engine CHEVROLET DYNASTY 1993 Service Manual

(5) Evacuate and charge the refrigerant system. If
oil loss of 3 ml (1 oz) or greater is suspected, refer to
Oil Level in the Refrigerant Service Procedures sec-
tion.
COMPRESSOR HIGH PRESSURE CUT-OUT SWITCH
The High Pressure Cut Out (HPCO) switch is lo-
cated on the rear cover of the Variable Displacement
Compressor (Fig. 6). The function of the switch is to disengage the compressor clutch by monitoring the
compressor discharge (high) pressure. The HPCO
Switch is in the same circuit as the Differential Pres-
sure Cut Out (DPCO) switch and Ambient Switch.
DIAGNOSIS
Review Safety Precautions and Warnings before
proceeding with this operation. Connect a suitable manifold gauge set to the refrig-
erant system service ports. Work area temperature
can not be below 21ÉC (70ÉF). (1) Raise hood of vehicle.
(2) With gear selector in park or neutral, and park
brake set, start engine and allow to idle at 1300 rpm. (3) Set the A/C controls to A/C and High blower.
(6) If the high pressure gauge reads below 2963
kPa (430 psi) 6138 kPa (20 psi) the compressor
clutch should be engaged.
CAUTION: Do not allow engine to overheat when ra-
diator air flow is blocked.
(7) Block radiator air flow with a suitable cover to
increase the high side pressure to at least 3100 kPa
(450 psi). Compressor clutch should disengage. (8) Remove cover from front of vehicle to allow
high side pressure to decrease. When pressure drops
below 1826 kPa (265 psi), compressor clutch should
engage.
REMOVAL AND INSTALLATION
(1) Using a refrigerant recovery machine, remove
the refrigerant from the A/C system.
Fig. 3 Remove Shaft Seal
Fig. 4 Shaft Seal Protector
Fig. 5 Install Shaft Seal
Fig. 6 Variable Displacement CompressorÐModel 6C17
Ä HEATING AND AIR CONDITIONING 24 - 21

FIXED DISPLACEMENT COMPRESSORÐMODEL 10PA17 INDEX
page page
Compressor ............................. 24
Compressor Clutch/Coil Assembly ............ 24
Compressor Front Shaft Seal ............... 27 Compressor High-Pressure Relief Valve
....... 30
Refrigerant System Diagnosis ............... 30
COMPRESSOR
COMPRESSOR NOISE
Excessive noise that occurs when the air condition-
ing is being used, can be caused by:
² Loose bolts
² Mounting brackets
² Loose clutch
² Excessive high refrigerant system operating pres-
sure Verify compressor drive belt condition, proper re-
frigerant charge and head pressure before compressor
repair is performed. For noise diagnostic procedures, refer to the Com-
pressor Noise and Compressor Clutch Diagnosis
chart in this section.
REMOVAL AND INSTALLATION
The A/C compressor may be removed and posi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the A/C
compressor clutch/coil assembly, engine, cylinder
head, or generator.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE
TURNED OFF. BEFORE REMOVING A FULLY
CHARGED COMPRESSOR, REVIEW THE SAFETY
PRECAUTIONS AND WARNINGS SECTION IN THIS
GROUP. DO NOT TWIST OR KINK THE REFRIGER-
ANT LINES WHEN REMOVING A FULLY CHARGED
COMPRESSOR. SAFETY GLASSES MUST BE
WORN.
(1) Disconnect Negative battery cable.
(2) Loosen and remove drive belts (refer to Group
7, Cooling System) and disconnect compressor clutch
wire lead. (3) Remove refrigerant lines from compressor (if
necessary). (4) Remove compressor attaching nuts and bolts.
(5) Remove compressor. If refrigerant lines were
not removed, lift compressor/clutch assembly and tie
it to a suitable component. To install, reverse the preceding operation. If nec-
essary, refer to Charging Refrigerant System in the
Refrigerant Service Procedures section.
COMPRESSOR CLUTCH/COIL ASSEMBLY
CLUTCH INOPERATIVE
The air conditioning compressor clutch electrical
circuit is controlled by the engine controller. The
controller is located in the engine compartment out-
board of the battery. If the compressor clutch does not engage:
Verify refrigerant charge.
