belt DODGE RAM SRT-10 2006 Service Repair Manual

Fig. 101 CENTER SHOULDER BELT REINFORCEMENT- QUAD CAB

HVAC - SERVICE INFORMATION
DESCRIPTION
A manually controlled single zone type heating-air conditioning system or a manually controlleddualzonetypeheat-
ing-air conditioning system is available on this model.
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 enginecooling systems.
The engine cooling system includes the radiator, thermostat, radiator hoses and the engine coolant pump. Refer to
7 - Cooling for more information before opening or attempting any service to the engine cooling system.
All vehicles are equipped with a common heater, ven-
tilation and air conditioning (HVAC) housing (1). The
system combines air conditioning, heating, and venti-
lating capabilities in a single unit housing mounted
within the passenger compartment under the instru-
ment panel. The HVAC housing includes:
Blend-air door(s) and actuator(s) (2)
Recirculation-air door and actuator (3)
A/C evaporator (4)
Blower motor (5)
Blower motor resistor (6)
Evaporator temperature sensor (7)
Heater core (8)
Mode-air doors and actuators (9)
Based upon the system and mode selected, conditioned air can exit the HVAC housing through one or a combi-
nation of the three main housing outlets: defrost, panel or floor. The defrost and the panel outlets are located on the
top of the housing and, the floor outlet is located on the bottom of the housing. Once the conditioned air exits the
HVAC housing, it is further directed through molded plastic ducts to the various outlets within the vehicle interior.
These outlets and their locations are as follows:
Defroster Outlet- A single large defroster outlet is located in the center of the instrumentpanel top cover,
near the base of the windshield.
Side Window Demister Outlets- There are two side window demister outlets, one is located at each out-
board end of the instrument panel top cover, near the belt line at the A-pillars.
Panel 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 thetop of the instrument panel center
bezel.
Front Floor Outlets- There are two front floor outlets, one located above each side of the floorpanel center
tunnel near the dash panel.
Rear Outlets- On Mega Cab models there are two outlets located at the rear of the center front seat.
OPERATION
Both the manual temperature control (MTC) single zone and dual zone heating-A/C system are blend-air type sys-
tems. In a blend-air heating-A/C, a blend-air door controls the amount of conditioned air that is allowed to flow
through, or around, the heater core.In the available dual zone system, twoblend-air doors are used to provide
completely independent side-to-side temperature control of the discharge air. The temperature control(s) determines
the discharge air temperature(s) by operating the blend door actuator(s), which move the blend-air door(s). This
design allows almost immediate control of output air temperature(s).

Condition Possible Causes Correction
5. Engine overheating.5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.1. Accessory drive belt
slipping.1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Fixed orifice tube not
installed.2. See A/C Orifice Tube in this group. Replace the
liquid line, if required.
3. Faulty A/C compressor.3. See A/C Compressor in this group. Replace the
compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
2. Restricted refrigerant flow
through the fixed orifice
tube.2. See A/C Orifice Tube in this group. Replace the
liquid line, if required.
3. Restricted refrigerant flow
through the condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
HEATER PERFORMANCE
Before performing the following tests, refer to Group 7 - Cooling for the procedures to check the engine coolant
level and flow, engine coolant reserve/recovery system operation, accessory drive belt condition and tension, radi-
ator air flow and the fan drive operation. Perform the HVAC System Test (refer to 24 - HVAC Electrical Diagnostics).
If any diagnostic trouble codes (DTCs) are found in the A/C-heater control, powertrain control module (PCM) or
engine control module (ECM) (depending on engine application), gateway module or totally integrated power module
(TIPM), repair as necessary.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system through two heater hoses. With the engine idling at normal oper-
ating temperature, set the temperature control to maximum heat position,the mode control to the floor position, and
the blower motor control to the highest speed position. Using a test thermometer, check the temperature of the air
being discharged from the floor outlets. Compare the test thermometer reading to the Heater Temperature Refer-
ence chart.
HEATER TEMPERATURE REFERENCE
Ambient Air Temperature16° C
(60° F)21° C
(70° F)26° C
(80° F)32° C
(90° F)
Minimum Air Temperature at
Floor Outlet62° C
(144° F)64° C
(147° F)65° C
(150° F)67° C
(153° F)
If the heater outlet air temperature is below the minimum specification, refer to Group 7 - Cooling. Both of the heater
hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than the coolant supply
heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine coolant flow
obstruction in the cooling system. RefertoGroup7-Coolingformoreinformation.
OBSTRUCTED COOLANT FLOW
Possible locations or causes of obstructed coolant flow are as follows:
Faulty water pump.
Faulty thermostat.
Pinched or kinked heater hoses.

CLUTCH-A/C COMPRESSOR
DESCRIPTION
NOTE: Denso 10S17 A/C clutch assembly shown.
Visteon HS-18 compressor similar.
The A/C compressor clutch assembly consists of a
stationary electromagnetic field coil (4), bearing and
pulley assembly (3), shims (7) and a clutch plate (2)
that is splined to the compressor shaft and secured by
a bolt (1). These components provide the means to
engage and disengage the A/C compressor from the
engine accessory drive belt.
The A/C clutch bearing and pulley assembly on both
A/C compressors are retained to the front of the com-
pressor with a snap ring (6). The A/C clutch field coil
on the Denso 10S17 A/C compressor is also retained
to the front of the compressor using a snap ring (5).
The field coil on the Visteon HS-!8 compressor is
pressed onto the front of the compressor.
OPERATION
The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the
engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and drives the compressorshaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is part of the pulley assembly.
A/C compressor clutch engagement is controlled by the powertrain controlmodule (PCM) or the engine control mod-
ule (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a
request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on
the CAN-C Bus to the PCM/ECM, which determines if operating conditions arecorrect for A/C clutch engagement.
When all operating conditions have been met, the PCM/ECM sends a signal on adedicated hard-wired circuit back
to the totally integrated power module (TIPM) to energize the internal A/Cclutch high side driver. When energized,
the A/C clutch high side driver provides battery current to the A/C clutch field coil.
The A/C clutch control system is diagnosed using a scan tool (Refer to 24 - HVAC Electrical Diagnostics and to 9
- Engine Electrical Diagnostics for more information).
The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced.
DIAGNOSIS AND TESTING
A/CCOMPRESSORCLUTCHCOIL
The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine
control module (ECM) (depending on engine application) through the totally integrated power module (TIPM) (Refer
to 24 - HEATING & AIR CONDITIONING/CONTROLS/COIL-A/C COMPRESSOR CLUTCH -OPERATION for more
information). Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.
PRELIMINARY CHECKS
1. Using a scan tool, check for diagnostic trouble codes (DTCs) in the A/C-heater control, TIPM, PCM/ECM and if
equipped with the 8.3L engine, the gateway module. If no DTCs are found, go to Step 2. If any DTCs are found,
repair as required.
2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS). If the refrig-
erant charge level is OK, go to TESTS . If the refrigerant charge level is notOK, adjust the refrigerant charge as
required.

REMOVAL
DENSO A/C COMPRESSOR
NOTE: The compressor clutch assembly can be serviced with the refrigerantsystem fully-charged.
NOTE: Typical A/C compressor shown in illustrations.
1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
3. Disconnect the engine wire harness from the com-
pressor clutch field coilconnector (1) located on
the top of the A/C compressor (5).
4. Remove the bolts that secure the A/C compressor
to the engine and support the A/C compressor.
5. Carefully remove the compressor clutch field coil
connector and wire lead from the connector bracket
(2).
6. Remove the compressor shaft bolt (3). A band-type
oil filter wrench or a strap wrench may be used to
hold the clutch plate (4) from rotating during bolt
removal.
CAUTION: Do not pry between the clutch plate and
the pulley and bearing assembly to remove the
clutch plate from the compressor shaft as this
may damage the clutch plate.
NOTE: Use care not to lose any clutch shim(s)
during removal of the clutch plate, as they may be
reused during the clutch plate installation process.
7. Tap the clutch plate (2) lightly with a plastic mallet
to release it from the splines on the compressor
shaft (1) and remove the clutch plate and shim(s)
(3).

1. Disconnect and isolate negative battery cable.
2. Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
3. Raise and support the vehicle.
4. Disconnect the engine wire harness from the clutch
field coil connector (4).
5. Remove the bolts that secure the A/C compressor
(5)tothemountingbracket(Referto24-HEAT-
ING & AIR CONDITIONING/PLUMBING/COM-
PRESSOR-A/C - REMOVAL).
6. Remove the A/C compressor from the mounting
bracket and support the compressor while servicing
the clutch.
7. Using compressor clutch holding fixture (Special
Tool 9351 in Kit 9349) (1), remove the bolt (2) that
secures the clutch plate (3) to the compressor
shaft.
NOTE: The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with
an 8 x 1.25 mm bolt.
NOTE: Clutch plate shim(s) may remain inside the hub of the clutch plate. Besure to remove all of the
shims from inside the hub or from the end of the compressor shaft.
8. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the
centeroftheclutchplateandturntheboltclockwiseuntiltheclutchplate is completely removed from the A/C
compressor.
9. Using snap ring pliers (1), remove the snap ring (2)
that secures the pulley and bearing assembly (3) to
the front of the A/C compressor (4).

