ECU DODGE RAM SRT-10 2006 Service Repair Manual

7. Install the blend-air doors (1) into each of the two
blend door plates (2).
8. Align the actuator coupler (3) with each blend-air
door pivot shaft and install the coupler into side of
each blend door plate. Be sure to install each cou-
pler with the coupler arm located between the two
stop tabs on each blend door plate.
9. Position the lower blend door assembly (2) into the
lower half of the HVAC housing (3) and fully
engage the three retaining tabs (1).
10. Position the upper blend door assembly into the
upper half of the HVAC housing and fully engage
the three retaining tabs.
NOTE: Route the wire lead for the evaporator tem-
perature sensor into the opening located on the
upper half of the HVAC housing prior to installing
the lower half of the HVAC housing.
11. Position the two halves of the HVAC housing
together (3).
12. Install the fifteen screws (6) that secure the two
housing halves together. Tighten the screws to 2.2
Nꞏm (20 in. lbs.).
13. Install the foam seal (4) onto the evaporator con-
densate drain tube (5).
14. Connect the linkage rod (1) to the two blend-air
door levers (2) located on the back of the HVAC
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.

22. Install the panel/floor-air doors (1) into the panel/
floor door plate (2).
23. Align the actuator coupler (3) with the panel/floor-
air door pivot shaft and install the coupler into
side of the panel/floor door plate. Be sure to
install the coupler with the coupler arm located
between the two stop tabs on the door plate.
24. Position the panel/floor door assembly (2) onto
the top of the HVAC housing (3).
NOTE: Install the two door springs onto the retain-
ing screws prior to installation.
25. Install the three screws (2) that secure the door
assembly to the HVAC housing. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
26. Position the panel/floor door outlet (2) onto the
top of the HVAC housing (3) and fully engage the
two retaining tabs (3).
27. Install the two screws (1) that secure the panel/
floor door outlet to the HVAC housing. Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).

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).

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).

MOTOR-BLOWER
DESCRIPTION
The blower motor (1) is used to control the velocity of
air moving through the HVAC housing by spinning the
blower wheel (3) within the HVAC air inlet housing at
the selected speed.
The blower motor is a 12-volt, direct current (DC)
motormountedwithinaplastichousingwithaninte-
gral wire harness connector (2) and squirrel cage-type
blower wheel (3) that is secured to the blower motor
shaft (4). The blower wheel is positioned within the air
inlet housing on the passenger side end of the HVAC
housing.
OPERATION
The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower
wheel within the HVAC air inlet housing at the selected speed.
The blower motor will operate whenever the ignition switch is in the Run position and the blower motor control is in
any position except Off. The blower motor receives battery current through the totally integrated power module
(TIPM) whenever the ignition switch is in the Run position.
Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor and
through the blower motor control located within the A/C-heater control.
The blower motor can be accessed for service from underneath the instrument panel.
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.
The blower motor control system is diagnosed using a scan tool (Refer to 24 -HVAC Electrical Diagnostics for more
information).
The blower motor and blower wheel are factory balanced and cannot be adjusted or repaired. If faulty or damaged,
the blower motor and wheel must be replaced as an assembly.
DIAGNOSIS AND TESTING
BLOWER MOTOR
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering
wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the
negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. Failure to take the proper precautions could result in accidental
airbag deployment and possible personal injury or death.

REMOVAL
NOTE: The blower motor is located on the passen-
ger side of the vehicle under the instrument panel.
The blower motor can be removed from the vehi-
cle without having to remove the HVAC housing.
1. Disconnect and isolate the negative battery cable.
2. Remove the passenger side cowl trim panel (Refer
to 23 - BODY/INTERIOR/COWL TRIM PANEL -
REMOVAL).
3. Disconnect the HVAC wire harness lead (1) from
the blower motor (2).
4. Remove the HVAC wire harness lead from the two
wire harness retainers (3).
5. Remove the three screws (4) that secure the
blower motor to the bottom of the HVAC housing
(5).
6. Remove the blower motor from the HVAC housing.
INSTALLATION
1. Position the blower motor (2) into the bottom of the
HVAC housing (5).
2. Install the three screws (4) that secure the blower
motor to the HVAC housing. Tighten the screws to
2.2 Nꞏm (20 in. lbs.).
3. Connect the HVAC wire harness lead (1) to the
blower motor and install the wire harness lead into
the two wire harness retainers (3).
4. Install the passenger side cowl trim panel (Refer to
23 - BODY/INTERIOR/COWL TRIM PANEL -
INSTALLATION).
5. Reconnect the negative battery cable.

PLUMBING
DESCRIPTION
The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components.
The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon
tube sandwiched between rubber layers. The nylon tube helps to contain theR-134a refrigerant, which has a
smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight alu-
minum or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and
can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should
be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80
millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s).
OPERATION
High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must
be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a
good practice to inspect all flexible hose refrigerant lines at least oncea year to make sure they are in good con-
dition and properly routed.
The refrigerant lines and hoses are coupled to other A/C system componentswith block-type fittings. An O-ring seal,
or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C
system components to ensure the integrity of the refrigerant system.
The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced.
WARNING
WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by
qualified service personnel. Severe personal injury or death may result from improper service procedures.
WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes,
nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can
result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately.
WARNING: Do not expose the refrigerant to open flame. Poisonous gas is createdwhenrefrigerantis
burned. An electronic leak detector is recommended. Severe personal injury or death may result from
improper service procedures.
WARNING: If accidental system discharge occurs, ventilate the work area before resuming service. Large
amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and
death.
WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high.
As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or del-
icate objects from direct contact with the refrigerant.
WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or
leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at
elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing
property damage, personal injury or death.

ACCUMULATOR-A/C
DESCRIPTION
The A/C accumulator (5) is mounted in the engine
compartment between the evaporator outlet tube (2)
and the A/C suction line (6). An integral mounting
bracket (4) is used to secure the accumulator to the
dash panel (3). The A/C low side service port (1) is
mountedtothetopoftheA/Caccumulator.
CAUTION: Use only O-ring seals specified for the
vehicle. Failure to use the correct O-ring seal will
cause the refrigerant system connections to leak.
The A/C accumulator has no serviceable parts except
for the rubber O-ring seals, low side service port
valve, cap and secondary retaining clips. The O-ring
seals used on the connections are made from a spe-
cial type of rubber not affected by R-134a refrigerant.
The O-ring seals must be replaced whenever the A/C
accumulator is removed and installed.
The A/C accumulator cannot be repaired and, if faulty
or damaged, it must be replaced.
OPERATION
Refrigerant enters the A/C accumulator (1) mostly as a
low pressure vapor through the inlet tube (2). Any liq-
uid, oil-laden refrigerant falls to the bottom of the can-
ister, which acts as a separator. A desiccant bag (3) is
mounted inside the accumulator canister to absorb
any moisture which may have entered and become
trapped within the refrigerant system. A filter (4) is also
mounted inside the canister to trap any foreign mate-
rial that may have entered the refrigerant system dur-
ing assembly. The low pressure vapor exits the A/C
accumulator through the outlet tube (5). On this
model, the low side service port (6) is located at the
top of the A/C accumulator.
The A/C accumulator cannot be repaired. If the A/C
accumulator is faulty or damaged, or if the A/C com-
pressor has failed, it must be replaced.
REMOVAL
WARNING: Review the warnings and cautions in the front of this section before performing the following
operation (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS).