSTALL (See BLOWER SCROLL HOUSING, page 103).
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 (2) and clamps.
4. Fill cooling system with coolant. Refer to the appropriate COOLING section in GROUP 12 of the Master
Service Manual, or the Operator Manual supplied with the vehicle.

HEATER HOUSING REMOVE AND INSTALL
NOTE – Verify that coolant system is leak-free before proceeding to the following steps.
5. Install cab cowl tray.
8.20. HEATER HOUSING

NOTE – Removing and installing the heater housing requires detaching and raising the Instrument
Panel (IP), and removing the evaporator housing from the cowl. Replacement of the heater housing is
necessary only if either the mode door mechanism or the housing itself is damaged. In either case the
entire heater housing is replaced as an assembly.
The Instrument Panel (IP) must be detached and raised prior to removing the heater housing. Accessing the
IP mounting hardware may require the removal of trim panels not described in this manual. The procedures
provided here cover a basic installation. Refer to the appropriate CAB section in Group 16 of the Master
Service Manual for additional procedures.
Remove
1. Inside cab, remove A-pillar trim from driver’s side.
2. Remove assist handle and A-pillar trim from passenger’s side.
3. Remove or disconnect trim panels from under IP to allow access to IP mounting hardware removed
in the following steps.
4. 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 section in Group 16 of the Master
Service Manual. Typically, the following mounting hardware must be removed:
a. Remove five bolts (1, Figure 39) securing top of IP to dash panel (located near windshield).
b. Remove two bolts (2) securing steering column module to IP.
c. Remove two bolts (3) securing each side of IP to dash panel.

REMOVE AND INSTALL HEATER HOUSING
1. TOP INSTRUMENT PANEL 4. TOP VIEW

MOUNTING BOLTS 5. BOTTOM VIEW
2. STEERING MODULE BOLTS
3. SIDE INSTRUMENT PANEL
MOUNTING BOLTS
Figure 39 Instrument Panel Mounting
5. To gain access to mounting nuts (14, Figure 40) for the heater housing (1), the evaporator housing (11)
must be removed from the cowl. Refer to AIR CONDITIONER (EVAPORATOR) HOUSING, REMOVE
AND INSTALL (See AIR CONDITIONER (EVAPORATOR) HOUSING, page 91).

6. Remove heater core (5) from heater housing, refer to HEATER CORE, REMOVE AND INSTALL (See
HEATER CORE – FRONT HVAC SYSTEM, page 104).
7. Disconnect HVAC wiring harness (4) from instrument panel wiring harness.
NOTE – It may be possible to remove the heater housing without disconnecting the passenger side floor
duct (6); however, the following steps are provided as an alternative.
NOTE – The driver side duct is connected to the heater housing 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 heater housing. There is one gasket (12)
where the housing mounts to the dash panel; and another gasket (2) where the IP rests on top of the
housing. If the gaskets are damaged when moving the housing or the IP, they must be replaced.
NOTE – In the following step, it will be necessary to raise the IP slightly while removing the heater
housing. This may require a second or third person.
8. Lift the IP and support it so that it provides the greatest amount of clearance for removing heater housing.
9. Disconnect passenger side floor duct (Items 2, 3, and 5, Figure 41) from heater housing.
a. Bottom section of duct is mounted to side of housing with one screw (4). After removing screw, bottom
section may be removed to provide better access to top section.
b. Top section of duct is connected to housing with a snap mount (slip-lock), and is disconnected
by pulling duct away from housing.
10. Remove mounting screw (8, Figure 40) from driver side floor duct (7) and move duct left to disconnect
it from housing.
11. On engine side of dash panel, remove four nuts (10) from heater housing mounting studs.
12. Pull heater housing to rear (to allow its mounting studs to clear dash panel). Heater housing (1) should
now be clear to slide out from under IP.
13. If mode door actuator (3) is being transferred to a replacement heater housing, remove two screws
securing actuator to housing (1), and pull actuator straight off of mode door shaft.

REMOVE AND INSTALL HEATER HOUSING
1. HEATER HOUSING 10. DRIVER SIDE DUCT DIFFUSER

2. GASKET/SEAL, HEATER 11. DASH PANEL
HOUSING TOP FACE REINFORCEMENT ASSEMBLY
3. ACTUATOR, MODE DOOR 12. MOUNTING NUTS, HEATER
4. DASH WIRING HARNESS HOUSING
5. HEATER CORE 13. EVAPORATOR HOUSING
6. DASH PANEL ASSEMBLY 14. TORQUE ALL NUTS TO 57.5
7. PASSENGER FLOOR DUCT LBF-IN (6.5 N•m)
8. DRIVER SIDE DUCT 15. GASKET/SEAL, HEATER
9. DRIVER DUCT MOUNTING HOUSING COWL FACE
SCREW
Figure 40 Heater Housing Mounting Diagram

1. HEATER HOUSING ASSEMBLY 4. MOUNTING SCREW

2. PASSENGER SIDE DUCT, 5. DIFFUSER
UPPER
3. PASSENGER SIDE DUCT,
LOWER
Figure 41 Passenger Side Air Duct
Install
NOTE – It may be possible to install the heater housing with the passenger side floor duct already
installed; however, the following procedure is provided as an alternative installation method.
1. Carefully slip mode door actuator (3, Figure 40) from removed housing, onto end of mode door shaft so that
mounting holes are properly aligned, if possible. If actuator drive collar must be moved to allow alignment:
2. Secure actuator to heater housing using two screws.
NOTE – In the following step, the IP must be raised slightly while installing the heater housing. This may
require a second or third person. To insure proper alignment and compression of the heater housing
top gasket, the IP must remain raised until the heater housing is securely mounted.
NOTE – While performing the following steps be careful not to damage the gaskets when moving the
heater housing or the IP.
3. Lift and brace IP so that it provides adequate clearance for installing heater housing.
4. With IP raised, carefully position heater housing (1, Figure 40) under passenger side instrument panel, so
that its mounting studs protrude through matching holes in dash panel.

REMOVE AND INSTALL FRONT HVAC CONTROL PANEL ASSEMBLY
5. On engine side of dash panel, secure heater housing by installing four nuts (10) on mounting studs.
Tighten to 5,400 to 7,600 N.mm (47.5 to 67.5 lbf-in).
6. Connect top section of passenger side floor duct (2, Figure 41) to outlet of heater housing (1). This
is a slip-lock type snap joint.
7. Slip bottom section of passenger side floor duct (3) onto top section and secure to side of heater housing
using one screw (4). Attach diffuser (5) if it was removed.
NOTE – The driver side duct is connected to the heater housing with a snap mount (slip-lock).
8. Connect driver’s side floor duct (7, Figure 40) to heater housing by slipping end of duct over heater
housing outlet. Secure floor duct to dash panel under instrument panel using its mounting screw (8).
Attach diffuser (9) if it was removed.
9. Carefully allow IP to return to its normal resting position.
10. Connect HVAC wiring harness (4) to instrument panel wiring harness.
11. Install heater core (5) and all related heater components, refer to HEATER CORE, REMOVE AND
INSTALL (See HEATER CORE – FRONT HVAC SYSTEM, page 104).
12. Install evaporator housing (11) onto cowl. Refer to AIR CONDITIONER (EVAPORATOR) HOUSING,
REMOVE AND INSTALL (See AIR CONDITIONER (EVAPORATOR) HOUSING, page 91).
13. Install IP mounting hardware that was removed earlier. More complete procedures for installing the IP
can be found in the appropriate CAB section in Group 16 of the Master Service Manual. Typically, the
following mounting hardware must be installed:
a. Install two bolts (3, Figure 39) securing each side of IP to dash panel.
b. Install two bolts (2) securing steering column module to IP.
c. Install five bolts (1) securing top of IP to dash panel (located near windshield).
14. Install or reconnect any trim panels under the IP that were removed to provide access to IP mounting
hardware.
15. Inside cab, install assist handle and A-pillar trim on passenger’s side.
16. Install A-pillar trim on driver’s side.
8.21. FRONT HVAC CONTROL PANEL ASSEMBLY

Remove
CAUTION
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.

HVAC CONTROLS (SLEEPER) REMOVE AND INSTALL
2. Remove four screws securing HVAC control panel assembly to IP.
1. TORQUE TO 20.35 TO 26.55

LBF-IN (23.00 TO 30.00 N•mm)
Figure 42 Control Panel Mounting – Front HVAC System
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.
Install
CAUTION
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.
2. With HVAC control panel assembly correctly oriented, insert it straight into IP mounting cavity.
3. Verify that control panel assembly is fully seated, then secure assembly using four screws. Tighten
screws to the torque indicated.
4. Install bezel in the center section of IP by aligning spring clips and carefully pressing bezel into position.
8.22. HVAC CONTROLS (SLEEPER)

CAUTION
Place the ignition key in the OFF position before removing or installing the sleeper HVAC
controls.

REMOVE AND INSTALL HVAC CONTROLS (SLEEPER)
Remove
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 connections 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.
1. ANALOG 2. DIGITAL
Figure 43 Sleeper HVAC Control Panels
Install, Rotary (Digital) Controls
1. Insert digital panel from the rear of the control panel and secure with 4 screws from the front of the
control panel.
2. Install electrical connector to rear of digital panel. Ensure that connector locks are engaged.
3. Secure control panel to its mounting bracket with 4 screws (1 in each corner) .
4. Install the trim bezel onto the sleeper control panel.
Install, Rotary (Analog) Controls
1. Insure that one locknut is threaded onto the shaft of the new control. Transfer from removed control, if
necessary.

HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT REMOVE AND INSTALL
2. Insert control from the rear of the control panel and secure with locknut from the front of the control panel.
3. Install electrical connector to control. Ensure that connector locks are engaged.
4. Install control knob.
5. Secure control panel to its mounting bracket with 4 screws (1 in each corner) .
6. Install the trim bezel onto the sleeper control panel.
8.23. HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT

Remove
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.
3. Under the cab, use clamping pliers to pinch both heater hoses closed (Figure 44). 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.
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 (Figure 45). Plug all open lines.
9. Remove the front hose hanger and retain the heat shield for use during installation (Figure 45).
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 (Figure 46).
11. Remove the disconnected line(s) towards the rear of the cab.
Install
1. With the ends sealed to prevent contamination, maneuver the new line into position from the rear (Figure
46).
2. Under the hood, connect the new heater line to the front heater line ’T’ fitting (Figure 45).
3. Under the vehicle, position the heater lines in the 3 middle line hangers. Leave the hangers loose at this
time.

