engine DODGE RAM SRT-10 2006 Service Repair Manual

5.CHECK (C123) CONDENSER FAN CONTROL OUTPUT FROM TIPM
Reconnect the TIPM C8 harness connector.
Ignition on, engine not running.
With a scan tool, actuate the Condenser Fan.
Using the 12-Volt test light connected to ground, probe the (C123) Con-
denser Fan Control Output circuit in the Condenser Fan Motor harness
connector.
Does the test light illuminate brightly?
Ye s>>
With a scan tool, de-actuate the Condenser Fan. Then,
replace the Condenser Fan Motor in accordance with the
Service Information.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8
- ELECTRICAL/ELECTRONIC CONTROL MODULES -
STANDARD PROCEDURE).
No>>
With a scan tool, de-actuate the Condenser Fan. Then,
replace the TIPM in accordance with the Service Informa-
tion.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).

2.CHECK FOR DTCs IN THE A/C HEATER CONTROL MODULE
Turn the ignition on.
With the scan tool, read HVAC DTCs.
Excluding B1079–Climate Control Cool Down Test Excessive Time, are any DTCs present in the A/C
Heater Control Module?
Ye s>>
Diagnose and Repair the DTC(s). Refer to the Table of Contents in this Section for a complete list of
HVAC related symptoms. Rerun the Cooldown Test after the repair is complete.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).
No>>
Go To 3
3.CHECK FOR DTCs IN THE TIPM
With the scan tool, read TIPM DTCs.
Are any DTCs present in the TIPM?
Ye s>>
Diagnose and Repair the DTC(s). Rerun the Cooldown Test after the repair iscomplete.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).
No>>
Go To 4
4.CHECK FOR DTCs IN THE PCM / ECM
With the scan tool, read PCM / ECM DTCs.
Are any DTCs present in the PCM / ECM?
Ye s>>
Diagnose and repair the DTC(s). (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) for the diagnostic
procedures. Rerun the Cooldown Test after the repair is complete.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).
No>>
Refer to the Service Information for additional Cooldown Test related diagnostic information and testing
procedures. Rerun the Cooldown Test after the repair is complete.
Perform BODY VERIFICATION TEST – VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).

*HVAC SYSTEM TEST
For a complete wiring diagramRefer to Section 8W.
Theory of Operation
The HVAC System Test provides a starting point in the diagnostic process byidentifying the appropriate diagnostic
procedure or system test to perform when diagnosing a given symptom, condition, or DTC. It also provides a means
for testing the entire HVAC system byutilizing the A/C-heater control’s On-Board System Tests. The On-Board Sys-
tem Tests can also assist in diagnosing stored DTCs. (Refer to 24 - HEATING &AIR CONDITIONING - DIAGNOSIS
AND TESTING) for additional information about on-board diagnostics.
Diagnostic Test
1.HVAC SYSTEM TEST
NOTE: Diagnose and repair all active DTCs before diagnosing and repairingstored DTCs.
Make a selection based on the symptom, condition, or DTC that you want to diagnose.
For Any Active DTC
Refer to the Table of Contents in this Section for a complete list of HVAC related symptoms.
Scan Tool Indicates HVAC Not Active On Bus
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES - DIAGNOSIS AND TESTING) for no
response related diagnostic procedures.
Blower Motor Inoperative
Refer to *Blower Motor Inoperative in this Section.
Complete HVAC System Test
Go To 2
A/C System Performance Test
Go To 2
Mode Switch & Door Actuator Ckt Test
Go To 3
Actuator DTC Detection Test
Go To 4
Actuator Calibration Test
Go To 5
2.A/C SYSTEM PERFORMANCE TEST
NOTE: The following are prerequisites of the Cooldown Test. Verify each ofthe following before running the
test:
If active, diagnose and repair Evaporator Temperature Sensor related DTCs before proceeding. Refer to
the Table of Contents in this Section for a complete list of HVAC related symptoms.
Verify that the refrigerant system has an adequate charge. Check and repair as necessary before pro-
ceeding. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - DIAGNOSIS ANDTESTING).
Verify that the blower motor operates correctly in all speeds. Diagnose and repair all blower related faults
before proceeding.
Verify that the work area ambient temperature is above 15.6°C (60°F) before proceeding. Move the vehicle
to a warmer work area if necessary.
Verify that the evaporator temperature is above 13°C (55°F) before proceeding.
Verify that the Mode Select control is set to the panel position.
Verify that the A/C compressor is not running. If the compressor is running, turn the A/C off and allow the
evaporator to warm up before proceeding.
NOTE: Running the AC Cooldown test will cause the A/C status indicator to flash.
NOTE: One or more status messages will display on the scan tool after running the Cooldown Test. These
messages will clear after paging back out of this test function. Therefore, it is important to note all mes-
sages before doing so.
Start the engine.
Turn the Blower control to the high speed position.