If the compressor clutch still does not engage check
for battery voltage at the low pressure or differential
pressure cut-off switch located on the expansion
valve. If voltage is not detected, refer to:
² Group 8W, Wiring Diagrams.
² The appropriate Powertrain Diagnostic Procedures
Manual for diagnostic information. If voltage is detected at the cut-off switch, recon-
nect switch. Then check for battery voltage between
the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil
Tests.
CLUTCH COIL TESTS
(1) Verify battery state of charge. (Test indicator
in battery should be green). (2) Connect an ammeter (0-10 ampere scale) in se-
ries with the clutch coil terminal. Use a volt meter
(0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch. (3) With A/C control in A/C mode and blower at
low speed, start the engine and run at normal idle. (4) The A/C clutch should engage immediately and
the clutch voltage should be within two volts of the
battery voltage. If the A/C clutch does not engage,
test the fusible link. (5) The A/C clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch
coil. This is with the work area temperature at 21ÉC
(70ÉF). If voltage is more than 12.5 volts, add electri-
cal loads by turning on electrical accessories until
voltage reads below 12.5 volts. If coil current reads zero, the coil is open and
should be replaced. If the ammeter reading is 4 am-
peres or more, the coil is shorted and should be re-
placed. If the coil voltage is not within two volts of
the battery voltage, test clutch coil feed circuit for
excessive voltage drop.
24 - 24 HEATING AND AIR CONDITIONING Ä

(7) Check bearing for roughness or excessive leak-
age of grease. Replace bearing as required.
INSTALLATION
(1) Align pin in back of field coil with hole in com-
pressor end housing, and position field coil into place.
Make sure that lead wires are properly routed, and
fasten with the wire clip retaining screw. (2) Install field coil retaining snap ring with Snap
Ring Pliers (C-4574). The bevel side of the snap ring
must be outward. Also both eyelets must be to the
right or left of the pin on the compressor. Press snap
ring to make sure it is properly seated in the groove.
CAUTION: If snap ring is not fully seated it will vi-
brate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
(3) Install pulley assembly to compressor. If neces-
sary, tap gently with a block of wood on the friction
surface (Fig. 5).
CAUTION: Do not mar the pulley frictional surface.
(4) Install pulley assembly retaining snap ring
(bevel side outward) with Snap Ring Pliers (C-4574).
Press the snap ring to make sure it is properly
seated in the groove. (5) If the original front plate assembly and pulley
assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 2.54 mm
(0.10 in.) thick, on the shaft against the shoulder. (6) Install front plate assembly onto shaft.
(7) With the front plate assembly tight against the
shim(s), measure the air gap between front plate and
pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (.020 and .035 inch) If proper
air gap is not obtained, add or subtract shims until
desired air gap is obtained.
(8) Install compressor shaft bolt. Tighten to 17.5 62
N Im (155 620 in. lbs.).
Shims may compress after tightening shaft nut.
Check air gap in four or more places to verify if air
gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After a new clutch has been installed cycle the A/C
clutch 20 times (5 sec. on and 5 sec. off). During this
procedure, set the system to the A/C mode, engine rpm at
1500-2000, and high blower speed. This procedure (bur-
nishing) will seat the opposing friction surfaces and
provide a higher clutch torque capability.
COMPRESSOR FRONT SHAFT SEAL
REMOVAL
(1) Using a refrigerant recovery machine, remove
the refrigerant from the system. (2) Remove A/C compressor.
(3) Remove compressor clutch/coil assembly.
(4) Remove compressor through-bolts (Fig. 1).
(5) Remove front cover by tapping on the outside
diameter of the cover with a plastic hammer (Fig. 2). (6) Remove steel valve plate gasket and O-ring seal
and discard (Fig. 3 and 4).
CAUTION:Never reuse cover O-rings or the steel
valve plate gaskets.
(7) Pry out the felt retainer and remove felt from
front cover (Fig. 5).
