light DODGE RAM SRT-10 2006 Service Repair Manual

SINGLE ZONE/DUAL ZONE DRIVER SIDE
1. Install the blend door actuator (1) onto the back of
the HVAC housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft (3) with those on the blend door lever
(4).
2. Install the screws (1) that secure the blend door
actuator (2) to the HVAC housing (3). Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
3. Connect the HVAC wire harness connector (4) to
the blend door actuator.
4. Install the instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).
5. Reconnect the negative battery cable.

INSTALLATION
NOTE: The heating-A/C system is equipped with two mode door actuators, onefor the panel/floor-air door
and one for the defrost-air door.
PANEL/FLOOR DOOR ACTUATOR
1. Install the panel/floor door actuator (1) onto the
back of the HVAC housing (2). If necessary, rotate
the actuator slightly to align the splines on the
actuator output shaft (3) with those on the panel/
floor door actuator coupler (4).
2. Install the screws (1) that secure the panel/floor
door actuator (2) to the HVAC housing (3). Tighten
the screws to 2.2 Nꞏm (20 in. lbs.).
3. Connect the HVAC wire harness connector (4) to
the panel/floor door actuator.
4. Install the instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).
5. Reconnect the negative battery cable.

DEFROST DOOR ACTUATOR
1. Install the defrost door actuator (1) onto the back of
the HVAC housing (2). If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft (3) with those on the defrost door
actuator coupler (4).
2. Install the screws (1) that secure the defrost door
actuator (2) to the HVAC housing (3). Tighten the
screws to 2.2 Nꞏm (20 in. lbs.).
3. Connect the HVAC wire harness connector (4) to
the defrost door actuator.
4. Install the instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).
5. Reconnect the negative battery cable.

REMOVAL
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
battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to
take the proper precautions could result in accidental airbag deploymentand possible personal injury or
death.
1. Disconnect and isolate the negative battery cable.
2. Remove the glove box from the instrument panel
(Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
3. Remove the two screws (1) that secure the recircu-
lation door actuator (2) to the side of the HVAC air
inlet housing (3).
4. Remove the recirculation door actuator from the air
inlet housing and disconnect the HVAC wire har-
ness connector (4) from the actuator.
5. Remove the recirculation door actuator from the
vehicle.
INSTALLATION
1. Install the recirculation door actuator (1) onto the
side of the HVAC air inlet housing (2). If necessary,
rotate the actuator slightly to align the splines on
the actuator output shaft (3) with those in the recir-
culation door actuator coupler (4).

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).

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.

LINE-A/C LIQUID
DESCRIPTION
The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The liquid
line for this model consist of two separate lines that connect to each otherusing a spring-lock type refrigerant line
coupler (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT LINE COUPLER - DESCRIP-
TION). The liquid lines are made from light-weight aluminum, and use braze-less fittings.
The front half of the liquid line includes the high-side service port and the rear half of the liquid line contains the
fixed orifice tube.
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 liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and
secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not
affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is removed and installed.
If the liquid line is found to be leaking or is damaged, it must be replaced.
REMOVAL
3.7L/4.7L/5.7L/5.9L 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:TheA/Cliquidlineisservicedintwosections.
FRONT SECTION
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3. If equipped with the diesel engine, remove the pas-
senger side battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - REMOVAL).
4. If equipped with a gasoline engine, remove the air
filter housing and mounting bracket (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR FILTER
HOUSING - REMOVAL).
5. Remove the plastic cover from the condenser out-
let stud.
6. Remove the nut (8) that secures the front section
of the A/C liquid line (10) to the A/C condenser (7).
7. Disconnect the A/C liquid line from the A/C con-
denser and remove and discard the O-ring and
dual plane seal.
8. Disengage the A/C liquid line from the body retain-
ing clips (1 and 9).
9. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C
liquid line to the rear section of the liquid line (4).

