Intake DODGE RAM 1500 1998 2.G Workshop Manual

The torquing force of this threaded nut (fitting)
provides a sealing pressure between the fuel line con-
nector and the fuel injector.Retaining nut torque
is very critical.If the nut (fitting) is under torqued,
the mating surfaces will not seal and a high-pressure
fuel leak will result. If the fitting is over torqued, the
connector and injector will deform and also cause a
high-pressure fuel leak. This leak will be inside the
cylinder head and will not be visible. The result will
be a possible fuel injector miss-fire and low power, or
a no-start condition.
The fuel injectors use hole type nozzles. High-pres-
sure flows into the side of the injector, the ECM acti-
vates the solenoid causing the injector needle to lift
and fuel to be injected. The clearances in the nozzle
bore are extremely small and any dirt or contami-
nants will cause the injector to stick. Because of this,
it is very important to do a thorough cleaning of any
lines before opening up any fuel system component.
Always cover or cap any open fuel connections before
a fuel system repair is performed.
Each fuel injector connector tube contains an edge
filter that is designed to beak up small contaminants
before entering the fuel injector.The edge filters
are not a substitute for proper cleaning andcovering of all fuel system components during
repair.
The bottom of each fuel injector is sealed to the
cylinder head with a1.5mmthick copper shim (gas-
ket). The correct thickness shim must always be re-
installed after removing an injector.
Fuel pressure in the injector circuit decreases after
injection. The injector needle valve is immediately
closed and fuel flow into the combustion chamber is
stopped. Exhaust gases are prevented from entering
the injector nozzle by the needle valve.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
Six individual, solenoid actuated high-pressure fuel
injectors are used (Fig. 14). The injectors are verti-
cally mounted into a bored hole in the top of the cyl-
inder head. This bored hole is located between the
intake/exhaust valves. High-pressure connectors (Fig.
15), mounted into the side of the cylinder head, con-
nect each fuel injector to each high-pressure fuel line.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.
(2) Remove breather assembly.
Fig. 15 HIGH-PRESSURE CONNECTOR
1 - HIGH-PRESSURE CONNECTOR (TO FUEL INJECTOR)
2 - O-RING
3 - CONNECTOR RETAINER4 - FUEL RAIL
5 - HIGH-PRESSURE FUEL LINES
6 - LOCATING PINS
DRFUEL INJECTION - DIESEL 14 - 75
FUEL INJECTOR (Continued)

(6) Install injector into cylinder head with male
connector port facing the intake manifold. Push down
on fuel injector mounting flange to engage o-ring and
seat injector.
(7) Tightening Sequence:
(a) Install fuel injector holdown clamp (mount-
ing flange) bolts.Do a preliminary tightening
of these bolts to 5 N´m (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.
(b) After tightening, relieve bolt torque, but
leave both bolts threaded in place.
(c) Install high-pressure connector and retaining
nut. Do a preliminary tightening to 15 N´m (11 ft.
lbs.) torque.
(d) Alternately tighten injector holdown bolts to
10 N´m (89 in. lbs.) torque.
(e) Do a final tightening of the high-pressure
connector and retaining nut. Tighten to 50 N´m (37
ft. lbs.) torque.
(8) Connect injector solenoid wires and nuts to top
of injectors (Fig. 18). Tighten connector nuts to 1.25
N´m (11 in. lbs.) torque.Be very careful not to
overtighten these nuts as damage to fuel injec-
tor will occur.
(9) Install exhaust rocker arm assembly. Refer to
Engine.
(10) Set exhaust valve lash. Refer to Engine.
(11) Install high pressure fuel line. Refer to Torque
Specifications.Be sure to use a secondary
back-up wrench on the connector nut (fitting)
while torquing fuel line fitting.Refer to Fuel Line
Installation for additional information.
(12) Install valve cover. Refer to Engine.
(13) Install breather assembly.
(14) Connect negative battery cables to both bat-
teries.
FUEL INJECTOR RAIL
DESCRIPTION
The fuel injector rail is bolted to the top of the
intake manifold.
OPERATION
The fuel rail is used as a distribution device to
supply high-pressure fuel to the high-pressure fuel
lines.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables at both
batteries. Isolate ends of both cables.
(2) Disconnect electrical connector at fuel pressure
sensor.
(3) Remove banjo bolt at fuel limiting valve.
(4) Disconnect necessary wiring harness retention
clips from intake manifold.
(5) Lift 2 rubber covers to gain access to positive
(+), intake heater cable nuts. Remove 2 nuts and
remove 2 cables from studs.
(6) Carefully remove 4 high-pressure fuel lines
from top of injector rail engine. Note position of each
line while removing.Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Carefully remove 2 high-pressure fuel lines at
each end of injector rail. Note position of each line
while removing.Do not bend lines while remov-
ing.
(8) Remove fuel line connecting injector pump to
fuel rail.
(9) Remove 3 injector rail mounting bolts (Fig. 22).
(10) Remove rail from top of intake manifold.
INSTALLATION
(1) Clean any dirt/debris from top of intake mani-
fold and bottom of fuel rail.
(2) Position fuel rail to top of manifold and install
3 mounting bolts. Refer to Torque Specifications.
(3) Install all high-pressure lines to rail. Refer to
Fuel Lines for procedures.
(4) Reposition wiring harness to intake manifold
and install new tie wraps.
(5) Install and tighten fuel limiting valve banjo
bolt. Refer to Torque Specifications.
(6) Connect electrical connector to fuel pressure
sensor.
(7) Position 2 positive (+) cables to intake heater
studs. Install 2 nuts.
14 - 78 FUEL INJECTION - DIESELDR
FUEL INJECTOR (Continued)