Fig. 5 Installing Pulley Assembly
Fig. 1 Compressor Through-Bolts
Ä HEATING AND AIR CONDITIONING 24 - 27

FIXED DISPLACEMENT COMPRESSORÐMODEL TR105 INDEX
page page
Compressor ............................. 32
Compressor Clutch/Coil Assembly ............ 32
Compressor Shaft Bearing/Seal .............. 35 Refrigerant System Diagnosis
............... 36
Thermal Limiter Switch .................... 34
COMPRESSOR
Cleanliness is extremely important when disassem-
bly of the compressor is necessary. The surfaces
around the suction and discharge ports of the com-
pressor should be cleaned thoroughly before opening
the system at these points. If compressor is removed
from vehicle, apply tape to the opened ports to pre-
vent any contamination.
REMOVAL
(1) Disconnect battery negative cable.
(2) Loosen and remove drive belts (refer to Group
7, Cooling System). (3) Disconnect compressor clutch wire lead.
(4) Using a refrigerant recovery machine, remove
refrigerant from the A/C system. (5) Remove refrigerant lines from compressor.
(6) Remove compressor attaching bolts.
(7) Remove compressor.
INSTALLATION
(1) Position the compressor on the mount and fit
drive belt. (2) Tighten the compressor attaching bolts to 41
N Im (30 ft. lbs.) torque.
(3) Adjust drive belt (see Group 7, Cooling Sys-
tem). (4) Install refrigerant hoses.
(5) Connect the clutch wire.
(6) Evacuate and charge the system.
(7) Connect the battery negative cable.
COMPRESSOR CLUTCH/COIL ASSEMBLY
CLUTCH INOPERATIVE
The air conditioning compressor clutch electrical
circuit is controlled by the engine controller. The
controller is located in the engine compartment out-
board of the battery. If the compressor clutch does not engage:
Verify refrigerant charge.
If the compressor clutch still does not engage check
for battery voltage at the low pressure or differential
pressure cut-off switch located on the expansion
valve. If voltage is not detected, refer to:
² Group 8W, Wiring Diagrams.
² The appropriate Powertrain Diagnostic Procedures
Manual for diagnostic information. If voltage is detected at the cut-off switch, recon-
nect switch. Then check for battery voltage between
the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil
Tests.
CLUTCH COIL TESTS
(1) Verify battery state of charge. (Test indicator
in battery should be green). (2) Connect an ammeter (0-10 ampere scale) in se-
ries with the clutch coil terminal. Use a volt meter
(0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch. (3) With A/C control in A/C mode and blower at
low speed, start the engine and run at normal idle. (4) The A/C clutch should engage immediately and
the clutch voltage should be within two volts of the
battery voltage. If the A/C clutch does not engage,
test the fusible link. (5) The A/C clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch
coil. This is with the work area temperature at 21ÉC
(70ÉF). If voltage is more than 12.5 volts, add electri-
cal loads by turning on electrical accessories until
voltage reads below 12.5 volts. If coil current reads zero, the coil is open and
should be replaced. If the ammeter reading is 4 am-
peres or more, the coil is shorted and should be re-
placed. If the coil voltage is not within two volts of
the battery voltage, test clutch coil feed circuit for
excessive voltage drop.
REMOVAL
(1) Remove the compressor from the mount.
(2) To prevent compressor shaft rotation, install 2
(6 mm) bolts, along with 2 wrenches, to the threaded
holes in the armature plate (Fig. 1). Remove com-
pressor shaft nut. (3) Tap the armature plate with a plastic and re-
move plate and shim(s).
CAUTION: Do not use screwdrivers between the ar-
mature plate assembly and rotor-pulley to remove
the armature plate. This may damage the armature
plate assembly.
24 - 32 HEATING AND AIR CONDITIONING Ä

(8) With the front clutch plate assembly tight
against the shims, measure the air gap between ar-
mature plate and rotor-pulley face with feeler gauges
(Fig. 4). The air gap should be between 0.35 and 0.65
mm (0.013 and 0.025 inch). If proper air gap is not
obtained, add or subtract shims until desired air gap
is obtained.
(9) Install compressor shaft nut. Tighten nut to
17.5 N Im (155 in. lbs.) torque.
Shims may compress after tightening shaft bolt.