With the scan tool in HVAC, select System Tests and then select Cooldown test. Allow the test to run to completion.
Does the scan tool display a status message that indicates a fault has occurred?
Yes, Conditions Too Cold - Test Not Run
If running, turn the A/C compressor off. Verify that the work area ambient temperature is above 15.6°C
(60°F). If not, move the vehicle to a warmer work area. Verify that the evaporator temperature is above
13°C (55°F). If not, set the blower to high speed and allow the blower to run for five minutes. Then, run
the Cooldown Test again.
Yes, Blowers Not On High - Test Not Run
Set the blower speed to high speed and then run the Cooldown Test again.
Yes, No Results Stored/Test Not Complete
Verify that power is not interrupted while rerunning the Cooldown Test.
Yes, Refrigerant Temperature Sensor Error
For Dual-Zone HVAC systems, refer to B10B2–A/C COOL DOWN TEST PERFORMANCEfor the diag-
nostic test procedure. For Single-Zone HVAC systems, refer to B1079–CLIMATE CONTROL COOL
DOWN TEST EXCESSIVE TIME for the diagnostic test procedure.
Yes, DTC Set During Routine - Test Not Passed
For Dual-Zone HVAC systems, refer to B10B2–A/C COOL DOWN TEST PERFORMANCEfor the diag-
nostic test procedure. For Single-Zone HVAC systems, refer to B1079–CLIMATE CONTROL COOL
DOWN TEST EXCESSIVE TIME for the diagnostic test procedure.
No>>
Asnecessary,eitherGoTo3,4,or5,or Perform BODY VERIFICATION TEST - VER1. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES - STANDARD PROCEDURE).
3.MODE SWITCH & DOOR ACTUATOR CIRCUIT TEST
NOTE: If at anytime a DTC becomes active during this test, proceed to the conclusion question.
NOTE: If multiple DTCs are active, diagnose those that relate to a short circuit first.
NOTE: Dual-Zone A/C Heater Controls do not set DTCs for stuck mode switches. Therefore, verify that the
A/C Heater Control is not damaged and that the mode switches and status indicators function properly and
repair as necessary before proceeding.
If not done so previously, start the engine.
Turn the Blower control to the low speed position.
Set the Blend control (single-zone) or Driver Blend control (dual-zone) to the full cold position.
If equipped, set the Passenger Blend control to the full cold position.
Monitor the scan tool for active HVAC DTCs while performing the following test steps.
If equipped, press the A/C mode switch on, wait 30 seconds, and then press itoff.
On Dual-Zone systems, press the Recirc mode switch on, wait 30 seconds, andthen press it off.
If equipped, press the EBL mode switch on, wait 30 seconds, and then press itoff.
Move the Blend control (single-zone) or Driver Blend control (dual-zone)from full cold to full hot, wait 30 seconds,
and then move it back to full cold.
If equipped, move the Passenger Blend control from full cold to full hot, wait 30 seconds, and then moved it back
to full cold.
Turn the Mode select control to the defrost position, wait 30 seconds, and then turn it to the panel position (dual-
zone) or panel / recirc position (single-zone). Wait 30 seconds before proceeding.
Does the scan tool display any active DTCs?
Ye s>>
Diagnose and repair the DTC(s). Refer to the Table of Contents in this Section for a complete list of
HVAC related symptoms.
No>>
If you are here due to a stored DTC, it is possible that a technician may not have erased the DTC
following a repair. If possible, verify if the vehicle was recently in for this type of service. Otherwise,
either Go To 4 or 5, or visually inspect the related wiring harness for chafed, pierced, pinched, and
partially broken wires and the wiring harness connectors for broken, bent, pushed out, and corroded
terminals, and repair as necessary.
Perform BODY VERIFICATION TEST - VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).