REMOVE AND INSTALL HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT
4. Connect the heater core inlet/outlet hoses to the heater core tubes.
5. Remove all clamping pliers used to pinch the heater lines closed.
6. With the A/C and heater lines positioned correctly, loosely install the rear AC/heater line hanger.
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 45).
8. Verify that heater and A/C lines are positioned correctly while tightening all remaining hanger bolts.
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.
Figure 44 Heater/AC Lines Clamped Under Cab

HEATER HOSE ASSEMBLY – TO REAR HVAC UNIT REMOVE AND INSTALL
1. HEAT SHIELD 4. HEATER SUPPLY LINE

2. A/C DISCHARGE LINE 5. HEATER RETURN LINE
3. A/C SUCTION LINE 6. FRONT HOSE HANGER
Figure 45 Heater/AC Hose Connections Under Hood

REMOVE AND INSTALL A/C HOSE ASSEMBLY – TO REAR HVAC UNIT
Figure 46 Heater/AC Lines Routing Under Cab
8.24. A/C HOSE ASSEMBLY – TO REAR HVAC UNIT

Remove
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 (Figure 45).
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.
4. From under the vehicle, remove the rear AC/heater line hanger (Figure 47).
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.

A/C HOSE ASSEMBLY – TO REAR HVAC UNIT REMOVE AND INSTALL
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 (Figure 47).
6. Remove the front hose hanger and retain the heat shield for use during installation (Figure 45).
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 (Figure 46). Leave the hangers connected
to provide support for the heater lines.
8. Remove the disconnected line(s) towards the rear of the cab.
Figure 47 Rear A/C and Heater Line Connections
Install
1. With the ends sealed to prevent contamination, maneuver the new line into position from the rear.
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 19,000 to 21,000 N.mm (170 to 190 lbf-in).
3. Under the vehicle, position the A/C lines in the 3 middle line hangers. Leave the hangers loose at this time.
NOTE – In the following step, keeping the A/C lines free of the hanger allows better alignment with the
TXV during installation.
4. Before securing the A/C lines with the rear hanger, connect them to the TXV using new O-rings, the lower
lock plate, and the lock plate retaining nut. Tighten to 9,000 to 10,000 N.mm (80 to 90 lbf-in). Refer
to Figure 47 and Figure 48.
5. Loosely install the rear hanger.
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 (Figure 45).
7. Verify that heater and A/C lines are positioned correctly while tightening all remaining hanger bolts
(Figure 46).

REMOVE AND INSTALL THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT
Figure 48 Connecting A/C Lines to Rear Thermal Expansion Valve
8.25. THERMOSTATIC EXPANSION VALVE – REAR HVAC UNIT

Remove
NOTE – It may be easier to disconnect the hoses in the following step if the rear AC/heater line hanger
is loosened or removed.
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. Refer to Figure 47 and Figure 48.
3. Remove 2 Torx head screws (2, Figure 49) securing TXV to upper lock plate. Remove TXV. Plug all open
A/C lines and tape over TXV ports to protect from contamination.

BLOWER/FAN ASSEMBLY – REAR HVAC UNIT REMOVE AND INSTALL
1. UPPER LOCKING PLATE 2. TORX HEAD SCREWS

(LOCATED INSIDE REAR HVAC 3. LOCK PLATE RETAINING NUT
UNIT)
Figure 49 Installation of Rear Thermal Expansion Valve
Install
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 2 Torx head screws removed earlier. Tighten to 4,000 to 4300 N.mm (35.4 to 38.0 lbf-in)
Refer to Figure 49.
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 9,000 to 10,000 N.mm (80 to 90 lbf-in).
3. With the A/C and heater lines positioned correctly, install and tighten the rear AC/heater line hanger
(Figure 47).
8.26. BLOWER/FAN ASSEMBLY – REAR HVAC UNIT

Remove
1. Set ignition key to OFF
2. Through the passenger side access door, disconnect blower electrical connector from linear power
module (6, Figure 50).
3. Remove 4 Torx head screws securing blower to rear HVAC unit.
4. Remove blower (5).

REMOVE AND INSTALL FILTER ELEMENT – REAR HVAC UNIT
Install
1. Position the blower assembly onto the rear HVAC unit and secure with the 4 Torx head screws removed
earlier.
2. Plug the blower electrical connector into the linear power module.
1. REAR HVAC CONTROLLER 4. FILTER ELEMENT

2. TEMPERATURE BLEND DOOR 5. BLOWER/FAN ASSEMBLY
ACTUATOR 6. LINEAR POWER MODULE
3. OUTLET DUCT TEMPERATURE 7. FRONT OF VEHICLE
SENSOR
Figure 50 Rear HVAC Unit Component Locations
8.27. FILTER ELEMENT – REAR HVAC UNIT

Remove
1. Raise and support bunk.
2. Remove filter element (4, Figure 50) from the cavity in the rear HVAC unit.
Install
1. With the pleats running horizontally, insert the filter element into the cavity in the rear HVAC unit.
2. Insure that the element is fully seated.
3. Carefully lower the bunk.
8.28. OUTLET DUCT TEMPERATURE SENSOR – REAR HVAC UNIT

NOTE – Refer to Figure 50 and Figure 51 while performing the following Remove and Install procedures.

LINEAR POWER MODULE – REAR HVAC UNIT REMOVE AND INSTALL
Remove
2. Disconnect the electrical connector to the outlet duct temperature sensor (5, Figure 51).
3. Grasp the sensor body and pull it straight out of the rear HVAC unit housing.
Install
1. Push the sensor into the rear HVAC unit housing until it is retained by friction .
2. Connect the electrical connector to the outlet duct temperature sensor.
1. REAR HVAC UNIT 5. OUTLET DUCT TEMPERATURE

2. REAR LINEAR POWER MODULE SENSOR
3. REAR HVAC CONTROLLER
4. TEMPERATURE BLEND DOOR
ACTUATOR
Figure 51 Rear HVAC Unit Component Mounting
8.29. LINEAR POWER MODULE – REAR HVAC UNIT

Remove
1. Set ignition key to OFF.
2. Through the passenger side access door, disconnect the 2 electrical connectors from Linear Power
Module (LPM).
3. Remove 2 Torx head screws securing LPM (2, Figure 51) to rear HVAC unit.
4. Remove LPM.

REMOVE AND INSTALL BLEND DOOR ACTUATOR – REAR HVAC UNIT
Install
1. Position the LPM assembly onto the rear HVAC unit and secure with the 2 Torx head screws removed
earlier.
2. Connect the 2 electrical connectors to the LPM.
8.30. BLEND DOOR ACTUATOR – REAR HVAC UNIT

Remove
2. Inside the sleeper, raise and support the lower bunk.
3. Disconnect the electrical connector on the blend door actuator (2, Figure 50) on the top of the rear
HVAC unit.
4. Remove the 3 screws securing the blend door actuator to the rear HVAC unit. Remove the actuator (4,
Figure 51).
Install
1. Position the blend door so that it will align with the drive collar on the blend door actuator as it is installed.
2. Install the blend door actuator and secure it with the 3 screws removed earlier.
3. Connect the electrical connector to the blend door actuator.
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.
8.31. SLEEPER HVAC CONTROLLER – REAR HVAC UNIT

Remove
3. Disconnect the electrical connector from the rear HVAC controller (1, Figure 50).
4. Remove 2 screws securing controller to rear HVAC unit.
5. Remove controller (3, Figure 51).
Install
1. Position the rear HVAC controller onto the rear HVAC unit and secure with the 2 screws removed earlier.

HEATER CORE – REAR HVAC UNIT REMOVE AND INSTALL
2. Connect the electrical connector to the controller.
3. Calibration of the blend door actuator will occur the next time the IGN key is set to IGN or ACCESSORY.
8.32. HEATER CORE – REAR HVAC UNIT

Remove
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. Refer to Figure 52.
2. Place a suitable drain pan under the heater core connections.
3. Disconnect the rubber hoses from the heater core tubes (Figure 53). Allow coolant from heater core
to drain into container.
Figure 52 Heater/AC Lines Clamped Under Cab

REMOVE AND INSTALL HEATER CORE – REAR HVAC UNIT
Figure 53 Rear A/C and Heater Line Connections
4. Inside the cab, raise and support the lower bunk.
5. Remove the 2 screws securing the heater core cover (1, Figure 54). 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 clamp plate (3, Figure 54) securing the heater core inlet and outlet tubes. Disconnect the
tubes from the core, and rotate them out of the way.
7. Remove the heater core (2, Figure 54).
8. If necessary, remove the heater core inlet and outlet tubes (4, Figure 54).

HEATER CORE – REAR HVAC UNIT REMOVE AND INSTALL
1. HEATER CORE COVER 4. HEATER CORE INLET/OUTLET

2. REAR HEATER CORE TUBES
3. CLAMP PLATE FOR
INLET/OUTLET TUBES
Figure 54 Rear Heater Core Installation
Install
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 (4, Figure 54) and rotate
them out of the way.
2. Install the heater core (2, Figure 54).
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.
3. Using new O-rings, insert the heater core inlet and outlet tubes into the core and secure with the clamp
plate.
4. Install heater core cover (1, Figure 54) and secure with 2 screws.
5. 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 53) if removed earlier.
6. Remove the clamping pliers used to pinch the heater lines closed.

REMOVE AND INSTALL TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT
8.33. TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT

Remove
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. Refer to Figure 52.
3. With a clean drain pan positioned under the heater core connections, disconnect the hoses from the heater
core tubes (Figure 53). Plug all open tubes/hoses.
5. Remove 4 Torx head screws securing blower to rear HVAC unit, and remove blower (5, Figure 50).
7. Remove the rear heater core and heater core inlet/outlet tubes (Figure 54), as follows:
a. Remove the 2 screws securing the heater core cover. Remove the cover.
NOTE – In the following step it may be easier to remove the clamp plate after lifting the heater
b. Remove the clamp plate securing the heater core inlet and outlet tubes to the core. Disconnect the
tubes from the core, and rotate them out of the way. Retain the clamp plate and mounting screw.
c. Remove the heater core.
d. Remove the heater core inlet and outlet tubes.
8. Disconnect all remaining electrical connections to the rear HVAC unit.

a. Rear HVAC controller – 1 connector
b. blend door actuator – 1 connector
c. outlet duct temperature sensor – 1 connector
d. rear linear power module – 1 connector (harness), blower connector was removed with blower.
9. Remove the rear HVAC unit outlet duct (1 screw). Refer to Figure 55. NOTE: It may be helpful to loosen
or remove some connected duct work.

TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT REMOVE AND INSTALL
1. OUTLET DUCT, REAR HVAC 3. AIR INLET

UNIT 4. AIR OUTLET VENT
2. REAR HVAC UNIT
Figure 55 Location of Rear HVAC Unit
10. Remove the filter element (3, Figure 55) from the air intake of the 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 (6, Figure 56).

REMOVE AND INSTALL TEMPERATURE BLEND AIR DOOR – REAR HVAC UNIT
1. THERMOSTATIC EXPANSION 5. EVAPORATOR CORE

VALVE (TXV) 6. TEMPERATURE BLEND AIR
2. FOAM SEAL, AIR INLET DOOR
3. UPPER LOCK PLATE FOR TXV 7. FOAM SEAL, AIR OUTLET
4. FOAM SEAL, EVAPORATOR
TUBES
Figure 56 Internal Components of the Rear HVAC Unit
Install
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 56).
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.
3. Install 15 screws securing the top housing of the HVAC unit to the bottom housing.
4. Install the rear HVAC unit outlet air duct (1 screw). Verify that all related duct work is positioned and
secured correctly (Figure 55).
5. Install the rear heater core and heater core inlet/outlet tubes (Figure 54), as follows.

EVAPORATOR CORE – REAR HVAC UNIT REMOVE AND INSTALL
a. Noting the position of the foam spacer and seal (below the housing), carefully install the heater core
inlet and outlet tubes and rotate them out of the way.
b. Install the heater core.
c. Using new O-rings, insert the heater core inlet and outlet tubes into the core. Secure with the clamp
plate and screw removed earlier.
d. Install heater core cover and secure with 2 screws.
6. Through the passenger side access door, position the blower assembly (5, Figure 50) onto the rear HVAC
unit and secure with the 4 Torx head screws removed earlier.
7. Plug the blower electrical connector into the linear power module (6, Figure 50).
8. Connect all electrical connections to the rear HVAC unit.

a. blend door actuator – 1 connector
b. outlet duct temperature sensor – 1 connector
c. linear power module – 1 connector (harness), blower connector was installed with blower.
d. Rear HVAC controller – 1 connector
9. 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 53).
8.34. EVAPORATOR CORE – REAR HVAC UNIT

Remove
3. If vehicle is equipped with aerodynamic side skirts, remove the rear passenger side skirt.
4. From under the vehicle, disconnect the A/C lines from the Thermostatic Expansion Valve (TXV). Refer to
Figure 57. Retain the lock plate and lock plate retaining nut. Plug all open tubes/ports.

REMOVE AND INSTALL EVAPORATOR CORE – REAR HVAC UNIT
5. Remove 2 Torx head screws securing TXV to upper lock plate (2, Figure 58). Remove TXV and tape
over ports to protect from contamination.
1. UPPER LOCKING PLATE 2. TORX HEAD SCREWS

(LOCATED INSIDE REAR HVAC 3. LOCK PLATE RETAINING NUT
UNIT)
Figure 58 Installation of Rear Thermal Expansion Valve
6. Using clamping pliers, pinch the rubber section of the rear heater lines closed. Place the clamps several
inches from the metal/rubber joint (Figure 52).
7. With a clean drain pan positioned under the heater core connections, disconnect the hoses from the heater
core tubes. Plug all open tubes/hoses.
9. Remove 4 Torx head screws securing blower to rear HVAC unit, and remove blower (5, Figure 50)..

EVAPORATOR CORE – REAR HVAC UNIT REMOVE AND INSTALL
11. Remove the rear heater core and heater core inlet/outlet tubes (Figure 54), as follows:
NOTE – In the following step it may be easier to remove the clamp plate after lifting the heater
tubes from the core, and rotate them out of the way. Retain the clamp plate and mounting screw.
12. Disconnect all remaining electrical connections to the rear HVAC unit.
d. rear linear power module – 1 connector (harness), blower connector was removed with blower.
13. Remove the rear HVAC unit outlet duct (1 screw). Refer to Figure 55. NOTE: It may be helpful to loosen
or remove some connected duct work.
14. Remove the filter element (4, Figure 50) from the air intake of the rear HVAC unit.
15. 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.
16. Lift the top housing off of the rear HVAC unit.
17. Note the location of all seals associated with the evaporator core and expansion valve. They must be
replaced correctly during installation.
18. Remove 1 screw securing the expansion valve upper lock plate to the bottom housing (Figure 56).
19. Lift the evaporator core from the bottom housing. Retain the upper lock plate and all foam seals for
use during installation.
Install
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.

REMOVE AND INSTALL EVAPORATOR CORE – REAR HVAC UNIT
1. From inside the sleeper, install the evaporator core into the bottom housing (Figure 56).
2. Insure that all seals associated with the evaporator core and expansion valve are in place. Secure the
expansion valve upper lock plate to the bottom housing with the 1 screw removed earlier.
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.
3. 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.
4. Install 15 screws securing the top housing of the HVAC unit to the bottom housing.
secured correctly (Figure 55).
c. Using new O-rings, insert the heater core inlet and outlet tubes into the core. Secure with the clamp
plate and screw removed earlier.
7. Through the passenger side access door, position the blower assembly onto the rear HVAC unit and
secure with the 4 Torx head screws removed earlier (Figure 50).
8. Plug the blower electrical connector into the linear power module.

c. linear power module – 1 connector (harness), blower connector will be installed with blower.
10. From under the vehicle, install new lubricated O-rings onto the evaporator tubes; then install the
Thermostatic Expansion Valve (TXV) onto the evaporator tubes (Figure 59). Secure the TXV to the upper
locking plate with the 2 Torx head screws removed earlier. Tighten to 4,000 to 4300 N.mm (35.4 to
38.0 lbf-in).
11. Using new O-rings, connect the A/C lines to the TXV. Secure with the lower locking plate and the lock plate
retaining nut (Figure 57). Tighten to 9,000 to 10,000 N.mm (80 to 90 lbf-in).
12. Connect the heater core inlet/outlet hoses to the heater core tubes (Figure 53). Install or tighten the rear
AC/heater line hanger, if removed earlier.

REAR HVAC UNIT, COMPLETE REMOVE AND INSTALL
16. If the vehicle is equipped with aerodynamic skirts, install the rear passenger side skirt.
8.35. 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 re-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.
Remove
3. If the vehicle is equipped with aerodynamic skirts, remove the rear passenger side skirt.
4. From under the vehicle, disconnect the A/C lines from the Thermostatic Expansion Valve (TXV). Refer to
Figure 57. Retain the lock plate and lock plate retaining nut. Plug all open tubes/ports.
5. Using clamping pliers, pinch the rubber section of the rear heater lines closed. Place the clamps several
inches from the metal/rubber joint (Figure 52).
6. With a clean drain pan positioned under the heater core connections, disconnect the hoses from the
heater core. Plug all open tubes/hoses.
8. Remove the rear heater core and heater core inlet/outlet tubes (Figure 54), as follows.

REMOVE AND INSTALL REAR HVAC UNIT, COMPLETE
NOTE – In the following step it may be easier to remove the clamp plate by raising the heater
tubes from the core, and rotate them out of the way.
9. Disconnect all electrical connections to the rear HVAC unit.

d. rear linear power module – 1 connector (harness). NOTE: Connector to blower can remain connected.
10. Remove the rear HVAC unit outlet duct (1 screw). NOTE: It may be helpful to loosen or remove some
connected duct work.
11. Remove inlet grille from front of bunk to provide additional clearance.
12. Remove 5 bolts securing housing to floor (Figure 59).
13. Support bunk with a separate prop; then, disconnect the bottom of the bunk support strut and position
it out of the way.
14. Carefully remove the rear HVAC unit through the passenger side access door.
15. Lower or secure the bunk to prevent accidental closure.
1. MOUNT BOLT 2. FRONT OF VEHICLE

Figure 59 Rear HVAC Unit Mounting Bolt Locations
Install
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.

REAR HVAC UNIT, COMPLETE REMOVE AND INSTALL
2. Verify that the rear HVAC unit is ready for installation, as follows.
a. Expansion valve 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 59).
5. Secure the unit to the floor with 5 bolts.
secured correctly.
7. Install the inlet grille at the front of bunk.
c. Using new O-rings, insert the heater core inlet and outlet tubes into the core and secure with the
clamp plate.

c. linear power module – 2 connectors (harness and blower, blower connector may not have been
disconnected).
10. Connect the bottom of the bunk support strut to its mounting plate.
11. From under the vehicle, using new lubricated O-rings, connect the A/C lines to the Thermostatic Expansion
Valve (TXV). Secure the lines to the TXV using the lower locking plate and the lock plate retaining nut
(Figure 57). Tighten to 9,000 to 10,000 N.mm (80 to 90 lbf-in).
12. Connect the heater core inlet/outlet hoses to the heater core tubes (Figure 53). Install or tighten the rear
AC/heater line hanger, if removed earlier.

SERVICE PROCEDURES FOR R-134A SERVICE WARNINGS
16. If the vehicle is equipped with aerodynamic skirts, install the rear passenger side skirt.
9. SERVICE PROCEDURES FOR R-134A

9.1. SERVICE WARNINGS
WARNING
WARNING
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
If the refrigerant should contact the eyes, DO NOT rub them. Splash the eyes with
cold water to gradually get the temperature above the freezing point. See a doctor
immediately.
WARNING
Wear nonporous gloves. (Nitril is the recommended material.) 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
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.

SERVICE WARNINGS SERVICE PROCEDURES FOR R-134A
WARNING
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
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
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
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
WARNING
Do not install or remove A/C testing or charging equipment while the engine is running.
Serious injury may result from doing so.
WARNING
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.

SERVICE PROCEDURES FOR R-134A SERVICE WARNINGS
WARNING
With the manifold gauge set connected to both the air conditioning system and the
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.
WARNING
When purging the system or components, do not use nitrogen at pressures over 200 psi.
Personal injury or death may result from doing so.
WARNING
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.
WARNING
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 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.
CAUTION
To prevent damage to the test equipment, make sure test equipment is clear of all moving
parts in the engine compartment.
CAUTION
When installing and removing any service hose or fitting, a small amount of refrigerant
may escape. Always follow all safety precautions to avoid injury.
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 – 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.
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.

