lock DODGE RAM 1500 1998 2.G Workshop Manual

(1) Position the hinge cover over the hinge and
close over the lock tabs.
(2) Install the pivot bolt and tighten to 10 N´m (89
in. lbs.).
(3) Reposition the storage bin/cushion cover.
(4) Connect the zip strip.
CENTER SEAT BACK HINGE
REMOVAL
NOTE: Do not reuse the seat fasteners, always
replace with new ones.
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/CENTER ARMREST / SEAT BACK -
REMOVAL)
Free Pivot Hinge/Cover
(1) Disconnect the storage bin/cushion cover j-strap
and position aside.
(2) Remove and discard the pivot bolt. (Fig. 7)
(3) Remove the hinge spacer. (Fig. 8)
(4) Open the hinge cover flap and remove the wire
harness, if equipped. (Fig. 9)
(5) Remove the cover from the hinge.
Fig. 7 PIVOT HINGE/COVER
1 - PIVOT BOLT
2 - HINGE COVER
3 - STORAGE BIN COVER
4 - 12V POWER SUPPLY HARNESS
5 - HINGE BOLTS (2)
6 - HINGE
Fig. 8 PIVOT HINGE SPACER
1 - HINGE COVER
2 - SPACER
3-STOPPIN
Fig. 9 PIVOT HINGE COVER
1 - HINGE COVER FLAP
2-STOPPIN
3 - HINGE COVER
4 - HINGE
5 - 12V POWER SUPPLY HARNESS
23 - 78 SEATSDR
CENTER SEAT BACK INERTIA HINGE COVER (Continued)

WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
²URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
²DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
²BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
²VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
²SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
²ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR -
REMOVAL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).(3) Remove the a-pillar weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/A-
PILLAR WEATHERSTRIP RETAINER - REMOVAL)
(4) Remove the a-pillar trim panels. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL)
(5) Remove the headliner and from the inside of
the vehicle, cut the upper urethane bonding from
around windshield upper edge using a suitable sharp
cold knife (C-4849). A pneumatic cutting device can
be used but is not recommended. (Refer to 23 -
BODY/INTERIOR/HEADLINER - REMOVAL)
(6) From the outside of the vehicle, cut urethane
bonding from the remaining sides of the windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended.
(7) Separate windshield from vehicle.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of
its old urethane bonding material. A small amount of
old urethane, approximately 1-2 mm in height,
should remain on the fence. Do not grind off or com-
pletely remove all old urethane from the fence, the
paint finish and bonding strength will be adversely
affected.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the outside
surface of the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation. Remove replace-
ment windshield from windshield opening (Fig. 5).
(2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 6).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with a new
clean and dry lint- free cloth.
(5) Apply black-out primer onto the glass using the
windshield molding as a guide. The primer should be
15 mm (5/8 in.) wide on the top and sides of the glass
23 - 88 STATIONARY GLASSDR