6. Install the clutch plate (4) onto the front of the A/C
compressor (5).
7. Install the compressor shaft bolt (3). Tighten the
bolt to 19 Nꞏm (168 in. lbs.).
NOTE: The shims may compress after tightening
the shaft bolt. Check the air gap in four or more
places to verify the air gap is correct. Spin the pul-
ley before performing a final check of the air gap.
NOTE: On models with the clutch plate recessed
intothepulley,usea90°wiregapgaugetomea-
sure the clutch air gap. On other models, use a
blade type feeler gauge to measure the air gap.
8. With the clutch plate assembled tight against the
shim(s), measure the air gap between the clutch
plate and the pulley and bearing assembly. The air
gap should be between 0.35 - 0.60 mm (0.014 -
0.024 in.). If the air gap is not between specifica-
tions, add or subtract shims as needed until the
correct air gap is obtained.
CAUTION: Be certain that the compressor clutch field coil wire harness is properly routed so that it is not
pinched between the A/C compressor and the field coil connector bracket.
9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2).
10. Install the compressor clutch fieldcoil connector (1) onto the connector bracket.
11. Position the A/C compressor to the engine and install the retaining bolts (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/COMPRESSOR-A/C - INSTALLATION).
12. Connect the engine wire harness to the compressor clutch field coil connector.
13. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/BELTS-DRIVE - INSTALLATION).
14. Reconnect the negative battery cable.
VISTEON A/C COMPRESSOR
1. Position the A/C clutch field coil (1) squarely onto
the front of the A/C compressor (2).
CAUTION: Position the A/C clutch field coil so that
the coil positioning tabs and the wire harness lead
are oriented in the correct direction. Failure to cor-
rectly position the fieldcoil on the A/C compres-
sor will result in field coil damage.
2. Align the field coil positioning tabs to the recessed
area at the front of the A/C compressor and install
the clutch field coil onto the compressor using a
two jaw puller (3), compressor field coil installer
(Special Tool 9352 in Kit 9349) (4) and the com-
pressor field coil installer spacer (Special Tool 9353
in Kit 9349) (5).

7. Verify that there is adequate clearance for the
clutch field coil wire lead and connector (4)
between the compressor housing and the pulley.
NOTE: When installing an original or a new clutch
assembly, try the original shims first. When install-
ing a clutch onto a compressor that previously did
not have a clutch, use the 1.0, 0.50 and 0.13 milli-
meter (0.040, 0.020 and 0.005 inch) shims from the
clutch hardware package which is provided with
the new clutch.
8. Install the clutch shims onto the compressor shaft.
9. Using compressor clutch holding fixture (Special
Tool 9351 in Kit 9349) (1), install the bolt (2) that
secures the clutch plate (3) to the A/C compressor
(5). Hold the clutch plate stationary with the holding
fixture and tighten the bolt to 15 Nꞏm (133 in. lbs.).
10. Using a feeler gauge (1), check the air gap
between the clutch plate (2) and the pulley and
bearing assembly (3). If the air gap is not 0.35 to
0.75 millimeter (0.014 to 0.030 inch), add or sub-
tract shims as required.
11. Position the A/C compressor (4) onto the mount-
ing bracket.
12. Install the bolts that secure the A/C compressor to
themountingbracket.Tightentheboltsto23Nꞏm
(17 ft. lbs.).
13. Connect the engine wire harness to the compres-
sor clutch field coil connector (5).
14. Lower the vehicle.
15. Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
16. Reconnect the negative battery cable.
17. Perform the Clutch Break-in Procedure (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/A/C COMPRESSOR CLUTCH - STANDARD PROCE-
DURE).