Check air gap in four or more places to verify if air
gap is still correct. Spin pulley for final check. (10) Install the compressor onto the mount.
CLUTCH/COIL BREAK-IN
After a new clutch/coil has been installed, cycle the
A/C clutch 20 times (5 sec. on and 5 sec. off). During
this procedure, run engine at 1500-2000 rpm and set
the A/C on the HIGH mode. This procedure (burnish-
ing) will seat the opposing friction surfaces and pro-
vide a higher clutch torque capability.
THERMAL LIMITER SWITCH
The Thermal Limiter Switch (Fig. 5) is bolted to
the side of the compressor case. It measures compres-
sor surface temperature and is used as a safety de-
vice to cut battery voltage to the compressor clutch
coil. This is performed if compressor case tempera-
ture is excessive. This switch is NOT USEDto cycle the clutch coil.
After the compressor has cooled to normal operating
temperature, the switch will reset.
DIAGNOSIS
The switch can remain bolted to the compressor for
testing. (1) Disconnect the wiring connectors from the ther-
mal limiter switch. (2) Using an ohmmeter, check for continuity be-
tween the two wiring leads. If continuity is not de-
tected, replace switch. Also check for possible
compressor overheating.
² Switch cut-out (no continuity) occurs at 125ÉC
6 3ÉC (255ÉF 637ÉF).
² Switch cuts back in (continuity) at 110ÉC 66ÉC
(230ÉF 642ÉF).
REMOVAL
The refrigerant system can remained fully charged
for thermal limiter switch replacement. After removing the thermal limiter switch, always
replace with a new unit. (1) Disconnect wiring connectors from switch.
(2) Remove the bolt retaining the switch holding
clamp and the switch to the side of the compressor
(Fig. 6). (3) Pry the switch from compressor case with a
screwdriver.
CLEANING
Remove silicone filler from the socket and thor-
oughly clean the socket with thinners.
INSTALLATION
(1) Place the new thermal limiter switch so that
the flat copper surface faces upward. (2) Apply the specified silicone filler (KE 347 RTV)
to the flat copper surface until the surface is evenly
covered. When silicone is applied, apply only from
tube and not by hand. (3) Install the thermal limiter switch into the
socket and secure it with the thermal protector (lim-
iting switch) fixing plate and bolt. Tighten the bolt
Fig. 4 Measuring Air Gap
Fig. 5 Thermal Limiter Switch
24 - 34 HEATING AND AIR CONDITIONING Ä

FIXED DISPLACEMENT COMPRESSORÐMODEL SD709P INDEX
page page
Compressor ............................. 38
Compressor Clutch/Coil Assembly ............ 38
Compressor Shaft Seal .................... 41 Cylinder Head/Valve Plate
.................. 44
Description ............................. 38
Refrigerant System Diagnosis ............... 45
DESCRIPTION
The Sanden compressor is a 7 piston design. Sys-
tem lubrication is provided by 135 ml 615 ml (4.6 oz.
6 0.5 oz.) of 500 viscosity refrigerant oil.
The clutch used on the compressor consists of 3 ba-
sic components:
² The pulley
² Front plate
² Field coil
The pulley and field coil are attached to the front
head of the compressor with tapered snap rings. The
hub is keyed to the compressor shaft and is retained
on the shaft with a self-locking nut. Special service
tools are required to remove and install the clutch
plate on the compressor shaft.
COMPRESSOR
The A/C compressor may be removed and posi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the A/C
compressor clutch/coil assembly, engine, cylinder
head, or generator.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE
TURNED OFF. BEFORE REMOVING A FULLY
CHARGED COMPRESSOR, REVIEW THE SAFETY
PRECAUTIONS AND WARNINGS SECTION IN THIS
GROUP. DO NOT TWIST OR KINK THE REFRIGER-
ANT LINES WHEN REMOVING A FULLY CHARGED
COMPRESSOR. SAFETY GLASSES MUST BE
WORN.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Loosen and remove drive belts (refer to group
7, Cooling System) and disconnect compressor clutch
wire lead. (3) Remove refrigerant lines from compressor (if
necessary). (4) Remove compressor attaching nuts and bolts.