4.ACTUATOR DTC DETECTION TEST
NOTE: The Actuator DTC Detection Test clears all door actuator related DTCs when the test is actuated.
If not done so previously, start the engine.
With the scan tool, select System Tests and then select Actuator DTC Detection. When the test is complete, select
View DTCs.
Does the scan tool display any DTCs?
Yes, Dual-Zone
Diagnose and repair the DTC(s). If multiple DTCs are present, beginning with the passenger blend door,
diagnose and repair all short high DTCs and then all short low DTCs. Refer tothe Table of Contents in
this Section for a complete list of HVAC related symptoms.
Yes, Single-Zone
Diagnose and repair the DTC(s). If multiple DTCs are present, beginning with the common circuit, diag-
nose and repair all short high DTCs and then all short low DTCs. Refer to the Table of Contents in this
Section for a complete list of HVAC related symptoms.
No>>
If you are here due to a stored DTC, it is possible that a technician may not have erased the DTC
following a repair. If possible, verify if the vehicle was recently in for this type of service. Otherwise,
either Go To 5 or visually inspect the related wiring harness for chafed, pierced, pinched, and partially
broken wires and the wiring harness connectors for broken, bent, pushed out, and corroded terminals,
and repair as necessary.
Perform BODY VERIFICATION TEST - VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).
5.ACTUATOR CALIBRATION TEST
NOTE: For vehicles equipped with EBL, running the HVAC Door Recalibrationwill cause the EBL status
indicator to flash.
NOTE: The Actuator Calibration Test clears all door actuator related DTCswhen the test is actuated.
If not done so previously, start the engine.
With the scan tool, select System Tests and then select Actuator Calibration Test. When the test is complete, select
View DTCs.
Does the scan tool display any DTCs?
Ye s>>
Diagnose and repair the DTC(s). Refer to the Table of Contents in this Section for a complete list of
HVAC related symptoms.
No>>
No problem found. However, if you are here due to a stored DTC, it is possiblethat a technician may
not have erased the DTC following a repair. If possible, verify if the vehicle was recently in for this type
of service. Otherwise, visually inspect the related wiring harness for chafed, pierced, pinched, and par-
tially broken wires and the wiring harness connectors for broken, bent, pushed out, and corroded ter-
minals, and repair as necessary.
Perform BODY VERIFICATION TEST - VER 1. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES - STANDARD PROCEDURE).

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).

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.
NOTE: The work area ambient temperature must be above 21° C (70° F) and the evaporator temperature
must be above 13° C (55° F) prior to conducting the A/C Performance Test.
1. Conduct the A/C System Performance Test (Cooldown Test) found within the HVAC System Test (refer to 24 -
HVAC Electrical Diagnostics). If no diagnostic trouble codes (DTCs) are found in the A/C-heater control, power-
train control module (PCM) or engine control module (ECM) (depending on engine application), gateway module
or the totally integrated power module (TIPM), go to Step 2. If any DTCs are found, repair as required, then
proceedtoStep2.
2. Connect a tachometer and a manifold gauge set or an A/C recycling/charging station.
3. Operate the heating-A/C system under the following conditions.
Engine at 1,000 rpm at operating temperature
Door or windows open
Transmission in Park or Neutral with parking brake set (depending on application)
A/C-heater controls set to Recirculation mode (max-A/C), full cool, panel mode, high blower and with A/C com-
pressor engaged. If the A/C compressor does not engage, see the A/C System Diagnosis chart.
4. Insert a thermometer in the driver side center panel air outlet and operate the A/C system until the thermometer
temperature stabilizes.
5. With the A/C compressor clutch engaged, compare the air temperature at the center panel outlet and the A/C
compressor discharge pressure (high side) to the A/C Performance Temperature and Pressure chart. The com-
pressor clutch may cycle, depending upon the ambient temperature and humidity. If the clutch cycles, use the
readings obtained before the clutch disengaged.
A/C PERFORMANCE TEMPERATURE AND PRESSURE
Ambient Air
Temperature21° C
(70° F)27° C
(80° F)32° C
(90° F)38° C
(100° F)43° C
(110° F)
Air Temperature at
Center Panel Outlet7° C
(45° F)7° C
(45° F)13° C
(55° F)13° C
(55° F)18° C
(64° F)
Compressor Inlet
Pressure at Service
Port (low Side)138 to 207 kPa
(20to30psi)172to241kPa
(25to35psi)207 to 276
kPa
(30to40psi)241 to 310
kPa
(35to45psi)276to345kPa
(40to50psi)
Compressor
Discharge Pressure at
Service Port (High
Side)1034 to 1724
kPa
(150 to 250
psi)1379to2068
kPa
(200 to 300
psi)1724to2413
kPa
(250 to 350
psi)1999 to 2689
kPa
(290 to 390
psi)2413to2965
kPa
(350 to 430 psi)
6. If the air outlet temperature fails to meet the specifications in the A/CPerformance Temperature and Pressure
chart, or if the A/C compressor discharge pressure is high, refer to the A/CSystem Diagnosis chart.
A/C SYSTEM 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.