SERVICE PROCEDURES SERVICE PROCEDURES FOR R-134A
9.2. SERVICE PROCEDURES

The service procedures for both the day cab and sleeper versions of the ProStar® and LoneStar® HVAC
system are described in this section. While the procedures for servicing the overall vehicle HVAC system
(including sleeper A/C) are the same, the refrigerant charge required by each system is different. Refer to the
SPECIFICATIONS table for the correct refrigerant charge values for each system.
In addition to the Service Warnings above, 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. Dry nitrogen cleaning 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.
7. Anytime an A/C fitting is disconnected, the O-ring and C-plate must be replaced (Figure 60). 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.
1. O-RING 2. C-PLATE
Figure 60 A/C Fitting C-Plate and O-Ring
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.

SERVICE PROCEDURES FOR R-134A SERVICE PROCEDURES
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 22, page 168). Use only a
torque wrench known to be accurate.
10. Whenever possible use a backup wrench when loosening or tightening fittings (Figure 61).
Figure 61 Use a Back-Up 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 or purged; 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 or purged any time the system has become contaminated
(such as due to an internal compressor failure). Refer to PURGING OR FLUSHING THE AIR
CONDITIONING SYSTEM, (See PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM, page
153).
14. Whenever the system is discharged, the refrigerant oil level must be checked and/or replaced as specified
in OIL FILL GUIDELINES, (See OIL FILL GUIDELINES, page 158).
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) before charging.
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.

REFRIGERANT IDENTIFICATION SERVICE PROCEDURES FOR R-134A
9.3. REFRIGERANT IDENTIFICATION
WARNING
Before doing any of the work below, read the SERVICE WARNINGS (See SERVICE
WARNINGS, page 138). Failure to read the Service Warnings and to be aware of the
dangers involved when working with refrigerant could lead to serious personal injury.
Before any work is done on an HVAC system the refrigerant should be identified.
Refer to Figure 62.
Figure 62 Refrigerant Identification Setup Diagram
1. Calibrate the Refrigerant Identifier per the manufacturer’s instructions.
2. Connect the sampling hose to the low pressure service port located on the evaporator outlet line.
3. Connect the other end of the sampling hose to the Refrigerant Identifier.
4. Open the service valve.
5. Start the sampling procedure (refer to the manufacturer’s instructions).

SERVICE PROCEDURES FOR R-134A MANIFOLD GAUGE SET
6. When the sampling is complete the Refrigerant Identifier will indicate a pass/fail condition, the type of
refrigerant, and the percentage of concentration. International recognizes only R134a in a 98%, or greater,
concentration. Anything else is considered contaminated.
7. Close the service valve and disconnect the sampling hose.
8. Verify that protective caps are installed on both vehicle service port fittings.
9.4. MANIFOLD GAUGE SET
WARNING
NOTE – The fittings on the service hoses for R-134a air conditioning systems are standard Metric SAE
quick-disconnect fittings that will work only on R-134a air conditioning systems service ports.
This information covering the manifold gauge set hookup is provided in case service equipment with an
internal gauge set is not available.
Install
Refer to Figure 63.
1. Remove the protection caps from both service ports.
2. On the Manifold Gauge Set, verify that all valves are closed.

MANIFOLD GAUGE SET SERVICE PROCEDURES FOR R-134A
1. LOW PRESSURE HOSE (BLUE) 4. CONNECT TO SERVICE

2. HIGH PRESSURE HOSE (RED) EQUIPMENT
3. SERVICE HOSE (YELLOW)
Figure 63 Typical Manifold Gauge Set Installation
3. Connect the Manifold Gauge Set to the system as follows:

a. Start with the blue manifold suction hose, and connect it to the low pressure service port located
on the evaporator outlet line.
b. Connect the red hose to the high pressure service port located on the compressor-to-condenser line.
c. Connect the yellow hose on the center fitting of the Manifold Gauge Set following the instructions
provided with the service equipment being used.
NOTE – DO NOT OPEN the valves on the manifold gauge set, or the valves on the quick-disconnect
fittings, until instructed to do so in the procedures. The quick-disconnect fittings must be connected
to the service ports on the vehicle; and the yellow service hose must be connected to the equipment
required for each specific procedure being performed.
Once the quick-disconnect fittings are attached to the service ports, turning the knob clockwise (CW)
pushes an internal pin down to open the service port valve. Turning the knob CCW raises the pin, closing
the service port valve. Once closed the quick-disconnect fitting can be removed without venting refrigerant
from the system.
Remove
1. Be sure the knobs on the quick-disconnect fittings, on the red and blue hoses, are set fully CCW.

SERVICE PROCEDURES FOR R-134A DISCHARGING THE SYSTEM (REFRIGERANT RECOVERY)
2. Verify that the manifold gauge set valves, at the manifold, are set fully clockwise.
3. Remove the blue (low pressure) and red (high pressure) hoses from the vehicle service ports.
4. Verify that protective caps are installed on both vehicle service port fittings.
5. Disconnect the yellow hose from the service equipment currently connected to it. Follow the instructions
provided with that service equipment.
9.5. DISCHARGING THE SYSTEM (REFRIGERANT RECOVERY)
WARNING
NOTE – If the system is being discharged because a leak is suspected, the leak must be located before
discharging the system. Refer to LEAK DETECTION (See LEAK DETECTION, page 163).
Refer to Figure 64.
1. Empty the ’recovered oil’ catch bottle on the recovery station. This is necessary to determine the amount
of oil recovered during the refrigerant recovery procedure.
2. Remove the protection caps from both service ports.
3. On the recovery station and hose fittings, verify that all valves are closed. The valves at the recovery
station must be set to the CLOSED position. The valves at the quick-disconnect fittings must be set
fully counter-clockwise (CCW).

DISCHARGING THE SYSTEM (REFRIGERANT RECOVERY) SERVICE PROCEDURES FOR R-134A
1. LOW PRESSURE HOSE (BLUE) 3. RECOVERY/RECYCLING/CHARGING

2. HIGH PRESSURE HOSE (RED) STATION
Figure 64 Typical Equipment Hookup for Servicing the System
4. Connect the recovery station to the system as follows:

a. Start with the blue low pressure hose, and connect it to the low pressure service port located on the
evaporator outlet line.
5. Open (turn cw) the valves on the quick-disconnect fittings connected to the service ports on the vehicle.
6. Set both hand valves on the recovery station to the RECOVERY/VACUUM position.
NOTE – During the recovery process in the next step, refrigerant may become trapped in the filter-drier.
Heating the filter-drier with a heat gun will force the refrigerant out of the filter-drier and assure that all
of the refrigerant is recovered from the system.

SERVICE PROCEDURES FOR R-134A EVACUATING THE SYSTEM
WARNING
Never use an open flame torch to heat the filter-drier. Heating the filter-drier with an open
flame could result in equipment damage and/or bodily injury.
7. Turn the recovery station main power switch on and press the RECOVER button. The recovery station will
automatically shut off when the refrigerant in the system has been exhausted to the storage tank.
8. Close the valves on the quick-disconnect fittings by turning them fully CCW; and set both valves on the
recovery station to the CLOSED position.
9. When recovering refrigerant by use of a recovery station, system oil is separated from the refrigerant
during the recovery cycle. When the refrigerant recovery operation is complete, the recovery station
will drain the oil into the station’s calibrated catch bottle. The amount of oil recovered may be used
to determine the amount of NEW oil that must be added back to the A/C system. Refer to OIL FILL
GUIDELINES, (See OIL FILL GUIDELINES, page 158).
10. Disconnect the blue and red hoses from the service ports on the vehicle.
11. Work may now begin on the air conditioning system.
9.6. EVACUATING THE SYSTEM
WARNING
CAUTION
The amount of oil lost during the recovery process, component replacement, or
purging/flushing must be replaced with new oil. The method for determining how much
refrigerant oil must be added to the A/C system is located in the OIL FILL GUIDELINES,
(See OIL FILL GUIDELINES, page 158).
CAUTION
Use only the specified PAG lubricant in the refrigerant system. PAG oils absorb
atmospheric moisture very quickly. Never leave PAG oil exposed to air for a prolonged
time. Tightly reseal the oil container immediately after each use.
CAUTION
Do not re-use recovered oil. Be sure to dispose of recovered oil properly to avoid an
environmental hazard.

EVACUATING THE SYSTEM SERVICE PROCEDURES FOR R-134A
Whenever the air conditioning system has been discharged, the system must be completely evacuated of
air and moisture before being recharged. After evacuation the system vacuum should measure between
750 and 1000 microns.
1. Determine the amount of NEW refrigerant oil to be added to the system. Refer to OIL FILL GUIDELINES
(See OIL FILL GUIDELINES, page 158). If oil is being added directly to the compressor, it must be added
before starting the evacuation procedure. If oil is to be added during the evacuation/charging procedure,
you must follow the instructions furnished with the recovery station, or refrigerant oil injector tool, to add
the oil before the charging procedure.
2. On the recovery station and hose fittings, verify that all valves are closed. The valves at the recovery
station must be set to the CLOSED position. The valves at the quick-disconnect fittings must be set
fully counter-clockwise (CCW).
3. Connect the electronic vacuum gauge to the recovery station, at the vacuum manifold, using a valve and
’T’ fittings (refer to Figure 66).
1. RECOVERY STATION 5. ELECTRONIC VACUUM GAUGE

(ORIGINAL CONNECTION) 6. PARTS NEEDED TO MODIFY
2. RECOVERY STATION MANIFOLD (ZTSE4624)
(MODIFIED CONNECTION) 7. RED HOSE
3. LOW SIDE 8. HIGH SIDE
4. BLUE HOSE
Figure 65 Connection of Electronic Vacuum Gauge
CAUTION
The valve for the electronic vacuum gauge must be in the closed position until instructed
to open it. If the valve is open during system charging, excess pressure may damage the
electronic vacuum gauge.
4. Connect the recovery station to the system as follows (refer to Figure 64):

SERVICE PROCEDURES FOR R-134A EVACUATING THE SYSTEM
a. Start with the blue low pressure hose, and connect it to the low pressure service port located on the
evaporator outlet line.
5. On the red and blue hoses, open the valves on the quick-disconnect fittings (turn the knobs fully CW).
6. On the recovery station, set both hand valves to the RECOVERY/VACUUM position.
7. On the recovery station, turn on main power switch and press the VACUUM button.
8. After the low pressure gauge on the station shows that vacuum is being established in the system,
continue to operate the vacuum pump for ten minutes.
9. After ten minutes, set both valves on the recovery station to the CLOSED position, and observe low side
gauge for one minute. The gauge should not indicate a rise of more than 2 inches-Hg. If the gauge rises
more than 2 inches-Hg in one minute, the system has a leak which must be repaired. Refer to LEAK
DETECTION (See LEAK DETECTION, page 163).
10. If there are no leaks:

a. Set both hand valves on the recovery station to the RECOVERY/VACUUM position and press the
VACUUM button.
b. Open the valve connecting the electronic vacuum gauge to the recovery station low side line.
c. Continue to operate the recovery station vacuum pump until the system has pulled a vacuum of 750 –
1000 microns as measured by the electronic vacuum gauge (10 minutes minimum).
d. Close both hand valves on the recovery station, AND the valve connecting the electronic vacuum
gauge to the recovery station low side line.
11. The A/C system is ready to be charged. REMEMBER if the full amount of refrigerant oil has not yet
been added to the system, it must be added before charging the system with refrigerant, as explained in
the following procedure.
NOTE – DO NOT disconnect the recovery/recycling/charging station from the A/C system before
charging the system.

CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE) SERVICE PROCEDURES FOR R-134A
9.7. CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE)
WARNING
WARNING
CAUTION
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
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 – If recycled refrigerant is to be used, follow the instructions supplied with the recycling equipment
to purge the air from the refrigerant before charging the system.
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).
• Refrigerant oil added (only if oil was added directly to the compressor, see OIL FILL GUIDELINES).
• System completely evacuated.
CAUTION
If the equipment being used adds system refrigerant oil during the evacuation/charging
procedure, you must first determine the amount of oil to be added (refer to OIL FILL
GUIDELINES), (See OIL FILL GUIDELINES, page 158). Then follow the instructions
furnished with the recovery station, or refrigerant oil injector tool, to add the correct
amount of NEW oil to the system during this procedure.

SERVICE PROCEDURES FOR R-134A ADDING REFRIGERANT TO THE SYSTEM
1. The recovery station blue (suction) and red (discharge) hoses should still be connected as they were
during the evacuation operation.
2. If necessary, add oil to return the system oil capacity to its correct level (refer to OIL FILL GUIDELINES),
(See OIL FILL GUIDELINES, page 158). To add oil during the evacuation/charging process, follow the
instructions furnished with the recovery station, or refrigerant oil injector tool.
CAUTION
Due to the density of R-134a, the amount of refrigerant required to charge a typical
air conditioning system has been reduced. Overcharging the system will result in
excessively high head pressures during operation and may damage the compressor.
Be sure to check specifications on the vehicle being serviced. This information is often
located on a label on the refrigerant compressor.
3. Determine the amount of refrigerant needed to charge the A/C system. This information can be found in
the SPECIFICATIONS section of this manual (See Table 23, page 171).
4. Following the instructions provided with the recovery station; set the recovery station to charge the system
with the specified amount of refrigerant.
5. On the recovery station, set the low side valve to CLOSED, and the high side valve to CHARGE.
6. Press the CHARGE button to start the charge procedure. When the system is fully charged, the recovery
station will turn off.
7. Complete the charging procedure by setting both hand valves on the recovery station to the CLOSED
position.
8. Before disconnecting the recovery station from the A/C system, perform A/C SYSTEM PERFORMANCE
TEST PROCEDURE (See A/C SYSTEM PERFORMANCE TEST PROCEDURE, page 45).
9. After the pressure test is completed, stop the engine and close the valves on the quick-disconnect fittings
(turn fully ccw) at the vehicle A/C service ports.
10. Disconnect the blue and red hose quick-disconnect fittings from the vehicle service ports.
11. Install the protective caps on both of the vehicle service port fittings.
9.8. ADDING REFRIGERANT TO THE SYSTEM

Since the introduction of R-134a and the new PAG oil, relying on a sight glass clearing up when the system
has a full charge is no longer reliable. DO NOT add refrigerant to the system in hopes of improving cooling. It’s
very possible that the system will be overcharged and cause component failure.
If it is found, during A/C system tests, that the system needs refrigerant; it will be necessary to perform
the following procedures:
• discharge the system, refer to DISCHARGING THE SYSTEM (See DISCHARGING THE SYSTEM
(REFRIGERANT RECOVERY), page 146);
• evacuate the system, refer to EVACUATING THE SYSTEM (See EVACUATING THE SYSTEM, page 148);

PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM SERVICE PROCEDURES FOR R-134A
• and recharge the system, refer to CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE) (See
CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE), page 151).
9.9. PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM
WARNING
WARNING
Dry nitrogen gas is recommended for flushing and/or purging. Do not use nitrogen at
pressures over 1378 kPa (200 psi). Personal injury or death may result from doing so.
Commercial cylinders of dry nitrogen contain pressures in excess of 13780 kPa (2000
psi). This pressure must be reduced, using a pressure regulator, to 1378 kPa (200 psi)
for purging.
CAUTION
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.
CAUTION
When flushing components, use only flushing agents approved for R-134a charged air
conditioning systems (refer to the Fleetrite HVAC catalog for an approved flush solvent).
R-11 and any other flushing agents that were used to flush R-12 charged air conditioning
systems CANNOT be used to flush R-134a systems. The residue left by these flushing
products will destroy the lubrication properties of the oil used in R-134a systems.
NOTE – A flush gun is required to inject the flushing agent into the component being flushed. Refer to
FLUSH GUN (See FLUSH GUN, page 178) for complete information on this service equipment.
NOTE – Special adapters are required to connect the service equipment to the block fittings used on the
A/C system components. Refer to BLOCK FITTING ADAPTERS (See Block Fitting Adapters, page 179)
for complete information on these service adapters. Standard fittings and adapters can be purchased
or fabricated locally. Quick disconnect fittings can reduce the time required to swap hoses, adapters
and components.
Systems that have had an internal compressor failure, that have been overcharged with refrigeration oil, or
that have been left open for an extended period of time, will need to be flushed, purged or both. Flushing
is generally necessary only after an internal compressor failure has contaminated the refrigerant system.

SERVICE PROCEDURES FOR R-134A PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM
Flushing and purging are performed on a system after the refrigerant has been recovered and before the
system is reassembled and evacuated.
Flushing removes heavy contamination, such as gritty oil and large dirt buildup, which occur after an internal
compressor failure. When a part is flushed, a flushing solvent is forced through it; the liquid solvent cleans the
part, picks up contaminants and flushes them out.
Purging must always be performed: after flushing the system; 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. This assures
that A/C system components are dry and free of any contaminants. If left in the system, these contaminants
would have a negative effect on the life and operation of the air conditioning system.
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) (See
OIL FILL GUIDELINES, page 158), reinstall the TXV, and replace the filter-drier prior to evacuating and
• 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 (See OIL FILL GUIDELINES,
page 158).
NOTE – The following procedures for flushing and purging are general. The actual fittings and adapters
required for each procedure will vary according to the component or components being connected.
Flushing Procedure
Refer to Figure 66.
CAUTION
Assemblies to be flushed must be no larger than one component and one attached hose.
1. Disconnect both ends of the component or components to be flushed, and tightly cap the rest of the system.
2. With the tank regulator (5, Figure 66) turned off (closed), open the main nitrogen tank valve (6), and using
the input gauge on the regulator, verify that enough pressure is available to perform the flushing procedure.
3. Connect the input of the flush gun (8) to the output of the supply line from the nitrogen tank. Some form of
shutoff valve should be installed at the input of the flush gun.
4. Using the correct fittings or block fitting adapters (3), connect the drain line (1) to the component to be
flushed. Components are flushed in the opposite direction of normal refrigerant flow.
5. Using the correct fittings or block fitting adapters, connect the flush gun output to the component to
be flushed.

6. Place the outlet of the drain line into a suitable waste container.
7. Fill the flush gun tank with an appropriate amount of flushing agent.
8. Set the supply line air regulator (5) to 75 psi.
9. Open the supply line valve (4) at the output of the tank regulator.
10. Slowly open the flush gun valve and allow the flushing solvent to flow through the system until the drain
line is clear; then, close the flush gun valve. If a trigger type air gun (9) is being used on the flush gun
output, actuate the trigger to release all pressure from the flush gun tank.
11. Close the supply line valve (4).
WARNING
The flush gun MUST be removed from the equipment setup before performing the purge
procedures. The flush gun is not designed to be used at the pressures used for the purge
procedures.
12. Connect the flushing equipment to the next component to be flushed; or, empty the flush gun tank and
remove the flush gun from the supply line.
13. Disconnect drain hose and all fittings and adapters from the component.
14. Plug the inlet and outlet of the component until it can be purged.
NOTE – After flushing a component, that component must be purged before connecting it to the air
conditioning system. Refer to PURGING PROCEDURE) (See Purging Procedure, page 156).

SERVICE PROCEDURES FOR R-134A PURGING OR FLUSHING THE AIR CONDITIONING SYSTEM
A. NITROGEN IN 6. NITROGEN BOTTLE CONTROL

B. TO WASTE CONTAINER VALVE
1. DRAIN LINE 7. NITROGEN BOTTLE
2. CONDENSER 8. FLUSH GUN
3. BLOCK FITTING ADAPTERS 9. TRIGGER TYPE AIR GUN
4. SUPPLY LINE VALVE 10. EVAPORATOR CORE
5. NITROGEN BOTTLE
REGULATOR/GAUGES
Figure 66 Typical Flushing and Purging Setup
Purging Procedure
Refer to Figure 66.
CAUTION
Assemblies to be purged must be no larger than one component and one attached hose.
1. Disconnect both ends of the component to be purged and tightly cap the rest of the system.
2. With the tank regulator (5) turned off (closed), open the main nitrogen tank valve (6), and using the input
gauge on the regulator, verify that enough pressure is available to perform the purging procedure.
3. Using the correct fittings or block fitting adapters (3), connect the drain line (1) to the component to be
purged. Components are purged in the opposite direction of normal refrigerant flow.
4. Using the correct fittings or block fitting adapters, connect the nitrogen supply line output to the component
to be purged. A trigger type air gun (9) may be hand–held for some components.