COMPRESSOR-A/C
DESCRIPTION
A/C COMPRESSOR
NOTE: Denso 10S17 compressor shown. Visteon
HS-18 compressor similar.
The A/C system on models equipped with the 3.7L,
4.7L, 5.7L and 8.3L engines use a Denso 10S17
reciprocating swash plate-type compressor (1). This
A/C compressor has a fixed displacement of 170 cubic
centimeters (10.3 cubic inches).
The A/C system on models equipped with the 5.9L
diesel engine use a Visteon HS-18 A/C compressor.
This A/C compressor is a 10 cylinder reciprocating
swash plate-type compressor with a fixed displace-
ment of 180 cubic centimeters (10.9 cubic inches).
Both A/C compressors have the suction and discharge
ports (2) located on the compressor cylinder head (3)
at the rear of the compressor and have a label identi-
fying the use of R-134a refrigerant.
HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the A/C compressor. This mechanical valve is designed to vent refrigerant
from the A/C system to protect against damage to the A/C compressor and other A/C system components, caused
by condenser air flow restriction or an overcharge of refrigerant.
OPERATION
A/C COMPRESSOR
The A/C compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. The A/C
compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant.
The A/C compressor draws in low-pressure refrigerant vapor from the A/C evaporator through its suction port. It then
compresses the refrigerant into a high-pressure, high-temperature refrigerant vapor, which is then pumped to the
A/C condenser through the compressor discharge port.
The A/C compressor cannot be repaired and, if faulty or damaged, it must be replaced. The compressor clutch,
pulley and bearing assembly, and clutch field coil are available for service. If an internal failure of the A/C compres-
sor has occurred, the A/C accumulator must also be replaced.
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents refrigerant from the A/C system when adischarge pressure of 3445 to 4135
kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure
of 2756 kPa (400 psi) is reached.
The high pressure relief valve vents only enough refrigerant to reduce theA/C system pressure, and then re-seats
itself. The majority of the refrigerant is conserved in the A/C system. If the high pressure relief valve vents refrig-
erant, it does not mean the valve is faulty.
The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or
otherwise disturbed. The valve is only serviced as a part of the A/C compressor.

DIAGNOSIS AND TESTING
A/C COMPRESSOR
When investigating an A/C system related noise, you must first know the conditions under which the noise occurs.
These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed, engine tempera-
ture, and any other special conditions. Noises that develop during A/C operation can often be misleading. For exam-
ple: What sounds like a failed front engine bearing or connecting rod, may be caused by loose bolts, nuts, mounting
brackets or a loose compressor clutch assembly.
Drive belts are speed sensitive. At different engine speeds and dependingupon drive belt tension, drive belts can
develop noises that are mistaken for an A/C compressor noise. Improper drive belt tension can cause a misleading
noise when the compressor clutch is engaged, which may not occur when the compressor clutch is disengaged.
Check the accessory drive belt condition and tension as described in Cooling before beginning this procedure.
1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Turn the A/C compressor
On and Off several times to clearly identify the compressor noise. Listen to the A/C compressor while the clutch
is engaged and disengaged. Probe the A/C compressor with an engine stethoscope or a long screwdriver with
the handle held to your ear to better localize the source of the noise.
2. Loosen all of the compressor mounting hardware and retighten. Check thecompressor clutch retainer. Be certain
that the clutch field coil is mounted securely to the A/C compressor, and that the clutch plate and pulley are
properly aligned and have the correct air gap (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/
CLUTCH-A/C COMPRESSOR - INSTALLATION).
3. To duplicate high-ambient temperature conditions (high head pressure), restrict the air flow through the A/C con-
denser. Install a manifold gauge set or a scan tool to be certain that the discharge pressure does not exceed
2760 kPa (400 psi).
4. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual
noises. Also check the refrigerant lines and hoses for kinks or sharp bendsthat will restrict refrigerant flow, which
can cause noises (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - DESCRIPTION - REFRIGER-
ANT LINES).
5. If the noise is from opening and closing of the high pressure relief valve, recover, evacuate and recharge the
refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY), (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE) and (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE). If the high pressure relief
valve still does not seat properly, replace the A/C compressor (Refer to 24- HEATING & AIR CONDITIONING/
PLUMBING/COMPRESSOR-A/C - REMOVAL).
6. If the noise is from liquid refrigerant slugging in the A/C suction line,replace the A/C accumulator (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/ACCUMULATOR-A/C - REMOVAL) and check the refrigerant oil
level and the refrigerant system charge (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL) (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING- STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).
7. If a slugging condition still exists after replacing the A/C accumulator, then replace the A/C compressor (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/COMPRESSOR-A/C - REMOVAL) and repeat Step 1.
REMOVAL
3.7L/4.7L ENGINES
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.
NOTE: The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or
discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch
coil, engine, engine cylinder head or the generator.