(5) Remove compressor. If refrigerant lines were
not removed, lift compressor/clutch assembly and tie
it to a suitable component. To install, reverse the removal procedure.
COMPRESSOR CLUTCH/COIL ASSEMBLY
The magnetic clutch consists of a stationary elec-
tro-magnetic coil and a rotating pulley and plate as-
sembly. The electromagnetic coil is retained on the com-
pressor with a snap ring and is dimpled to maintain
its position. The pulley and plate assembly are mounted on the
compressor shaft. When the compressor is not in operation, the pul-
ley free wheels on the clutch hub bearing. When the
coil is energized the plate is magnetically engaged
with the pulley and turns the compressor shaft.
REMOVAL
(1) Insert the 2 pins of the front plate spanner into
any 2 threaded holes of the clutch front plate (Fig.
1). Hold clutch plate stationary. Remove hex nut
with 19 mm (3/4 inch) socket.
(2) Remove clutch front plate using puller. Align
puller center bolt to compressor shaft (Fig. 2). Thumb
tighten the puller bolts into the threaded holes. (3) Turn center bolt clockwise with 19 mm (3/4
inch) socket until front plate is loosened. (4) Remove shaft key by lightly tapping it loose
with a slot screwdriver and hammer (Fig. 3). (5) Remove the external front housing snap ring
by using spread type snap ring pliers (Fig. 4).
Fig. 1 Hex Nut Removal
24 - 38 HEATING AND AIR CONDITIONING Ä

COMPONENT SERVICE PROCEDURES INDEX
page page
Air Distribution Duct ...................... 50
Air Distribution Duct ...................... 52
Ambient Switch .......................... 47
Blend-Air Door .......................... 64
Blower Motor ............................ 58
Blower Motor Wheel Assembly .............. 58
Blower Resistor Block ..................... 49
Condensate Drain Tube ................... 64
Condenser Assembly ...................... 57
Condenser Fan Control Switch .............. 47
Defroster Duct ........................... 51
Defroster Duct Adapter .................... 51
Defroster Ducts/Demister Ducts and Hoses ..... 52
Differential Pressure Cut-Out Switch Diagnosis . . 48
Evaporator Coil .......................... 64 Expansion Valve
......................... 55
Filter-Drier Assembly ...................... 57
Fin-Sensing Cycling Clutch Switch ............ 53
Heater Core ............................ 64
Heater Hoses ........................... 51
Heater-A/C Unit AssemblyÐRemoval and Installation ............................ 61
Heater-A/C Unit Recondition ................ 63
Low or Differential Pressure Cut-Off Switch ..... 54
Temperature Control CableÐAA,AP,AG and AJ Models ............................ 49
Temperature Control CableÐAC/AY Models .... 48
Vacuum ActuatorÐFresh/Recirc Door ......... 50
Vacuum ActuatorsÐMode Doors ............. 52
AMBIENT SWITCH
The ambient switch is a temperature sensor located
in front of the condenser behind the grille (Fig. 1).
The ambient switch prevents the compressor from
engaging in cold temperatures. The ambient switch
is a sealed factory calibrated unit. It must be re-
placed if defective.
AMBIENT SWITCH TEST
(1) Disconnect ambient switch wire connector.
(2) Using a suitable ohm meter or continuity
tester, test for continuity across the ambient switch
terminals. (a) At temperature above 10ÉC (50ÉF), the switch
circuit should be complete. (b) Chill the switch with ice to below 10ÉC (50ÉF)
and test for continuity. The switch circuit should
be open, with continuity not detected.
Replace ambient switch if defective.
REMOVAL AND INSTALLATION
(1) Remove the one attaching screw.
(2) Remove the sensor/bracket assembly from the
vehicle. To install, reverse the preceding operation.
CONDENSER FAN CONTROL SWITCH
The Fan Control Switch is located on the plumbing
discharge line at the A/C compressor (Fig. 2). The fan
control switch cycles the radiator/condenser fan on and
off by monitoring the compressor discharge pressure.
The radiator top tank temperature sensor can over ride
the function of the fan control switch. It can cycle the
radiator/condenser fan on and off depending on the
engine temperature.