5. Place the outlet of the drain line into a suitable waste container.
6. Set the supply line pressure regulator (5) to 28 kPa (4 psi).
7. Slowly open the supply line valve (4) at the output of the tank regulator. If a trigger type air gun is being
used, actuate the trigger.
8. Let the dry nitrogen flow at 28 kPa (4 psi) for one to two minutes, or until there is no trace of refrigerant
flushing agent or refrigerant oil flowing from the drain tube.
9. Using the pressure regulator, raise the pressure to 1378 kPa (200 psi) and let the dry nitrogen flow
for 25 to 30 seconds.
10. Adjust the pressure regulator for 0 psi; then, close the supply line valve (4).
11. If a trigger type air gun is being used, actuate the trigger to release pressure in the hose.
12. Disconnect the supply and drain lines from the part, and remove all fittings and adapters (3). Tightly cap
the openings of the part until you are ready to install it into the system.
13. The component is now ready to be installed into the air conditioner system using new O-rings and C-plates.
14. After purging the system, change oil in the compressor (refer to OIL FILL GUIDELINES) (See OIL FILL
GUIDELINES, page 158), reinstall (or replace) the TXV, and replace the filter-drier prior to evacuating and

SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES
9.10. OIL FILL GUIDELINES
WARNING
CAUTION
Do not re-use recovered oil. Be sure to dispose of recovered oil properly to avoid an
environmental hazard.
CAUTION
Replacement compressors contain a quantity of oil when shipped. This oil must be
drained from the new compressor before refilling the compressor (and system) with the
correct amount of new oil.
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 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 AIR
CONDITIONING SYSTEM SPECIFICATIONS (See Table 23, page 171). Replacement oil may be added
directly into the compressor before evacuation, or injected into the system after evacuation. 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 thermistor, add the amount of oil removed from the system during the refrigerant
recovery procedure.
• Total replacement oil quantity = oil from refrigerant recovery procedure.

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 before filling with new 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.

OIL FILL GUIDELINES SERVICE PROCEDURES FOR R-134A
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 21.
• 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
and purge the system, and replace the compressor, expansion valve, and filter-drier. The new
compressor must be drained of shipping oil before filling with new 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 may be added to the compressor before installing
it. Refill the system with a full refill of new oil.
• Total replacement oil quantity = total system capacity as specified in AIR CONDITIONING
SYSTEM SPECIFICATIONS (See Table 23, page 171) minus 0.5 fl. oz (oil film left in new
compressor after draining shipping oil).
• Total replacement oil quantity = 10.14 fl. oz (300 cc) minus 0.5 fl. oz (15 cc) = 9.64 fl. oz
(285 cc)
Table 21 Oil Capacity by Component (Including Sleeper A/C System)
Typical oil amount

Component cc fl.oz.
Evaporator 60 2.0
(Front or Rear)
Condenser 30 1.0
Filter-drier 15 0.5
Expansion valve(s) 0 0
Hoses (Each) 10 0.3
Thermistor 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 NEW oil that must be added to the system before or during the recharging of the
A/C system. Do not use recovered refrigerant oil.
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.

SERVICE PROCEDURES FOR R-134A OIL FILL GUIDELINES
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 (See LEAK DETECTION, page 163).
2. Discharge the system. Refer to DISCHARGING THE SYSTEM (See DISCHARGING THE SYSTEM
(REFRIGERANT RECOVERY), page 146),
3. Make any necessary repairs.
4. If the system does not appear to be contaminated, purge the system. If the system appears contaminated,
such as after an internal compressor failure, it must be flushed before purging. Refer to PURGING
OR FLUSHING THE AIR CONDITIONING SYSTEM (See PURGING OR FLUSHING THE AIR
5. If the removed refrigerant was not contaminated:
A. Reinstall the expansion valve (removed for purging).

B. Drain and discard the old oil from the compressor. Refer to CHECKING COMPRESSOR
OIL LEVEL, that follows.
C. Refill compressor with new oil; then, install compressor.
Total replacement oil quantity = total system capacity as specified in AIR CONDITIONING
SYSTEM SPECIFICATIONS (See Table 23, page 171) minus 0.5 fl. oz (oil film left in
compressor after draining old oil).
Total replacement oil quantity = 10.14 fl. oz (300 cc) minus 0.5 fl. oz (15 cc) = 9.64 fl. oz
(285 cc)
D. Install a new filter-drier.
6. If the removed refrigerant was contaminated:
A. Install a new expansion valve.

B. Add new refrigerant oil to a new compressor; then, install compressor. NOTE: New
compressors must be drained of shipping oil before filling with new oil. Refer to CHECKING
COMPRESSOR OIL LEVEL, that follows.
Total replacement oil quantity = total system capacity as specified in AIR CONDITIONING
SYSTEM SPECIFICATIONS (See Table 23, page 171) minus 0.5 fl. oz (oil film left in new
compressor after draining shipping oil)
Total replacement oil quantity = 10.14 fl. oz (300 cc) minus 0.5 fl. oz (15 cc) = 9.64 fl. oz
(285 cc)
C. Install a new filter-drier.
7. Evacuate the system; refer to EVACUATING THE SYSTEM (See EVACUATING THE SYSTEM, page 148).

CHECKING COMPRESSOR OIL LEVEL SERVICE PROCEDURES FOR R-134A
8. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE) (See
9. 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.
10. After running the system, retest the repaired area to verify the repair.
9.11. CHECKING COMPRESSOR OIL LEVEL
WARNING
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 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 calibrated container.
1. Verify that the system is discharged.
2. Remove the compressor.
3. Remove the oil plug and drain as much oil as possible into a suitable calibrated container (refer to
Figure 67).
Figure 67 Drain as Much Oil as Possible
4. Remove the caps (if present) from the suction and discharge ports.
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 (refer to
Figure 68). Replace the caps on the suction and discharge ports.

SERVICE PROCEDURES FOR R-134A CHECKING COMPRESSOR OIL LEVEL
Figure 68 Drain Oil While Turning Shaft
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.
9. If the oil is not contaminated, add the correct amount of new oil to the compressor as determined by the
OIL FILL GUIDELINES (See OIL FILL GUIDELINES, page 158). Refer to Figure 69.
Figure 69 Add New Oil to Compressor
10. Install oil fill plug taking care not to twist the O-ring seal. Replace the O-ring if damaged. Torque oil plug to
15 to 20 N.m (11 to 15 lbf-ft). Do not over-tighten plug to stop a leak. Stop leaks first by fixing any seat
damage, removing dirt and installing a new O-ring.

LEAK DETECTION SERVICE PROCEDURES FOR R-134A
9.12. LEAK DETECTION
WARNING
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.
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.
NOTE – Refrigerant leaks are often indicated by an oily residue at the point of the leak.
There are several methods of refrigerant leak detection. The method used could depend on many factors
including equipment availability, layout of the system being serviced, or even personal preference. The
primary recommended methods are the electronic refrigerant leak detector and the phosphor dye/ultraviolet
lamp method. In addition, brief descriptions are provided for two alternate methods (ultrasonic leak detection
and soap solution). By using the described methods, either separately or in some combination, it should be
possible to locate and verify most refrigerant leaks.
Electronic Leak Detectors
NOTE – To use the characteristics of the A/C system to your advantage while leak testing with an
electronic leak detector; check the high pressure side of the system with the system running, and
check the low pressure side of the system with the system (and engine) off.
In terms of sensitivity and safety, the electronic leak detector (refer to Figure 70) is excellent for finding both
slow and major system leaks. Ensure that the detector being used is intended for use with R134a refrigerant.
Many leak detectors intended for use with R-12 cannot detect R134a leaks. The detector is also listed in the
SPECIAL TOOLS section (See SPECIAL TOOLS, page 172).

SERVICE PROCEDURES FOR R-134A LEAK DETECTION
Figure 70 Electronic Leak Detector
The unit is a hand-held device 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 instructions
for the detector being used. 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 J1628.
Before starting 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.
Ultraviolet Lamp Leak Testing
An alternate method to electronic leak testing is ultraviolet light. The desiccant located in the filter-drier
contains a phosphor dye that will produce a bright yellow-green trace at the leak, when illuminated by an
ultraviolet (UV) lamp. This dye is also included in replacement filter-driers. The kit illustrated in Figure 71
provides the UV lamp used to illuminate the suspected leaks. The kit also contains connection hoses and a
dye injector, as well as, eyeglasses used to enhance the effect of the UV light on the dye. A UV dye cleaner
should be used to clean the HVAC system connections after repairs have been made.

Figure 71 Ultraviolet Lamp Kit
It has been discovered during the use of UV light, and phosphor dyes, that other types of leaks also appear as
a yellow-green trace when the UV light shines on them. If an UV lamp is used for leak detection, it is also
recommended that an electronic leak detector be used to verify that any detected leaks are, in fact, refrigerant
leaks. Refer to ELECTRONIC LEAK DETECTORS (See Electronic Leak Detectors, page 163).
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. 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.
Soap Solution with Nitrogen
Another alternative method of leak detection is the soap solution method. To improve the results of this
method the refrigerant system is first discharged, and then pressurized to 300 psi using dry nitrogen. Refer
to REFRIGERANT LEAK TESTING WITH NITROGEN. A solution of soap and water is then sprayed on the
suspected joints or components. A leak is indicated by bubbles forming at the point where the pressurized
nitrogen is escaping.
Refrigerant Leak Testing with Nitrogen
NOTE – Before pressurizing the system with nitrogen the system refrigerant must be recovered.
When checking for refrigerant leaks using an ultrasonic detector or a soap solution, the refrigerant in the
system must first be recovered; then, the system must be pressurized with dry nitrogen, as follows.