TUBE-A/C ORIFICE
DESCRIPTION
The fixed A/C orifice tube is installed in the A/C liquid
line and provides a restriction in the liquid refrigerant
line between the A/C condenser and the A/C evapora-
tor. This restriction established the pressure differential
between the high and low-pressure sides of the A/C
system.
The A/C orifice tube includes a diffuser screen (1),
O-ring seals (2) to seal it to the inner wall of the A/C
liquid line, an inlet filter screen (3) and the fixed orifice
(4).
OPERATION
The fixed A/C orifice tube is used to meter the flow of liquid refrigerant into the A/C evaporator. The high-pressure
liquid refrigerant from the A/C condenser expands into a low-pressure liquid as it passes through the metering orifice
and diffuser screen of the A/C orifice tube.
The A/C orifice tube is not serviceable and cannot be repaired and, if faulty or plugged, the A/C liquid line must be
replaced (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - DESCRIPTION).
DIAGNOSIS AND TESTING
A/C ORIFICE TUBE
WARNING: The A/C liquid line between the A/C condenser and the A/C orifice tube can become hot enough
to burn the skin. Use extreme caution when performing the following test toprevent possible personal
injury.
NOTE: The A/C orifice tube can be checked for proper operation using the following procedure. However,
the A/C orifice tube is only serviced as a part of the A/C liquid line. If the results of this test indicate that the
A/C orifice tube is obstructed or missing, the A/C liquid line must be replaced.
1. Confirm that the refrigerant system is properly charged (Refer to 24 - HEATING & AIR CONDITIONING - DIAG-
NOSIS AND TESTING - A/C PERFORMANCE).
2. Start the engine. Turn on the A/Csystem and confirm that the compressor clutch is engaged.
3. Allow the A/C system to operate for five minutes.
4. Lightly and cautiously touch the A/C liquid line near the condenser outlet at the front of the engine compartment.
TheA/Cliquidlineshouldbehottothetouch.
5. Touch the A/C liquid line near the evaporator inlet at the rear of the engine compartment. The A/C liquid line
should be cold to the touch.
6. If there is a distinct temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is in
good condition. If there is little or no detectable temperature differential between the two ends of the A/C liquid
line, the A/C orifice tube is obstructed or missing and the A/C liquid line must be replaced (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - REMOVAL).

During periods of moderate manifold vacuum, the
plunger is only pulled part way back from inlet. This
results in maximum vapor flow through the valve.
DIAGNOSIS AND TESTING
PCVVALVE-3.7LV-6/4.7LV-8
1. Disconnect PCV line/hose (5) by disconnecting rub-
ber connecting hose at PCV valve fitting.
2. Remove PCV valve at oil filler tube by rotating PCV
valve downward until locating tabs (2) have been
freed at cam lock (3). After tabs have cleared, pull
valve straight out from filler tube.To prevent dam-
age to PCV valve locating tabs, valve must be
pointed downward for removal. Do not force
valve from oil filler tube.
3. After valve is removed, check condition of valve
O-ring (1). Also, PCV valve should rattle when
shaken.
4. Reconnect PCV valve to its connecting line/hose.
5. Start engine and bring to idle speed.
6. If valve is not plugged, a hissing noise will be
heard as air passes through valve. Also, a strong
vacuum should be felt with a finger placed at valve
inlet.
7. If vacuum is not felt at valve inlet, check line/hose
for kinks or for obstruction. If necessary, clean out
intake manifold fitting at rear of manifold. Do this
byturninga1/4inchdrill(byhand)throughthefittingtodislodgeanysolid particles. Blow out the fitting with
shop air. If necessary, use a smaller drill to avoid removing any metal fromthe fitting.
8.Do not attempt to clean the old PCV valve.
9. Return PCV valve back to oil filler tube by placing valve locating tabs (2) into cam lock (3). Press PCV valve in
and rotate valve upward. A slight click will be felt when tabs have engaged cam lock. Valve should be pointed
towards rear of vehicle.
10. Connect PCV line/hose (5) and connecting rubber hose to PCV valve.
11. Disconnect rubber hose from fresh air fitting at air cleaner resonatorbox. Start engine and bring to idle speed.
Hold a piece of stiff paper (such as a parts tag) loosely over the opening of the disconnected rubber hose.

1. The PCV valve is sealed to the intake manifold
with 2 O-rings (2).
2. Remove PCV valve by rotating counter-clockwise
90 degrees until locating tabs (3) have been freed.
After tabs have cleared, pull valve straight up from
intake manifold.
3. After valve is removed, check condition of 2 valve
O-rings (2).
INSTALLATION
3.7L V6 / 4.7L V-8
The PCV valve is located on the oil filler tube. Two locating tabs are locatedonthesideofthevalve.These2tabs
fit into a cam lock in the oil filler tube.An O-ring seals the valve to the filler tube.
1. Return PCV valve back to oil filler tube by placing valve locating tabs into cam lock. Press PCV valve in and
rotate valve upward. A slight click will be felt when tabs have engaged cam lock. Valve should be pointed
towards rear of vehicle.
2. Connect PCV line/hose and rubber hose to PCV valve.
5.7L V-8
1. Clean out intake manifold opening.
2. Check condition of 2 O-rings on PCV valve.
3. Apply engine oil to 2 O-rings.
4. Place PCV valve into intake manifold and rotate 90 degrees clockwise forinstallation.