FAN CONTROL SWITCH DIAGNOSIS
Review Safety Precautions and Warnings before pro-
ceeding. Connect a manifold gauge set to the refriger-
ant system service ports. Work area temperature can
not be below 21ÉC (70ÉF).
Fig. 1 Ambient Temperature Sensor SwitchÐTypical Mounting
Fig. 2 Condenser Fan Control Switch
Ä HEATING AND AIR CONDITIONING 24 - 47

WARNING: AVOID RADIATOR/CONDENSER FAN
BLADES WHEN WORKING IN THE RADIATOR
AREA. FAN IS CONTROLLED BY TEMPERATURE
AND CAN START ANY TIME IGNITION IS ON. PER-
SONAL INJURY CAN RESULT.
(1) Disconnect fan control switch wire connector.
(2) Using a suitable jumper wire, jump across ter-
minals in wire connector. (3) Connect a suitable continuity tester across fan
control switch terminals. (4) Start engine and set idle at 1300 rpm. The ra-
diator fan should run constantly. (5) Set the A/C controls to A/C and high blower.
(6) If the high pressure gauge reads below 1102
kPa (160 psi) there should be no continuity across
the switch terminals.
CAUTION: Do not allow engine to overheat when ra-
diator air flow is blocked.
(7) Block radiator air flow with a suitable cover to
increase the high side pressure to at least 1585 kPa
(230 psi). Electrical continuity should be detected
across the fan control switch terminals. (8) Remove cover from front of vehicle to allow
high side pressure to decrease. When pressure drops
below 1102 kPa (160 psi), continuity should cease. If fan control switch is defective, replace it.
REMOVAL AND INSTALLATION
CAUTION: Refrigerant removal is not necessary
when removing the Condenser Fan Control Switch.
However, a small amount of refrigerant will vent
from the switch port. Review the refrigerant han-
dling section of Safety Precautions and Warnings in
the General Information section of this Group.
(1) Disconnect wire connector from condenser fan
control switch. (2) Loosen and quickly rotate the switch counter-
clockwise and separate from the high pressure line
switch port. To install, reverse the preceding operation.
DIFFERENTIAL PRESSURE CUT-OUT SWITCH
DIAGNOSIS
The Differential Pressure Cut-Out (DPCO) Switch
(Fig. 3) monitors the liquid refrigerant pressure on
the liquid side of the system. The DPCO is located on
the expansion valve. The expansion valve is black in
color when a variable displacement compressor is
used. The DPCO turns off voltage to the compressor
clutch coil when liquid refrigerant pressure drops to
levels that could damage the compressor. The DPCO
is a sealed factory calibrated unit. It must be re-
placed if defective.
DPCO SWITCH DIAGNOSIS
The work area must not be below 10ÉC (50ÉF) to
test the compressor clutch circuit. (1) With gear selector in park or neutral, and park
brake set, start engine and allow to idle. (2) Raise hood and disconnect DPCO switch con-
nector boot. (3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot. (4) If clutch does not engage, the wiring, fuse, re-
lay, ambient switch, or high pressure cut-off switch
can be defective. Refer to Group 8W, Wiring Dia-
grams. (5) If clutch engages, connect a suitable manifold
gauge set. Read low pressure gauge. At pressure 283
kPa (41 psi) and above, DPCO switch will complete
the clutch circuit. If the low pressure gauge reads be-
low 317 kPa (46 psi), the system is low on refrigerant
charge or empty due to a leak. Refer to Testing For
Refrigerant Leaks in the Refrigerant Service Proce-
dures section. (6) Install connector boot on switch and repeat step
number 3. If the clutch does not engage, replace the
DPCO switch.
TEMPERATURE CONTROL CABLEÐAC/AY MODELS
REMOVAL AND INSTALLATION
A Temperature Control Cable is used on non-ATC
heat or heater-A/C systems only. ATC (Automatic
Temperature Control) systems use an electrically op-
erated temperature control. Refer to the ATC section
of this Group. (1) Remove the A/C-Heater control panel assembly.
Refer to A/C-Heater Control Replacement in Group
8E Instrument Panel. Disconnect the cable attaching
flag from the A/C-heater control and remove the ca-
ble from control panel.