and 25 mm (1 in.) on the bottom of windshield. Allow
at least three minutes drying time.
(6) Locatenewsupport spacers on support brack-
ets and adjust to lowest height. (Fig. 5)
(7) Position seven new foam spacers on the inside
surface of the windshield, flush with the lower and
side edges. (Fig. 7)
(8) Position three new foam spacers on the inside
surface of the windshield, at a minimum distance of
3 mm (0.12 in.) from the top edge of the windshield.
(Fig. 7)
(9) Apply a 13 mm (1/2 in.) high and 10 mm (3/8
in.) wide bead of urethane around the perimeter of
windshield. At the top, apply the bead 7 mm (1/4 in.)
inboard from the glass edge. On the other three sides
apply the bead 14 mm (0.55 in.) inboard from the
glass edge. The urethane bead should be shaped in a
triangular cross-section, this can be achieved by
notching the tip of the applicator (Fig. 8).
(10) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(11) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers.
(12) Slowly lower windshield glass to the fence
opening guiding the lower corners into proper posi-
tion. Beginning at the bottom and continuing to the
top, push glass onto fence along the A-Pillars. Push
windshield inward to the fence at the bottom corners
(Fig. 9).
(13) Push windshield upward, setting the wind-
shield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12
in.) and ratchet up the adjustable support brackets.
(14) Using clean water, lightly mist the support
spacers.
(15) Clean excess urethane from exterior with
MOPARtSuper Clean or equivalent.
(16) Install cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - INSTALLATION).
(17) Install rear view mirror support bracket.
(Refer to 23 - BODY/INTERIOR/REAR VIEW MIR-
ROR - INSTALLATION).
(18) Install rear view mirror. (Refer to 23 - BODY/
INTERIOR/REAR VIEW MIRROR - INSTALLA-
TION).
(19) Install the a-pillar weatherstrip retainer.
(Refer to 23 - BODY/WEATHERSTRIP/SEALS/A-
PILLAR WEATHERSTRIP RETAINER - INSTALLA-
TION)
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig. 5 CENTER WINDSHIELD AND MARK AT
SUPPORT
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 6 WORK SURFACE SET UP
1 - WINDSHIELD AND MOLDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (0.3 in.) FROM
EDGE
3 - BLOCKS
DRSTATIONARY GLASS 23 - 89
WINDSHIELD (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING
SYSTEM REQUIREMENTS...............1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
OPERATION - HEATER AND AIR
CONDITIONER........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................3DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST..................6
SPECIFICATIONS - A/C SYSTEM............7
CONTROLS.............................9
DISTRIBUTION..........................26
PLUMBING.............................41
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser
will reduce the performance of the A/C and engine
cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manually controlled single zone type heating-air
conditioning system or a manually controlled dual
zone type heating-air conditioning system is available
on this model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing
mounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block²Heater core
²Evaporator coil
²Blend door and actuator
²Defrost door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
a combination of the three main housing outlets:
defrost, panel or floor. The defrost outlet is located on
the top of the housing, the panel outlet is located on
the face of the housing and the floor outlet is located
on the bottom of the housing. Once the conditioned
air exits the unit housing, it is further directed
through molded plastic ducts to the various outlets in
the vehicle interior. These outlets and their locations
are as follows:
²Defroster Outlet- A single large defroster out-
let is located in the center of the instrument panel
top cover, near the base of the windshield.
²Side Window Demister Outlets- There are
two side window demister outlets, one is located at
each outboard end of the instrument panel top cover,
near the belt line at the A-pillars.
²Panel Outlets- There are four panel outlets in
the instrument panel, one located near each outboard
end of the instrument panel facing the rear of the
vehicle and two located near the top of the instru-
ment panel center bezel.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel near the dash panel.
OPERATION - HEATER AND AIR CONDITIONER
The heating and air conditioning systems pulls
outside (ambient) air through the cowl opening at the
base of the windshield, then into the plenum cham-
DRHEATING & AIR CONDITIONING 24 - 1

PERFORMANCE TEMPERATURE AND PRESSURE
Ambient Air
Temperature21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Air Temperature at
Center Panel Outlet7É C
(45É F)7É C
(45É F)13É C
(55É F)13É C
(55É F)18É C
(64É F)
Compressor Inlet
Pressure at Service
Port (low Side)138 to 207 kPa
(20 to 30 psi)172 to 241 kPa
(25 to 35 psi)207 to 276
kPa
(30 to 40 psi)241 to 310
kPa
(35 to 45 psi)276 to 345 kPa
(40 to 50 psi)
Compressor
Discharge Pressure at
Service Port (High
Side)1034 to 1724
kPa
(150 to 250
psi)1379 to 2068
kPa
(200 to 300
psi)1724 to 2413
kPa
(250 to 350
psi)1999 to 2689
kPa
(290 to 390
psi)2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor discharge pressure to
the Performance Temperature and Pressure chart. Ifthe compressor discharge pressure is high, see the
Pressure Diagnosis chart.
PRESSURE DIAGNOSIS
Condition Possible Causes Correction
Constant compressor
engagement and warm air
from passenger vents.1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the
refrigerant system.1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty A/C compressor
clutch coil.3. See A/C Compressor Clutch Coil in this group.
Test the compressor clutch coil and replace, if
required.
4. Faulty A/C compressor
clutch relay.4. See A/C Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty Evaporator
Temperature Sensor.5. See Evaporator Temperature Sensor in this
group. Reinstall or replace the sensor as
required.
6. Faulty A/C pressure
transducer.6. See A/C pressure transducer in this group.
Test the switch and replace, if required.
7. Faulty Powertrain Control
Module (PCM).7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
24 - 4 HEATING & AIR CONDITIONINGDR
HEATING & AIR CONDITIONING (Continued)