(8) Connect battery cables to both batteries.
(9) Start engine and check for leaks.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combination, dual function Inlet Air Tempera-
ture/Pressure Sensor is located on the air cleaner (fil-
ter) cover.
OPERATION
The Inlet Air Temperature/Pressure Sensor is a
combination dual-function sensor. The sensor element
extends into the intake air stream at the top of the
air filter housing. Ambient air temperature as well as
barometric pressure is monitored by this sensor. The
Engine Control Module (ECM) monitors signals from
this sensor.
REMOVAL
The Inlet Air Temperature/Pressure Sensor is
located on the air cleaner cover (Fig. 23).
(1) Disconnect electrical connector at sensor (Fig.
24).
(2) Remove two Torx-type mounting screws.
(3) Remove sensor from air cleaner cover.
(4) Check condition of sensor o-ring (Fig. 25).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Position sensor into top of air cleaner cover
with a slight twisting action.
(3) Install 2 mounting screws.
(4) Install electrical connector.
Fig. 22 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
3 - FUEL INJECTOR RAIL
Fig. 23 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
DRFUEL INJECTION - DIESEL 14 - 79
FUEL INJECTOR RAIL (Continued)

INTAKE AIR HEATER
DESCRIPTION
The intake manifold air heater element assembly
is located in the top of the intake manifold.
OPERATION
The air heater elements are used to heat incoming
air to the intake manifold. This is done to help
engine starting and improve driveability with cool or
cold outside temperatures.
Electrical supply for the 2 air heater elements is
controlled by the Engine Control Module (ECM)
through the 2 air heater relays. Refer to Intake Man-
ifold Air Heater Relays for more information.
Two heavy-duty cables connect the 2 air heater ele-
ments to the 2 air heater relays. Each of these cables
will supply approximately 95 amps at 12 volts to an
individual heating element within the heater block
assembly.
Refer to the Powertrain Diagnostic Procedures
manual for electrical operation and complete descrip-
tion of the intake heaters, including pre-heat and
post-heat cycles.
REMOVAL
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Disconnect both negative battery cables at both
batteries. Cover and isolate ends of both cables.
(2) Remove both the intake manifold air intake
tube (above injection pump), and its rubber connector
hose (Fig. 26).
(3) Lift 2 rubber covers (Fig. 27) to gain access to 2
positive (+) cable nuts. Remove these 2 nuts (Fig. 28)
and remove 2 cables from studs.
(4) Disconnect ground strap (Fig. 27) at heater ele-
ment stud.
(5) Remove wiring harness clips.
(6) Remove engine oil dipstick tube bracket from
air inlet connection and fuel filter housing.
(7) Remove 4 housing mounting bolts (Fig. 27) and
remove heater element assembly.
INSTALLATION
If servicing either of the heater elements, the
entire block/element assembly must be replaced.
(1) Using 2 new gaskets, position element assem-
bly and air housing to intake manifold.
(2) Install ground cable to air housing.
(3) Install 4 housing bolts and tighten to 24 N´m
(18 ft. lbs.) torque.
(4) Connect 2 positive (+) heater cables at cable
mounting studs.Do not allow either of the cable
eyelets to contact any other metal source other
than the cable nuts/studs.
Fig. 24 INLET/PRESSURE SENSOR REMOVAL/
INSTALLATION
1 - INLET/PRESSURE SENSOR
2 - ELEC. CONNECTOR
3 - SENSOR MOUNTING SCREWS (2)
4 - TOP OF AIR FILTER COVER
Fig. 25 SENSOR O-RING
1 - IAT/PRESSURE SENSOR
2 - O-RING
14 - 80 FUEL INJECTION - DIESELDR
INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)