Fig. 3 Differential Pressure Cut-Out Switch
24 - 48 HEATING AND AIR CONDITIONING Ä

DEFROSTER DUCT ADAPTER
REMOVAL AND INSTALLATION
AA BODY On AA body, the instrument panel must be rolled
down to service duct. Refer to Group 8E, Instrument
Panel.
AC, AP, AY BODY
(1) Remove air distribution duct.
(2) Separate the defroster adapter from the heater-
A/C unit and pull the adapter downward and out
from under the instrument panel. To install, reverse the preceding operation.
DEFROSTER DUCT
REMOVAL AND INSTALLATION
AA, AG, AND AJ BODY
On AA, AG, and AJ Body, the instrument panel
must be rolled down to service duct. Refer to Group
8E, Instrument Panel.
AC, AP, AY BODY
(1) Remove the air distribution duct.
(2) Remove the defroster duct adapter.
(3) Remove the instrument panel top cover. Refer
to Group 8E, Instrument Panel. (4) Locate and remove defroster duct attaching
screws at the ends of each outlet (Fig. 10). (5) Allow the defroster duct to drop downward and
remove it from the vehicle. To install, reverse the preceding operation.
HEATER HOSES
REMOVAL AND INSTALLATION
Review Cooling System Precautions before
proceeding with this operation. (1) Drain engine cooling system. Refer to Group 7,
Cooling System. (2) Loosen clamps at each end of hose to be re-
moved (Figs. 11 or 12).
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple.
CAUTION: When removing hoses from heater core
inlet or outlet nipples DO NOT exert excess pres-
sure. The heater core may become damaged and
leak engine coolant into heater-A/C unit.
Fig. 9 Air Distribution DuctsÐTypical
Fig. 10 Removing or Installing Defroster DuctÐTypical
Fig. 11 Heater Hose RoutingÐ2.2 L, 2.5 LEnginesÐTypical
Ä HEATING AND AIR CONDITIONING 24 - 51

To install, reverse the preceding operation.
VACUUM ACTUATORSÐMODE DOORS
The Vacuum Actuators for the Mode Doors are lo-
cated on the drivers side of heater/AC housing above
the accelerator pedal.
REMOVAL
(1) Remove the instrument panel cover under the
steering column. Refer to Group 8E, Instrument
Panel. Heat/Defrost Actuator:
Remove two screws from bracket. Lift actuator up-
ward and pull out (Fig. 13).
Mode Door Actuator:
Remove two screws from bracket (Fig. 14). Rotate
actuator counter-clockwise to unhook from door and
pull to remove.
INSTALLATION
Heat/Defrost Actuator: Install actuator link through housing and insert in
heat defrost door slot. Push down to hook link to
door. Locate the bracket to the housing and install
two screws. Mode Door Actuator:
Insert the actuator shaft through the hole in the
housing and heat/defrost door. Attach through
mounting hole in the mode door. Install two screws
in bracket. Install the instrument panel cover under the steer-
ing column.
AIR DISTRIBUTION DUCT
REMOVAL AND INSTALLATION
(1) Instrument panel assembly must be removed.
Refer to Group 8E, Instrument Panel. (2) After instrument panel has been removed, sep-
arate the defroster/demister ducts from the air distri-
bution duct. (3) Remove the air distribution duct-to-instrument
panel mounting screws (Fig. 15). To install, reverse removal procedure.
DEFROSTER DUCTS/DEMISTER DUCTS AND
HOSES
REMOVAL AND INSTALLATION
(1) Instrument panel assembly must be removed.
Refer to Group 8E, Instrument Panel. (2) After instrument panel has been removed, sep-
arate the defroster/demister ducts from the air distri-
bution duct. (3) Remove the demister tubes and hoses (Fig. 16).
To install, reverse removal procedure.
Fig. 12 Heater Hose RoutingÐ3.0 L EngineÐTypical
Fig. 13 Removing or Installing Heat/Defrost Vacuum Actuator Assembly
Fig. 14 Mode Door Vacuum Actuators
24 - 52 HEATING AND AIR CONDITIONING Ä