DODGE RAM SRT-10 2006 Service Repair Manual

CORE-HEATER
DESCRIPTION
The heater core (1) is a heat exchanger made of rows
of tubes and fins. The heater core is positioned within
the HVAC housing through the panel (2) located at the
front of the HVAC housing. The heater core tubes (3)
are attached to the front of the heater core and are
secured to the HVAC housing by a bracket.
The heater core can be serviced by removing the
HVAC housing assembly from the vehicle.
OPERATION
Engine coolant is circulated through the heater hoses to the heater core atall times. As the coolant flows through
the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed
through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the
heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor
speed controls the volume of air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or damaged, it must be replaced.
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
negative battery (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.
NOTE: Disassembly of the HVAC housing is not required to remove heater core.

1. RemovetheHVAChousing(Referto24-HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - REMOVAL).
2. Remove the foam seal from the heater core tubes.
3. If equipped with the dual zone heating-A/C system,
remove the linkage rod (4) to gain access to the
heater core (3).
4. Remove the two screws (1) that secure the heater
core tube bracket (2) to the HVAC housing and
remove the bracket.
5. Carefully pull the heater core out of the front of the
HVAC housing.
6. Inspect all foam seals and replace as required.
INSTALLATION
1. Carefully install the heater core (3) into the front of
the HVAC housing.
2. Position the heater core tube bracket (2) onto the
HVAC housing.
3. 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.).
4. If equipped with the dual zone heating-A/C system,
install the linkage rod (4).
5. Install the foam seal onto the heater core tubes.
NOTE: If the heater core is being replaced, flush
the cooling system (Refer to 7 - COOLING - STAN-
DARD PROCEDURE - COOLING SYSTEM CLEAN-
ING/REVERSE FLUSHING).
6. Install the HVAC housing (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION/HOUSING-
HVAC - INSTALLATION).

CORE-VALVE-SERVICE PORT
DESCRIPTION
Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant sys-
tem. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not
accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant.
The high side service port is located on the A/C discharge line. The A/C pressure transducer is mounted on the high
side service port (Refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/TRANSDUCER-A/C PRESSURE -
DESCRIPTION). The low side 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. Both the highside and low side A/C service port valve
cores are serviceable.
Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the
refrigerant system, always reinstall both of the service port caps.
REMOVAL
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: Typical A/C service port shown.
1. Remove the protective cap (1) from the service
port (2).
2. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
3. Using a Schrader-type valve core tool, remove the
valve core (3) from the service port.
4. Install a plug in or tape over the opened service
port(s).

INSTALLATION
NOTE: Typical A/C service port shown.
1. Lubricate the valve core (3) with clean refrigerant
oil prior to installation. Use only refrigerant oil of
the type recommended for the A/C compressor in
the vehicle.
2. Remove the tape or plug from the service port (2).
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
3. Using a Schrader-type valve core tool, install and
tighten the valve core into the service port(s).
4. Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
5. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from
contamination. Remember to always reinstall the protective cap onto the service port when refrigerant sys-
tem service is complete.
6. Install the protective cap (1) onto the service port.

COUPLER-REFRIGERANT LINE
DESCRIPTION
Spring-lock type refrigerant line couplers (1 and 4) are
used to connect the A/C suction line (6) to the A/C
accumulator (5) and, the A/C accumulator and the A/C
liquid line to the A/C evaporator tubes (3). Secondary
retaining clips (2 and 7) are installed over the con-
nected couplers for added protection.
The spring-lock refrigerant line couplers require spe-
cial disconnect tools for disengaging the two coupler
halves.
OPERATION
The spring-lock type refrigerant line coupler is held
together by a garter spring (6) inside a circular cage
(7) on the male half of the fitting (1). When the two
coupler halves are connected, the flared end of the
female fitting (2) slips behind the garter spring inside
the cage on the male fitting. The garter spring and
cage prevent the flared end of the female fitting from
pulling out of the cage. Some applications use a con-
nection indicator ring (4) to help indicate when the two
coupler halves are fully connected.
Two O-rings (8) are used to seal the coupler connec-
tions. These O-rings are compatible with R-134a
refrigerant and must be replaced with O-rings made of
the same material.
A secondary retaining clip (3) is installed over the con-
nected coupler (5) for added protection.
REMOVAL
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.

