heating DODGE RAM SRT-10 2006 Service Repair Manual

1. Remove the air inlet housing (1) from the HVAC
housing and place it on a workbench (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - AIR INLET HOUSING -
REMOVAL)
2. Remove the two foam insulators (2) from the air
inlet housing.
3. To remove the recirculation-air door (1) from the air
inlet housing (2), first carefully release the retaining
tabs of actuator coupler (3) located on the inside
surface of the air inlet housing and pull the actuator
coupler out of the pivot shaft of the recirculation-air
door.
NOTE: If the seals on the air door is deformed or
damaged, the air door must be replaced.
4. Remove the recirculation-air door from the air inlet
housing.

15. Position the front floor distribution duct (1) to the
bottom of the HVAC housing (2).
16. Install the screws (3) that secure the front floor
distribution duct to the HVAC housing. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
17. Carefully install the heater core (3) into the front
of the HVAC housing.
18. Position the heater core tube bracket (2) onto the
HVAC housing.
19. Install the two screws (1) that secures the heater
core bracket to the HVAC housing. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
20. If equipped with the dual zone heating-A/C sys-
tem, install the linkage rod (4).
21. Install the foam seal onto the heater core tubes.

28. Install the air inlet housing (3) onto the top of the
HVAC housing (4) (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/HOUSING-
HVAC - AIR INLET HOUSING - INSTALLATION).
29. Install the HVAC wire harness (1) onto the HVAC
housing. Make sure the wires are routed through
all wiring retainers.
30. Connect the HVAC wire harness to evaporator
temperature sensor (2).
31. Position the blower motor resistor (7) and the
blower motor (2) into the bottom of the HVAC
housing (5).
32. Install the screws (4 and 6) that secure the blower
motor resistor and the blower motor to the HVAC
housing. Tighten the screws to 2.2 Nꞏm (20 in.
lbs.).
33. Connect the HVAC wire harness connectors (1
and 3) to blower motor resistor and the blower
motor.
34. Position the recirculation door actuator (3) onto
the air inlet housing (4) and install the retaining
screws. Tighten the screws to 2.2 Nꞏm (20 in.
lbs.).
35. Position the mode door actuators (1) and the
blend door actuators (2) onto the HVAC housing
(5) and install the retaining screws. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
36. Connect the HVAC wire harness connectors to the
actuators.
37. Install the HVAC housing assembly (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - HVAC HOUSING ASSEMBLY -
INSTALLATION).

AIR INLET HOUSING
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the
recirculation-air door.
NOTE: If the seals on the air door is deformed or
damaged, the air door must be replaced.
1. Position the recirculation-air door (1) into the air
inlet housing (2).
CAUTION: Make sure that the recirculation-air
door pivot shaft is properly seated in the pivot
seat located in the air inlet housing.
2. Align the actuator coupler (3) with the recirculation-
air door pivot shaft and install the coupler until the
coupler retaining tabs are fully engaged to the air
inlet housing. Be sure to install the coupler with the
coupler arm located between the two stop tabs on
the air inlet housing.
3. Install the two foam insulators (2) into the air inlet
housing (1).
4. Install the air inlet housing onto the HVAC housing
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HOUSING-HVAC - AIR INLET
HOUSING - INSTALLATION).
INSTALLATION
HVAC HOUSING ASSEMBLY
NOTE: The HVAC housing must be removedfrom the vehicle and disassembled for service of the A/C evap-
orator, evaporator temperature sensor, mode-air and blend-air doors.

1. If removed, install the fresh air inlet (2) onto the
dash panel (1).
2. Position the HVAC housing assembly (4) into the
passenger compartment with the mounting studs
and the condensate drain tube in their proper loca-
tions in the dash panel.
3. Install the two nuts (3 and 7) that secure the HVAC
housing to the passenger compartment side of the
dash panel. Tighten the nuts to 6.2 Nꞏm (55 in.
lbs.).
4. Install the bolt (5) that secures the HVAC housing
to the floor bracket (6). Tighten the bolt to 6.2 Nꞏm
(55 in. lbs.).
5. Install the instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
6. On Mega Cab models, install the floor console duct
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/DUCT-FLOOR CONSOLE - INSTALLATION).
7. Install the two nuts (3) that secure the HVAC hous-
ing (1) to the engine compartment side of the dash
panel (2). Tighten the nuts to 6.2 Nꞏm (55 in. lbs.).
8. Install the powertrain control module (PCM) (Refer
to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/POWERTRAIN CONTROL MODULE -
INSTALLATION).
9. Connect the heater hoses to the heater core tubes.
10. Connect the A/C liquid line and the A/C accumu-
lator to the A/C evaporator (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING /LINE-
A/C LIQUID - INSTALLATION) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR-A/C - INSTALLATION).
11. Reconnect the negative battery cable.
12. If the heater core is being replaced, flush the
coolingsystem(Referto7-COOLING-STAN-
DARD PROCEDURE - COOLING SYSTEM
CLEANING/REVERSE FLUSHING).
13. Refill the engine cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE - COOLING SYSTEM
REFILL).
14. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
15. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
AIR INLET HOUSING
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the
recirculation-air door.

NOTE: If the foam seal on the air inlet housing is
deformed or damaged, it must be replaced.
1. Position the air inlet housing (2) onto the top of the
HVAC housing (3).
2. Engage the two retaining clips (1) that secure the
front of the air inlet housing to the HVAC housing.
3. Install the two screws (3) that secure the rear of
the air inlet housing (2) to the top of the HVAC
housing (5). Tighten the screws to 2.2 Nꞏm (20 in.
lbs.).
4. Install the recirculation door actuator (1) onto the
air inlet housing (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/ACTUATOR-RECIR-
CULATION DOOR - INSTALLATION).
5. Connect the HVAC wire harness (4) to the recircu-
lation door actuator.
6. Install the HVAC housing assembly (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - HVAC HOUSING ASSEMBLY -
INSTALLATION).