²Faulty A/C-heater control.
²Faulty related wiring harness or connectors.
²Improper engine coolant temperature.
SPECIFICATIONS - A/C SYSTEM
The R-134a refrigerant system charge capacity for
this vehicle can be found on the underhood Specifica-
tion Label.
A/C SYSTEM SPECIFICATION CHART
Item Description Notes
Compressor Saden SD-7
(5.9L engine)SP-15 PAG oil
Denso 10S17
(3.7L/4.7L/5.7L
engines)ND-8 PAG oil
Freeze±up
ControlEvaporator
Temperature
SensorEvaporator coil
mounted
High psi Control A/C pressure
transducerDischarge line
mounted
Compressor
Clutch Coil
Draw2 - 3.9 amps @
12V   0.5V @
21É C (70É F)5.9L engine
2.2 amps @
12V   0.5V @
21É C (70É F)3.7L/4.7L/5.7L
engines
Compressor
Clutch Air Gap0.41 - 0.79 mm
(0.016 - 0.031
in.)5.9L engine
0.35 - 0.65 mm
(0.013 - 0.025
in.)3.7L/4.7L/5.7L
engines
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A/C Compressor Shaft Nut 15-20 11-15 ±
A/C Compressor Bolt-Inner
Front-3.7L,4.7L40 30 ±
A/C Compressor Bolt-Inner
Rear-3.7L,4.7L55 41 ±
A/C Compressor Rear Bolt-
3.7L,4.7L55 41 ±
A/C Compressor Lower Bolts-5.7L 40 30 ±
A/C Compressor Rear Bolt-5.7L 55 41 ±
A/C Compressor Bolts-5.9L Diesel 24 17 ±
A/C Compressor Clutch Coil Wire
Retainer Screw2.2 ± 20
A/C-Heater Control Screws 2.2 ± 20
Accumulator Bracket Bolts 4.5 ± 40
Blower Motor Screws 2.2 ± 20
Blower Motor Resistor Block
Screws2.2 ± 20
Center Distribution Duct Screws 2.2 ± 20
DRHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - A/C
COMPRESSOR CLUTCH COIL...........10
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN.......10
REMOVAL.............................10
INSPECTION..........................11
INSTALLATION.........................12
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................14
A/C HEATER CONTROL
DESCRIPTION.........................14
REMOVAL.............................15
INSTALLATION.........................15
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................15
OPERATION...........................16
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................16
REMOVAL.............................16
INSTALLATION.........................16
BLEND DOOR ACTUATOR
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................18
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................18OPERATION...........................18
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK..............19
REMOVAL.............................19
INSTALLATION.........................19
BLOWER MOTOR SWITCH
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH......................20
DEFROST DOOR ACTUATOR
DESCRIPTION.........................20
OPERATION...........................21
REMOVAL.............................21
INSTALLATION.........................21
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................22
MODE DOOR ACTUATOR
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................24
INSTALLATION.........................25
A/C COMPRESSOR CLUTCH/
COIL
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil, a pulley bearing and
pulley assembly, and a clutch plate (Fig. 1). The elec-
tromagnetic coil and the pulley bearing and pulley
assembly are each retained on the nose of the com-
pressor front housing with snap rings. The clutch
plate is keyed to the compressor shaft and secured
with a nut. These components provide the means toengage and disengage the compressor from the
engine serpentine accessory drive belt.
OPERATION
The A/C compressor clutch provides the means to
engage and disengage the A/C compressor from the
engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the pulley bearing, which is
part of the pulley assembly. The compressor clutch
DRCONTROLS 24 - 9

and coil are the only serviced parts on the compres-
sor.
A/C compressor clutch engagement is controlled by
several components: the A/C-heater control, A/C pres-
sure transducer, A/C compressor clutch relay, evapo-
rator temperature sensor and the powertrain control
module (PCM). The PCM may delay compressor
clutch engagement for up to thirty seconds (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The battery must
be fully-charged before performing the following
tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0 to 20 volt scale) with clip-type leads for measuring
the voltage across the battery and the compressor
clutch coil.
(2) With the A/C-heater controls in any A/C mode,
and the blower motor switch in the lowest speed
position, start the engine and run it at normal idle.
(3) The compressor clutch coil voltage should read
within 0.2 volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch
coil feed circuit for excessive voltage drop and repair
as required. If there is no voltage reading at the
clutch coil, use a DRB IIItscan tool and (Refer to
Appropriate Diagnostic Information) for testing of thecompressor clutch circuit and PCM control. The fol-
lowing components must be checked and repaired as
required before you can complete testing of the clutch
coil:
²Fuses in the junction block and the power distri-
bution center (PDC)
²A/C-heater control
²A/C compressor clutch relay
²A/C pressure transducer
²Evaporator temperature sensor
²Powertrain control module (PCM)
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is within
specifications with the electrical system voltage at
11.5 to 12.5 volts (Refer to 24 - HEATING & AIR
CONDITIONING - SPECIFICATIONS). This should
only be checked with the work area temperature at
21É C (70É F). If system voltage is more than 12.5
volts, add electrical loads by turning on electrical
accessories until the system voltage drops below 12.5
volts.
(a) If the clutch coil current reading is above
specifications, the coil is shorted and should be
replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C-heater control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, rotor, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the compressor clutch coil wire har-
ness connector.
(4) Remove the bolts that secure the compressor to
the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
Fig. 1 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (not used on KJ)
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLSDR
A/C COMPRESSOR CLUTCH/COIL (Continued)