(5) Install engine oil dipstick tube and mounting
bolt.
(6) Connect rubber connector hose and intake tube
to air intake housing. Tighten clamp bolts to 11 N´m
(95 in. lbs.) torque.
(7) Connect both negative battery cables at both
batteries.
Fig. 26 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
Fig. 27 AIR HEATER MANIFOLD
1 - GROUND CABLE
2 - MOUNTING BOLTS (4)
3 - RUBBER COVERS
4 - OIL DIPSTICK TUBE
5 - DIPSTICK MOUNTING BOLT
6 - NUT (GROUND CABLE)
Fig. 28 AIR HEATER ELEMENTS
1 - MOUNTING BOLTS (4)
2 - AIR HEATER MANIFOLD
3 - INTAKE MANIFOLD
4 - HEATER ELEMENTS
5 - LOWER GASKET
6 - NUTS (2) POSITIVE CABLES
7 - UPER GASKET
DRFUEL INJECTION - DIESEL 14 - 81
INTAKE AIR HEATER (Continued)

INTAKE AIR HEATER RELAY
DESCRIPTION
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 29).
OPERATION
The Engine Control Module (ECM) operates the 2
heating elements through the 2 intake manifold air
heater relays.
Refer to Powertrain Diagnostic Procedures for an
electrical operation and complete description of the
intake heaters, including pre-heat and post-heat
cycles.
REMOVAL
The 2 intake manifold air heater relays are located
in the engine compartment. They are attached to a
common bracket. This bracket is attached to the
right battery tray (Fig. 29).
The mounting bracket and both relays are replaced
as an assembly.
(1) Disconnect both negative battery cables at both
batteries.
(2) Disconnect four relay trigger wires at both
relays. Note position of wiring before removing.
(3) Lift four rubber shields from all 4 cables.(4) Remove four nuts at cable connectors. Note
position of wiring before removing.
(5) Remove relay mounting bracket bolts and
remove relay assembly.
INSTALLATION
(1) Install relay assembly to battery tray. Tighten
mounting bolts to 4.5 N´m (40 in. lbs.) torque.
(2) Connect eight electrical connectors to relays.
(3) Connect battery cables to both batteries.
INTAKE AIR TEMPERATURE
SENSOR/MAP SENSOR
DESCRIPTION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold.
OPERATION
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP Sensor is installed into
the top of the intake manifold with the sensor ele-
ment extending into the air stream.
The IAT portion of the sensor provides an input
voltage to the Engine Control Module (ECM) indicat-
ing intake manifold air temperature. The MAP por-
tion of the sensor provides an input voltage to the
ECM indicating turbocharger boost pressure.
REMOVAL
The combination, dual function Intake Manifold
Air Temperature Sensor/MAP (IAT/MAP) sensor is
installed into the top of the intake manifold (Fig. 30).
(1) Clean area around sensor.
(2) Disconnect electrical connector from IAT/MAP
sensor.
(3) Remove two T-15 Torx headed screws.
(4) Remove sensor from intake manifold.
(5) Check condition of sensor o-ring (Fig. 31).
INSTALLATION
(1) Check condition of sensor o-ring.
(2) Lubricate sensor o-ring with clean engine oil.
(3) Clean sensor mounting area at intake mani-
fold.
(4) Position sensor into intake manifold.
(5) Install and tighten 2 sensor mounting screws
to 1 N´m (9 in. lbs.) torque.
(6) Connect electrical connector to sensor.
Fig. 29 INTAKE MANIFOLD AIR HEATER RELAYS
1 - BATTERY
2 - CABLES TO INTAKE HEATERS
3 - RELAY TRIGGER WIRES
4 - INTAKE AIR HEATER RELAYS (2)
14 - 82 FUEL INJECTION - DIESELDR