1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Remove the secondary retaining clip from the
spring-lock type refrigerant line coupler.
3. Fit the proper size A/C line disconnect tool (Special
Tool Kit 7193 or equivalent) over the coupler cage
(1).
4. Close the two halves of the A/C line disconnect tool
around the coupler (2).
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it
into the coupler cage opening.
5. Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter
spring (3). Once the garter spring is expanded, pull
on the refrigerant line attached to the female half of
the coupler until the flange on the female fitting is
separated from the garter spring and cage on the male fitting.
6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4).
INSTALLATION
1. Clean any dirt or foreign material from the spring-
lock type refrigerant line coupler.
2. Check to make sure that the garter spring (6) is
located within the cage (7) of the male half of the
refrigerant line coupler (1), and that the garter
spring is not damaged.
a. If the garter spring is missing, install a new
spring by pushing it into the coupler cage
opening.
b. If the garter spring is damaged, remove it from
the coupler cage with a small hook (DO NOT
use a screwdriver) and install a new garter
spring.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a system. The use of any other O-rings may allow the connec-
tion to leak.
3. Install new O-rings (8) on the male half of the refrigerant line coupler.
4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
5. Position the female half of the coupler over the male half of the coupler.
6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the
male half of the coupler snaps over the flanged end on the female half of the coupler.
7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each
other on both sides of the coupler.
8. Install the secondary retaining clip (3) over connected coupler cage (5).
9. Evacuate the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).

10. Charge the refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).

EVAPORATOR-A/C
DESCRIPTION
The A/C evaporator (1) for the heating-A/C system is
located within the HVAC housing, behind the instru-
ment panel. The A/C evaporator and its insulator (2)
are positioned in the HVAC housing so that all air
entering the housing must pass over the evaporator
fins before it is distributed through the heating-A/C
system ducts and outlets. However, air passing over
the evaporator fins will only be conditioned when the
A/C compressor is engaged and circulating refrigerant
through the A/C evaporator.
The A/C evaporator can be serviced by removing and
disassembling the HVAC housing assembly.
OPERATION
Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of
liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and
the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The
refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.
The A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced.
REMOVAL
1. RemovetheHVAChousingandplaceitonawork-
bench (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/HOUSING-HVAC -
REMOVAL).
2. Disassemble the HVAC housing to access the A/C
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HOUSING-HVAC - DIS-
ASSEMBLY).
3. Remove the probe of the evaporator temperature
sensor (1) from the fins of the A/C evaporator (2)
and position the wire lead (3) out of the way.
NOTE: If the foam insulator around the A/C evap-
orator is deformed or damaged, the insulator must
be replaced.
4. Carefully lift the A/C evaporator and the foam insu-
lator out of the upper half of the HVAC housing (4).
NOTE: If the foam seal around the evaporator tap-
ping block is deformed or damaged, the seal must be replaced.
5. If required, remove the foam seal from the inlet and outlet tubes of the A/Cevaporator.

INSTALLATION
NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
NOTE: Make sure that the foam insulator is prop-
erly positioned in the HVAC housing.
1. Carefully install the A/C evaporator (2) and its foam
insulator into the upper half of the HVAC housing
(4).
2. Install the probe of the evaporator temperature
sensor (1) between the fins of the A/C evaporator.
3. Route the wire lead (3) of the evaporator tempera-
ture sensor into the opening located on the upper
half of the HVAC housing.
4. Assemble the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - ASSEMBLY).
5. Install the HVAC housing (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION/HOUSING-
HVAC - INSTALLATION).

FAN-A/C CONDENSER
DESCRIPTION
All models equipped with gasoline engines, except
SRT 8, use an electric cooling fan to help pull heat out
of the A/C system, especially during idle conditions.
Without a cooling fan, A/C high side pressures would
increase and A/C system performance would eventu-
ally deteriorate.
The A/C condenser fan consists of a plastic fan blade
assembly which is driven by a 12-volt direct current
(DC) motor (1) with an integral wire harness connector
(2). The A/C condenser fan is mounted within a plastic
shroud (3) behind the A/C condenser (4) located in the
left front of the engine compartment.
OPERATION
The A/C condenser fan used in gasoline engine equipped models (except SRT 8) is controlled by the powertrain
control module (PCM). 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 sends a signal on a dedicated hard-wired circuit to the totally integrated power module (TIPM)
to energize the internal A/C condenser fan high side driver. When energized, the A/C condenser fan high side driver
provides battery current to the condenser fan motor.
The A/C condenser fan control system isdiagnosed using a scan tool (Refer to 24 - HVAC Electrical Diagnostics for
more information).
The components of the A/C condenser fan cannot be repaired and, if faulty ordamaged, they must be replaced as
an assembly.
REMOVAL
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.
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. Disconnect the A/C discharge line and the A/C liq-
uidlinefromtheA/Ccondenser(Referto24-
HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C DISCHARGE - REMOVAL) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
LINE-A/C LIQUID - REMOVAL).
4. Disconnect the wire harness connector (8) from the
A/C condenser cooling fan motor (7).