NOTE: The blower motor is supplied with a 12V feed from the TIPM, through theresistor block, whenever
the ignition switch is in the RUN position. Due to an open circuit conditionwithin the blower motor control
switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor.
To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the
negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. For circuit
descriptions and diagrams, refer to Air Conditioning/Heater in Group 8W -Wiring Diagrams.
OPERATION
Possible causes of the blower motor not operating include:
Faulty blower motor
Faulty blower motor circuit wiring or wire harness connectors
Faulty blower motor control
Possible causes of the blower motor not operating in one or more speeds include:
Faulty blower motor resistor
Faulty blower motor circuit wiring or wire harness connectors
Faulty blower motor control
VIBRATION
Possible causes of blower motor vibration include:
Improper blower motor mounting
Improper blower wheel mounting
Deformed blower wheel
Out of balance blower wheel due to foreign material in the wheel
Faulty blower motor
NOISE
To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify
that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the
heating-A/C system. If the noise goes away, possible causes include:
Foreign material in the HVAC air inlet housing
Improper blower motor mounting
Improper blower wheel mounting
Faulty blower motor

DIAGNOSIS AND TESTING
REFRIGERANT SYSTEM LEAKS
WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested
with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures
are potentially dangerous and may result in fire or explosion causing property damage, personal injury or
death.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure mayirritate eyes, nose and throat.
Use only approved service equipment meeting SAE requirements to discharge R-134a system. If accidental
system discharge occurs, ventilate work area before resuming service.
NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually
inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C
system leak location.
NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to com-
pletely evacuate and recharge the A/C system.
Connect a suitable manifold gauge setand determine if the static A/C system pressure is above or below 345 kPa
(50 psi) (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT). If less than 345 kPa (50 psi), proceed to SYSTEMEMPTY . If greater than 345
kPa (50 psi), go to SYSTEM LOW .
SYSTEM EMPTY
1. Evacuate the refrigerant system to the lowest degree of vacuum possible(approximately -88 kPa (- 26 in. Hg) or
greater vacuum) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE). Determine if the system holds a vacuum for 15 minutes. If vacuum is
held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2.
2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerantinto the evacuated refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE) and proceed to Step 1 of the System Low procedure.
SYSTEM LOW
1. Position the vehicle in a wind-freework area. This will aid in detectingsmall leaks.
2. Operate the heating-A/C system with the engine at idle under the following conditions for at least five minutes.
Doors or windows open
Transmission in Park or Neutral with the parking brake set (depending on application)
A/C-heater controls set to outside air, full cool, panel mode, high blowerand with A/C compressor engaged
CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant
system.
3. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a
refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant
leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air
outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye.

STANDARD PROCEDURE
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: Eye protection must be worn when servicing an A/C refrigerant system. Turn all valves off
(rotate clockwise) on the equipment being used before connecting or disconnecting service equipment from
the refrigerant system. Failure to observe these warnings may result in personal injury or death.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
When servicing the A/C system, an R-134a refrigerant
recovery/recycling/charging station (1) that meets SAE
standard J2210 must be used. Contact an automotive
service equipment supplier for refrigerant recovery/re-
cycling/charging equipment. Refer to the operating
instructions supplied by the equipment manufacturer
for proper care and use of this equipment.
A manifold gauge set (1) may be needed with some
recovery/recycling/charging equipment. The manifold
gauge set should have manual shut-off valves (2 and
6), or automatic back-flow valves located at the ser-
vice port connector end of the manifold gauge set
hoses (4 and 5). This will prevent refrigerant from
being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible
and system damage will result.

RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE– The center manifold hose (Yellow, or White, with
Black stripe) (3) is used to recover, evacuate, and charge the refrigerantsystem. When the low or high pressure
valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.
HIGH PRESSURE GAUGE HOSE– The high pressure hose (Red with Black stripe) (4) attaches to the high side
service port. This service port is located on the A/C discharge line. On this model, an A/C pressure transducer is
installed on the high side service port. A/C high-side pressures can be read using a scan tool. Refer to 9 - Engine
Electrical Diagnostics for more information.
LOW PRESSURE GAUGE HOSE– The low pressure hose (Blue with Black stripe) (5) attaches to the low side
service port. This service port is located either on the top of the A/C accumulator or on the A/C suction line near the
accumulator, depending on engine application.
REFRIGERANT SYSTEM RECOVERY
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS). Failure to follow the warnings and cautions could result
in possible personal injury or death.
An R-134a refrigerant recovery/recycling/charging sta-
tion (1) that meets SAE standard J2210 must be used
to recover the refrigerant from the R-134a refrigerant
system. Refer to the operating instructions supplied by
the equipment manufacturer for the proper care and
use of this equipment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent moisture from entering the A/Csystem oil. Moisture in the oil
is very difficult to remove and will cause a reliability problem with the compressor.
If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of
time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be
used. This will eliminate the possibility of contaminating the refrigerant system.
If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled.
Moisture and air mixed with the refrigerant will raise the compressor headpressure above acceptable operating
levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at
near room temperature when exposed to vacuum. To evacuate the refrigerantsystem:
NOTE: When connecting the service equipment coupling to the line fitting,verify that the valve of the cou-
pling is fully closed. This will reduce the amount of effort required to make the connection.
1. Recover the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM RECOVERY).
2. Connect a suitable charging station, refrigerant recovery machine or amanifold gauge set with vacuum pump
and refrigerant recovery equipment (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT).
3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of
45minutespriortochargetoeliminateall moisture in system. When the suction gauge reads to the lowest