MAP SENSOR
DESCRIPTION
A combination, dual function Intake Manifold Air
Temperature Sensor/MAP Sensor is used. Refer to
Intake Air Temperature Sensor/MAP Sensor for infor-
mation.
THROTTLE CONTROL CABLE
REMOVAL
If Equipped With Engine Mounted Accelerator Pedal
Position Sensor
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 32). The plas-
tic cable retainer snaps into pedal arm.
(3) From inside vehicle, remove cable clip (Fig. 32).
(4) Remove cable core wire at pedal arm.
(5) Remove cable housing from dash panel and
pull cable into engine compartment.
(6) Remove cable cover (Fig. 33). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 33). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
(7) Using 2 screwdrivers, pry cable connector
socket from throttle lever ball (Fig. 34).Be very
careful not to bend throttle lever arm.
If Equipped With Battery Tray Mounted Accelerator Pedal
Position Sensor
The Throttle Control Cable connects the accelera-
tor pedal to the Accelerator Pedal Position Sensor
(APPS). A separate mechanical cable is not routed to
the throttle body.
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal, cables or APPS.
(1) Disconnect both negative battery cables at both
batteries.
(2) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer and throttle cable core
wire from upper end of pedal arm (Fig. 35). The plas-
tic cable retainer snaps into pedal arm.
(3) Remove cable core wire at pedal arm.
(4) Remove APPS. Refer to (Diesel) Accelerator
Pedal Position Sensor (APPS) Removal / Installation.
(5) From inside vehicle, remove cable clip (Fig. 35).
Fig. 30 INTAKE/MAP SENSOR
1 - TOP OF INTAKE MANIFOLD
2 - IAT/MAP SENSOR
3 - ELEC. CONNECTOR
4 - MOUNTING BOLTS (2)
Fig. 31 SENSOR O-RING
1 - IAT/MAP SENSOR
2 - O-RING
DRFUEL INJECTION - DIESEL 14 - 83
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR (Continued)

(8) Fill the system with fluid and perform Steering
Pump Initial Operation, (Refer to 19 - STEERING/
PUMP - STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes
then stop the engine.
(10) Remove the return line/lines from the pump
and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check
the draining fluid for contamination. If the fluid is
still contaminated, then flush the system again.
(12) Install the return line/lines and perform
Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
REMOVAL
REMOVAL - GAS
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose. (Fig. 2)
(4) Disconnect the pressure hose. (Fig. 2)
(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes. (Fig. 2)
REMOVAL - DIESEL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Disconnect the return hose.
(4) Disconnect the pressure hose.(5) Access to remove the three bolts securing the
pump to the cylinder head can be gained thru the
pulley holes.
(6) Loosen the pump bracket to the block.
(7) Remove the 6 intake plenum bolts (Fig. 3).
(8) loosen the inner cooler tube clamp at the
intake plenum and remove the intake plenum.
(9) Loosen the inner cooler tube clamp at the radi-
ator support side and remove the tube from the vehi-
cle.
(10) Remove the power steering pump from the top
of the engine compartment where the intake plenum
was (Fig. 3).
Fig. 2 POWER STEERING PUMP
1 - POWER STEERING PULLEY
2 - POWER STEERING RESERVOIR
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
Fig. 3 POWER STEERING PUMP ACCESS
1 - INTAKE PLENUM MOUNTING
2 - POWER STEERING PUMP
DRPUMP 19 - 41
PUMP (Continued)