SERVICE PROCEDURES FOR R-134A LEAK DETECTION
1. Connect a manifold gauge set to the a/c system. Refer to Figure 72.
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.)
NOTE: 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.
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 or a soap solution.
4. After locating the leak, set the nitrogen cylinder regulator to 0 PSI.
WARNING
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 (See EVACUATING THE SYSTEM, page 148).
8. Charge the system; refer to CHARGING THE AIR CONDITIONING SYSTEM (FULL CHARGE) (See

1. LOW PRESSURE VALVE AND 3. NITROGEN CYLINDER AND

GAUGE (MANIFOLD GAUGE REGULATOR
SET)
2. HIGH PRESSURE VALVE AND
GAUGE (MANIFOLD GAUGE
SET)
Figure 72 Using Nitrogen to Pressurize the A/C System

SPECIFICATIONS TORQUE CHART
10. SPECIFICATIONS
10.1. TORQUE CHART
Table 22 Torque Chart
Item Item Description Torque Value

No.* (Quantity) N•m Lbf-ft Lbf-in
1 Air Conditioner Block Fittings 19 to 21 14.2 to 15.8 170 to 190
2 Refrigerant Compressor Mtg Bolts (4) 23 to 29 16.9 to 21.4 203.6 to 256.7
3 Refrigerant Compressor Oil Plug 15 to 20 11 to 15 132 to 180
4 Pressure Transducer (1) 6.8 to 13.6 5 to 10 60 to 120
5 Heater Housing Mtg Bolt (4) 5.4 to 7.6 4 to 5.6 47.5 to 67.5
6 Evaporator Housing Mtg Bolt (4) 5.4 to 7.6 4 to 5.6 47.5 to 67.5
7 Filter Drier Mtg Bolt (2) 11.0 to 11.6 8.1 to 8.5 97 to 103
8 Thermistor (2) 5 to 9.5 3.7 to 7 44.3 to 84.1
(Located on evaporator inlet and outlet lines.)

9 M5 Capscrew, 3mm Allen Head (2) 3.6 to 4.3 2.7 to 3.1 31.9 to 38
Secures Expansion Valve Bottom Plate

(Front Expansion Valve)
10 M6 Screw, T30 Torx Head 9 to 10 6.7 to 7.5 80 to 90
Secures Expansion Valve Top Plate (Front

Expansion Valve)
11 M5 Capscrew, Torx Head (2) 4.0 to 4.3 2.9 to 3.1 35.4 to 38.0
Secures Expansion Valve Top Plate (Rear

Expansion Valve)
12 M6 Nut, 9 to 10 6.7 to 7.5 80 to 90
Secures Expansion Valve Bottom Plate

(Rear Expansion Valve)
13 Block Fittings for Rear Air Conditioner 19 to 21 14.2 to 15.8 170 to 190
System
* Refer to the torque location diagrams (Figures 73, 74, 75, and 76) that follow this table.

TORQUE CHART SPECIFICATIONS
Figure 73 Torque Locations (Figure 1 of 4)

SPECIFICATIONS TORQUE CHART
Figure 74 Torque Locations (Figure 2 of 4)
Figure 75 Torque Locations – Rear Thermostatic Expansion Valve (Figure 3 of 4)

AIR CONDITIONING SYSTEM SPECIFICATIONS
Figure 76 Torque Locations – Block Fittings for Rear A/C System (Figure 4 of 4)
10.2. AIR CONDITIONING SYSTEM

Table 23 Air Conditioning System Specifications
ITEM SPECIFICATION
Refrigerant Type R-134a
Refrigerant Quantity (Full Charge)
ProStar® and LoneStar® Models 40 +2/-0 oz.
(Day Cabs) (2.5 +0.125/-0 lbs)
(1.13 +0.05/-0 kg)

ProStar® and LoneStar® Models 48 +2/-0 oz.
(Sleeper Cabs) (3.0 +0.125/-0 lbs)
(1.36 +0.05/-0 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 Mineral Oil
use as compressor refrigerant oil.
International P/N ZGGR6912
Compressor Belt Drive Tension Controlled by auto-tensioner.

SPECIAL TOOLS AIR CONDITIONING SYSTEM
11. SPECIAL TOOLS

CAUTION
The servicing tools recommended for this system were designed specifically for use with
R-134a A/C systems. Servicing tools designed and/or used for R-12 A/C 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. The tools shown
in Figure 77 can be obtained from local sources.
Table 24 Special Service Tools
DESCRIPTION PART NO.

Recovery/Recycling/Recharging Station (R-134a) ZTSE4615
Manifold Gauge Set (R-134a) ZTSE4623
Electronic Vacuum Gauge ZTSE4620
Electronic Vacuum Gauge Manifold ZTSE4624
Refrigerant Identifier ZTSE4616
Electronic Leak Detector ZTSE4617
Ultraviolet Lamp Leak Detector ZTSE4618
Digital Thermometer ZTSE4619
Block Fitting Adapters
Male Adapter, ½ Inch ZTSE4503
Male Adapter, ¾ Inch ZTSE4501
Female Adapter, ½ Inch ZTSE4504
Female Adapter, ¾ Inch ZTSE4502
Electronic Service Tool (EST), EZ-Tech
and Interface Communications Cable
Dry Nitrogen, Cart, Regulator Obtain Locally
Flush Gun Obtain Locally
Drain Hose with Compression Fitting and Adapters Obtain Locally

AIR CONDITIONING SYSTEM SPECIAL TOOLS
1. Nitrogen Cylinder, Regulator and 3. Drain Hose with Compression

Cart Fitting and Adapters
2. Flush Gun
Figure 77 Service Tools that may be Obtained Locally

SPECIAL TOOLS RECOVERY/RECYCLING/RECHARGING STATION
11.1. RECOVERY/RECYCLING/RECHARGING STATION

The Recovery/Recycling/Recharging Station (ZTSE4615) for R-134a is a totally integrated A/C service system,
which recovers, recycles, evacuates, and recharges R-134a quickly and accurately (refer to Figure 78).
Figure 78 Recovery/Recycling and Charging Station, ZTSE4615
With its built-in manifold, all A/C service work is done with one hookup. The unit is programmed at its
panel-mounted keypad. Computerized controls and solenoids precisely monitor evacuation and charging
time. It is designed to automatically shut off after the recovery cycle. A moisture indicator will change from
yellow to green when recycling is complete.
11.2. MANIFOLD AND GAUGE SET

The manifold gauge set (ZTSE4623) for R-134a systems consists of the necessary pressure and vacuum
gauges, and control valves and fittings for evacuating and charging air conditioner systems (refer to Figure 79).
The unit features sidewheel style, color-coded valve handles, 63.5 mm (2.5 inch) vibration-free gauges, hose
holders, a hanging hook, and two 183 cm (72 in) color-coded hoses with Metric SAE quick-disconnect fittings
(with valves). The hose connection fittings on the manifold gauge set have Acme threads.
NOTE – The manifold gauge set and service hoses must be dedicated to R-134a.

ELECTRONIC VACUUM GAUGE AND MANIFOLD SPECIAL TOOLS
1. HIGH PRESSURE GAUGE 6. LOW PRESSURE HOSE (BLUE)

2. HIGH PRESSURE VALVE 7. LOW PRESSURE VALVE
3. HIGH PRESSURE HOSE (RED) 8. LOW PRESSURE GAUGE
4. SERVICE HOSE (YELLOW)
5. METRIC SAE QUICK CONNECT
FITTINGS
Figure 79 Manifold and Gauge Set (Shown with Hose Set and Quick-Disconnect Fittings)
11.3. ELECTRONIC VACUUM GAUGE AND MANIFOLD

Before recharging the A/C refrigerant system, a vacuum must be drawn in the system to boil away all of the
moisture in the system. A vacuum level of 500 to 1000 microns is sufficient to evacuate the system and
remove all of the moisture. An accurate way to measure a vacuum at these levels is with an electronic
vacuum gauge (refer to Figure 80). The electronic vacuum gauge (ZTSE4620) measures vacuum levels from
10 to 20,000 microns in twenty steps.
The vacuum gauge is susceptible to damage from high pressures. Therefore, it must be connected to the
recovery station through a manifold that allows the gauge to be isolated from the recovery station low pressure
line when high pressures are present (refer to Figure 81).
CAUTION
Close the valve on the electronic vacuum gauge manifold before recharging the A/C
system.

SPECIAL TOOLS REFRIGERANT IDENTIFIER
Figure 80 Electronic Vacuum Gauge, ZTSE4620
1. RECOVERY STATION 5. ELECTRONIC VACUUM GAUGE

(ORIGINAL CONNECTION) 6. PARTS NEEDED TO MODIFY
2. RECOVERY STATION MANIFOLD (ZTSE4624)
(MODIFIED CONNECTION) 7. RED HOSE
3. LOW SIDE 8. HIGH SIDE
4. BLUE HOSE
Figure 81 Electronic Vacuum Gauge Manifold, ZTSE4624
11.4. REFRIGERANT IDENTIFIER

In today’s environment there are a lot of alternative and blended refrigerants; International only recognizes
R-134a for this A/C system. The only way to know for sure if you can safely recover the refrigerant in an A/C
system is through the use of a refrigerant identifier (refer to Figure 82). The refrigerant identifier (ZTSE4616)
samples the refrigerant; then displays the type and purity of the refrigerant in the system. The refrigerant
identifier is supplied as part of a kit which includes the necessary hoses and fittings.

ELECTRONIC LEAK DETECTOR SPECIAL TOOLS
CAUTION
When red spots or discoloration begins to appear on the white outside diameter of the
filter element, THE FILTER MUST BE REPLACED. Failure to properly maintain the sample
filter may result in severe instrument damage that is not covered under warranty repairs.
Figure 82 Refrigerant Identifier, ZTSE4616
11.5. ELECTRONIC LEAK DETECTOR

Electronic Leak Detector (ZTSE4617) detects leaks in air conditioning systems by utilizing 100 per cent solid
state electronic circuitry (refer to Figure 83). An LED provides a low battery warning. The LED also indicates
when calibration is accomplished without the usual, inconvenient, external reference leak source. An audio
leak indicator ensures efficient operation even in bright sunlight. The power source is four "AA" alkaline
batteries. This detector may be used for both R-12 and R-134a systems.
Figure 83 Electronic Leak Detector, ZTSE4617

SPECIAL TOOLS ULTRAVIOLET LAMP LEAK DETECTOR
11.6. ULTRAVIOLET LAMP LEAK DETECTOR

An ultraviolet leak detector is used with phosphor dye to detect very minute leaks. Leak Detector (ZTSE4618)
is for use under all ambient lighting conditions, except direct sunlight (refer to Figure 84). It uses a special
self-ballasted bulb, which eliminates the need for an external transformer. When this light is shined on a
suspected area, leaking refrigerant will be visible as a bright yellow-green glow. The leak detector kit includes
the accessories needed to inject dye into other systems.
Figure 84 Ultraviolet Lamp Leak Detector, ZTSE4618
11.7. FLUSH GUN