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.

Improper heater hose routing.
Plugged heater hoses or supply and return ports at the cooling system connections.
Plugged heater core.
If proper coolant flow through the cooling system is verified, and heater outlet air temperature is low, a mechanical
problem may exist.
MECHANICAL PROBLEMS
Possible locations or causes of insufficient heat due to mechanical problems are as follows:
Obstructed cowl air intake.
Obstructed heater system outlets.
Blend-air door(s) or actuator(s) not functioning properly.
Faulty blower motor system
Faulty A/C-heater control
TEMPERATURE CONTROL
If the heater outlet air temperature cannot be adjusted with the temperature control on the A/C-heater control, the
following could require service:
Faulty A/C-heater control.
Faulty blend door actuator(s).
Faulty, obstructed or improperly installed blend-air door.
Faulty related wiring harness or connectors.
Improper engine coolant temperature.
SPECIFICATIONS
A/C SYSTEM
Item Description Notes
A/C Compressor Denso 10S17 (3.7L/4.7L/5.7L/8.3L
engines)ND-8 PAG oil
Visteon HS-18 (5.9L engine) VC-46 PAG oil
Freeze–up Control Evaporator Temperature Sensor A/C evaporator mounted
High psi Control A/C pressure transducer A/C discharge line mounted
Refrigerant Charge Capacity Refer to the A/C Underhood
Specification Label located in the
engine compartment.R134a refrigerant
A/C Clutch Field Coil Draw 3.2 - 3.3 amps @ 12V ± 0.5V @
21° C (70° F)3.7L/4.7L/5.7L/8.3L engines
3.1 - 4 amps @ 12V ± 0.5V @ 21°
C(70°F)5.9L engine
A/C Clutch Air Gap 0.35 - 0.60 mm (0.014 - 0.024 in.) 3.7L/4.7L/5.7L/8.3L engines
0.35 - 0.75 mm (0.014 - 0.030 in.) 5.9L engine
TORQUE

Description Nꞏm Ft. Lbs. In. Lbs.
All Screws NOT Listed
Below2.2 — 20
A/C Accumulator Bolts 4.5 — 40
A/C Compressor to Engine
#3 Bolt (3.7L/4.7L)40 30 —
A/C Compressor to Engine
(except #3) Bolts
(3.7L/4.7L)55 41 —
A/C Compressor to
Mounting Bracket Lower
Bolts (5.7L)40 30 —
A/C Compressor to
Mounting Bracket Rear
Bolt (5.7L)55 41 —
A/C Compressor to
Mounting Bracket Bolts
(5.9L)23 17 —
A/C Compressor to Engine
Bolts (8.3L)23 17 —
A/C Condenser Bolts 10.5 — 95
A/C Compressor Clutch
Plate Bolt (3.7L/4.7L/5.7L/
8.3L)19 — 168
A/C Compressor Clutch
Plate Bolt (5.9L)15 — 133
A/C Compressor Clutch
Plate Bolt (3.7L/4.7L/5.7L/
8.3L)19 — 168
HVAC Housing to Engine
Side of Dash Panel Nuts6.2 — 55
HVAC Housing to Floor
Bracket Bolt6.2 — 55
HVAC Housing to
Passenger Side of Dash
Panel Nuts6.2 — 55
Refrigerant Line to A/C
Compressor Bolt/Nut
(3.7L/4.7L/5.7L/8.3L)20 15 —
Refrigerant Lines to A/C
Compressor Bolt (5.9L)23 17 —
Refrigerant Line to A/C
Condenser Nut20 15 —