INSTALLATION
INSTALLATION - GAS
(1) Align the pump with the mounting holes in the
left cylinder head.
(2) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(3) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(4) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - DIESEL
(1) Set the power steering pump in place in the
engine compartment from the top (Fig. 3).(2) Install the inner cooler tube.
(3) Tighten the inner cooler tube clamp at the
radiator support side.
(4) Install the 6 intake plenum bolts (Fig. 3).
(5) Tighten the inner cooler tube clamp at the
intake plenum.
(6) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(7) Tighten the pump bracket to the block.
(8) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(9) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pressure
Switch10 Ð 80
Power Steering Line
Pressure Line32 23 Ð
Power Steering Line
Return Line
HD51 38 Ð
Power Steering Line
Return Line
LD70 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
Power Steering Pump
Mounting Bolts28 27 Ð
Power Steering Pump
Reservoir Bolts13 10 120
Power Steering Pump
Bracket Bolts5562
19 - 42 PUMPDR
PUMP (Continued)

ber above the heating, ventilation and air condition-
ing (HVAC) housing. On models equipped with air
conditioning, the air passes through the evaporator
coil. Air flow can be directed either through or
around the heater core. This is done by adjusting the
blend door with the temperature control knob on the
A/C-heater control located the instrument panel. The
air flow can then be directed from the panel, floor
and defrost outlets in various combinations using the
mode control knob located on the A/C-heater control.
Air flow velocity can be adjusted with the blower
speed selector located on the A/C-heater control.
NOTE: It is important to keep the air intake opening
clear of debris. Leaf particles and other debris that
is small enough to pass through the cowl opening
screen can accumulate within the HVAC housing.
The closed, warm, damp and dark environment cre-
ated within the housing is ideal for the growth of
certain molds, mildews and other fungi. Any accu-mulation of decaying plant matter provides an addi-
tional food source for fungal spores, which enter
the housing with the fresh intake-air. Excess debris,
as well as objectionable odors created by decaying
plant matter and growing fungi can be discharged
into the passenger compartment during heater-A/C
operation if the air intake opening is not kept clear
of debris.
The heater and air conditioning systems are blend-
air type systems. In a blend-air system, a blend door
controls the amount of unconditioned air (or cooled
air from the evaporator on models with air condition-
ing) that is allowed to flow through, or around, the
heater core. A temperature control knob determines
the discharge air temperature by actuating an elec-
tric motor, which operates the blend door. This allows
an almost immediate control of the output air tem-
perature of the system.
On all models, the outside air intake can be shut
off by selecting the Recirculation Mode with the
mode control knob. This will operate a electric actu-
ated recirculation air door that closes off the outside
fresh air intake and recirculates the air that is
already inside the vehicle.
The air conditioning compressor can be engaged in
any mode by pressing the snowflake, A/C on/off but-
ton. It can also be engaged by placing the mode con-
trol in the mix to defrost positions. This will remove
heat and humidity from the air before it is directed
through or around the heater core. The mode control
knob on the A/C-heater control is used to also direct
the conditioned air to the selected system outlets.
The mode control switch uses an electric motor to
control the mode doors.
The defroster outlet receives airflow from the
HVAC housing through the molded plastic defroster
duct, which connects to the HVAC housing defroster
outlet. The airflow from the defroster outlets is
directed by fixed vanes in the defroster outlet grilles
and cannot be adjusted. The defroster outlet grilles
are integral to the instrument panel top cover.
The side window demister outlets receive airflow
from the HVAC housing through the molded plastic
defroster duct and two molded plastic demister ducts.
The airflow from the side window demister outlets is
directed by fixed vanes in the demister outlet grilles
and cannot be adjusted. The side window demister
outlet grilles are integral to the instrument panel.
The demisters direct air from the HVAC housing
through the outlets located on the top corners of the
instrument panel. The demisters operate when the
mode control knob is positioned in the floor-defrost
and defrost-only settings. Some air may be noticeable
from the demister outlets when the mode control is
in the bi-level to floor positions.
Fig. 1 HVAC Housing - Dual Zone Shown, Single
Zone Typical
1 - NUT
2 - PASSENGER BLEND DOOR ACTUATOR
3 - NUT
4 - INLET BAFFLE
5 - RECIRCULATION DOOR ACTUATOR
6 - RECIRCULATION DOOR
7 - DRIVER SIDE BLEND DOOR ACTUATOR
8 - HVAC HOUSING
9 - BOLT
10 - DEFROSTER DOOR ACTUATOR
11 - MODE DOOR ACTUATOR
24 - 2 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)