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 (refer to Figure 85) 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.
WARNING
The nitrogen supplied to the flush gun must not exceed 75 psi.
Figure 85 Flush Gun and Drain Hose (Obtain Locally)

DIGITAL THERMOMETER SPECIAL TOOLS
11.8. DIGITAL THERMOMETER

Two thermometers are needed for A/C system testing and diagnostics. Digital thermometers provide a simple
and accurate means of measuring air temperature (refer to Figure 86).
Figure 86 Digital Thermometer, ZTSE4619
11.9. BLOCK FITTING ADAPTERS

When performing flushing and/or purging operations, adapters are required to connect the service equipment
to the HVAC system components (refer to Figure 87).
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 87 Block Fitting Adapters

SPECIAL TOOLS ELECTRONIC SERVICE TOOL (EST), EZ-TECH
11.10. ELECTRONIC SERVICE TOOL (EST), EZ-TECH

The EZ-Tech electronic service tool (refer to Figure 88), running diagnostic software allows the servicer to
monitor the HVAC electrical circuits. The EZ-Tech is connected to the vehicle diagnostic connector through
an interface communications cable. When used in conjunction with the electrical troubleshooting manual,
the EZ-Tech allows the servicer to isolate electrical faults efficiently. See the diagnostic software manual for
details on using the software.
Figure 88 Electronic Service Tool, EZ-Tech

ELECTRONIC SERVICE TOOL (EST), EZ-TECH SPECIAL TOOLS
12. GLOSSARY
Refer to the following terms for a better understanding of the heater/air conditioning system.
• ACTUATOR - An electrical device that performs a mechanical action based on an electrical input, (similar
to a servo motor).
• AIR CONDITIONER - A device used to control the temperature, humidity, cleanliness and movement of air.
• AIR PRESSURE - The pressure exerted in every direction at any given point. Normal atmospheric pressure
(that is, the pressure caused by the weight of the atmosphere) at sea level is 101.60 kPa (14.696 psi).
• AMBIENT AIR TEMPERATURE - The temperature of air around an object; the outside temperature.
• BLOWER - A motor and fan used to draw air through the evaporator, and force it through the heater
core and into the cab.
• BOILING POINT - The temperature at which a liquid changes to a gas, at a certain pressure.
• CFM - Cubic feet per minute. The metric equivalent of one CFM is 28.3 Liters per minute.
• CHARGE - A specific amount of refrigerant or oil by volume or weight. Also, the act of placing an amount
of refrigerant or oil into the air conditioning system.
• COLD - The absence of heat. (The lowest possible temperature is believed to be -273 degrees C (-459
degrees F).
• COMPRESSOR - An assembly used to draw low pressure, low temperature refrigerant gas from the
evaporator and squeeze it into a high pressure, high temperature gas. This causes the refrigerant to have
a higher temperature than the surrounding air, allowing the condenser to change the gas back into a liquid.
A secondary purpose of the compressor is to move refrigerant and oil through the system.
• CONDENSATE - Water, taken from the air, which forms (condenses) on the outer surface of the evaporator.
• CONDENSER - A heat exchanger that is used to remove heat from refrigerant, changing it from a high
temperature, high pressure gas into a high temperature, high pressure liquid.
• CONTAMINANTS - Anything other than refrigerant or refrigerant oil in the system. Usually means water in
the system.
• DEHUMIDIFY - To remove water from the air, at the evaporator coils.
• DESICCANT - A drying agent used in the refrigerant system (in the filter-drier) to remove moisture.
• DISCHARGE - To remove some or all of the refrigerant from the air conditioning system using a
recovery/recycling station.
• DISCHARGE LINE - Connects the refrigerant compressor outlet to the condenser inlet. (High pressure
line).
• DISCHARGE PRESSURE - Pressure of the refrigerant leaving the compressor; high side pressure.
• DISCHARGE SERVICE PORT - A fitting that is located in the system on the discharge (high pressure)
side of the compressor. It allows the connection of service equipment for monitoring high side pressure
and for performing other service related tasks.
• DRYING AGENT - See "Desiccant."
• ELECTRONIC VACUUM GAUGE - A high vacuum gauge sensitive to pressures ranging from 10 to
20,000 microns.
• EVACUATE - Evacuation pumps the contents out of the refrigerant system, creating a vacuum. It
dehydrates all traces of moisture and is used to determine if the system has any leaks before installing
a charge of refrigerant in the system.

SPECIAL TOOLS ELECTRONIC SERVICE TOOL (EST), EZ-TECH
• EVAPORATE - A change of state from a liquid to a gas.

• EVAPORATOR CORE - A component of the air conditioning system in which liquid refrigerant changes
to a gas after it absorbs heat from the air. The external surface of the evaporator core also collects
cab moisture.
• EXPANSION VALVE - See Thermostatic Expansion Valve.
• FILTER-DRIER - A combination desiccant, filter, and storage container for liquid refrigerant.
• FLUSHING - A process of forcing a solvent through a refrigerant part to remove dirt and contaminants.
Flushing is used to remove heavy contamination, such as gritty oil and large dirt buildup, that cannot
be removed by purging.
• FREEZE-UP - Failure of a unit to operate properly because of ice forming at the thermostatic expansion
valve or on the evaporator coils or fins.
• HEAD PRESSURE - Refrigerant pressure from the discharge side of the compressor to the condenser and
expansion valve inlet.
• HUMIDITY - The amount of water vapor in the air.
• LEAK DETECTOR - A device used to detect a refrigerant leak in the air conditioning system.
• LINEAR POWER MODULE - An electrical module that controls the amount of voltage going to the blower
motor, based on an input signal from the HVAC control head panel (and blower speed control). The
amount of voltage going to the blower motor determines the speed of the blower.
• LOW SUCTION PRESSURE - Low side pressure that is lower than normal due to a system problem.
• MAGNETIC CLUTCH - An electrical coupling device used to engage or disengage the refrigerant
compressor.
• MANIFOLD GAUGE SET - A manifold that is complete with gauges and charging hoses and used
to measure or test pressure.
• MICRON - A metric measurement of mercury equal to one-thousandth of one millimeter. Therefore,
one-tenth of an inch of mercury equals 2540 microns. Measurement in microns is the only accurate way to
determine the amount of pressure that is left in a refrigerant system by a high vacuum pump.
• MINERAL BASED OIL - A type of oil used on seals and O-rings in A/C systems to lubricate them and keep
them from drying out.
• NITROGEN - A colorless, odorless, dry, inert gas that can be used to purge light contaminants from
air conditioning parts.
• OVERCHARGED - Too much refrigerant or oil in an A/C system.
• PAG OIL - A specific type of oil carried by the refrigerant and used to lubricate the components of some
A/C systems.
• PRESSURE TRANSDUCER - A device with electrical characteristics that vary according to the pressure
it senses.
• PULSE WIDTH MODULATION - A type of electrical signal that uses pulses to represent specific values.
• PURGE - To remove damp air, traces of refrigerant, and loose dirt from a system part by blowing
pressurized dry nitrogen through the part.
• REFRIGERANT (R-134a) - The cooling agent used in automotive air conditioning systems.
• REFRIGERATION CYCLE - The complete circulation of refrigerant through an air conditioning system,
accompanied by changes in temperature and pressure.

ELECTRONIC SERVICE TOOL (EST), EZ-TECH SPECIAL TOOLS
• SUCTION PRESSURE - Compressor inlet pressure (the system low side pressure).
• SUCTION SIDE SERVICE PORT - A fitting that is located in the system on the suction (low pressure) side
of the compressor. It allows the connection of service equipment for monitoring low side pressure and for
performing other service related tasks.
• THERMISTOR - A device, used as an sensor for an electrical circuit, that changes its apparent resistance
based on the temperature it senses.
• THERMOSTATIC EXPANSION VALVE - The expansion valve is the dividing line between the high and
low pressure sides of the system. The valve regulates the amount of refrigerant that is routed to the
evaporator core, based on the temperature of the refrigerant leaving the evaporator core. Sometimes
abbreviated as TXV.
• TXV - See THERMOSTATIC EXPANSION VALVE.
• VACUUM - Refers to pressure that is less than atmospheric pressure.
• VACUUM PUMP - A mechanical device used to evacuate and place a high vacuum in the refrigerant
system.
• VAPOR - The gaseous state of material.

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SERVICE MANUAL

SERVICE MANUAL SECTION

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM

2. GENERAL DESCRIPTION – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. GENERAL DESCRIPTION – REAR HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

4. SYSTEM OPERATING CONTROLS – FRONT HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) i

TABLE OF CONTENTS (CONT.)

5. SYSTEM OPERATING CONTROLS – SLEEPER HVAC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6. SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

7. DIAGNOSIS AND TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

8. REMOVE AND INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

ii HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

TABLE OF CONTENTS (CONT.)

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) iii

TABLE OF CONTENTS (CONT.)

9. SERVICE PROCEDURES FOR R-134A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

iv HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

TABLE OF CONTENTS (CONT.)

10. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

11. SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172

12. GLOSSARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) v

To avoid personal injury or death, refer to the manufacturer’s service information

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 1

2 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 3

2. GENERAL DESCRIPTION – FRONT HVAC SYSTEM

4 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

1. FRESH AIR 5. DRIVER FLOOR AIR

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 5

1. PRESSURE TRANSDUCER 7. THERMISTOR (EVAPORATOR

6 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

1. HVAC CONTROL PANEL 3. FUSE PANEL COVER

2.1. SYSTEM DESCRIPTION – FRONT HVAC SYSTEM

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 7

1. DEFROST DUCT (PART OF 10. A/C EVAPORATOR

8 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

Air Distribution (Air Conditioning)

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 9

Air Distribution (Heat and Ventilation)

10 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

Air Distribution (Defrost)

A/C Refrigerant Flow – Front A/C System

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 11

1. DIRECTION OF RAM AIR 11. THERMISTOR (OUTLET)

12 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

2.2. COMPONENTS – FRONT HVAC SYSTEM

Compressor and Clutch

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 13

1. GROUND TERMINAL 3. OUTPUT TERMINAL

14 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

Thermostatic Expansion Valve (TXV) – Front A/C System

Figure 9 Thermostatic Expansion Valve – Front A/C System

Thermistors (Evaporator Inlet and Outlet)

HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039) 15

Linear Power Module

16 HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM (S16039)

Figure 11 Linear Power Module - Front HVAC System