(6) Insert the two pins of the spanner wrench
(Special Tool C-4489 or equivalent) into the holes of
the clutch plate. Hold the clutch plate stationary and
remove the hex nut (Fig. 2).
(7) Remove the clutch plate.
(8) Remove the compressor clutch shims.
(9) Remove the external front housing snap ring
with snap ring pliers (Fig. 3).
(10) Install the lip of the rotor puller (Special Tool
C-6141-1 or equivalent) into the snap ring groove
exposed in the previous step, and install the shaft
protector (Special Tool C-6141-2 or equivalent) (Fig.
4).
(11) Install the puller through-bolts (Special Tool
C-6461 or equivalent) through the puller flange and
into the jaws of the rotor puller and tighten (Fig. 5).Turn the puller center bolt clockwise until the rotor
is free.
CAUTION: DO NOT APPLY FORCE TO THE END OF
THE COMPRESSOR SHAFT.
(12) Remove the screw and retainer from the
clutch coil lead wire harness on the compressor front
housing (Fig. 6).
(13) Remove the snap ring from the compressor
hub and remove the clutch field coil (Fig. 7). Slide
the clutch field coil off of the compressor hub.
INSPECTION
Examine the friction surfaces of the clutch pulley
and the clutch plate for wear. The pulley and clutch
plate should be replaced if there is excessive wear or
scoring.
Fig. 2 Clutch Nut Remove - Typical
1 - CLUTCH PLATE
2 - SPANNER
Fig. 3 External Snap Ring Remove - Typical
1 - PULLEY
2 - SNAP RING PLIERS
Fig. 4 Shaft Protector and Puller - Typical
1 - PULLER JAW
2 - SHAFT PROTECTOR
Fig. 5 Install Puller Plate - Typical
1 - PULLER JAW
2 - PULLER
DRCONTROLS 24 - 11
A/C COMPRESSOR CLUTCH/COIL (Continued)

NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. The dual zone system has two blend door
actuators, one for the driver side blend air door and
one for the passenger side blend air door. The
same service procedures can be used for each of
these actuators.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the wire harness connector from the
blend door actuator(s) (Fig. 16).
(4) Remove the screws that secure the blend door
actuator(s) to the HVAC housing.
(5) Remove the blend door actuator(s) from the
HVAC housing.INSTALLATION
(1) Position the blend door actuator(s) into the
HVAC housing. If necessary, rotate the actuator(s)
slightly to align the splines on the actuator output
sleeve(s) with those on the blend door linkage.
(2) Install and tighten the screws that secure the
blend door actuator(s) to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the HVAC wire harness connector to
the blend door actuator(s).
(4) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(5) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
The blower motor resistor is mounted to the bot-
tom side of the HVAC housing near the blower motor.
It can be accessed for service from underneath the
instrument panel.
OPERATION
The resistor has multiple resistor wires, each of
which will reduce the current flow to the blower
motor to change the blower motor speed by changing
the resistance in the blower motor ground path. The
blower motor switch directs the ground path through
the correct resistor wire to obtain the selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through all of the resistor wires. Each higher speed
selected with the blower motor switch applies the
blower motor ground path through fewer of the resis-
tor wires, increasing the blower motor speed. When
the blower motor switch is in the highest speed posi-
tion, the blower motor resistor is bypassed and the
blower motor receives a direct path to ground.
The blower motor resistor cannot be repaired and,
if faulty or damaged, it must be replaced.
Fig. 16 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 - 18 CONTROLSDR
BLEND DOOR ACTUATOR (Continued)