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Home >> Dodge or Ram Truck >> 2012 >> RAM 3500 Truck 4WD L6-6.7L DSL Turbo High Output >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Overhaul >> HVAC Housing - Assembly >> HVAC Housing

HVAC Housing






HVAC HOUSING

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system [1][2]Capacity Specifications . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system[1][2]Capacity Specifications .

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: Replacement of the O-ring seals is required anytime the A/C expansion valve is removed from the A/C evaporator. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.






NOTE: Typical actuator coupler shown.

1. Install the actuator coupler(s) (1) into the HVAC housing (3), as required. Make sure the arm (2) on the coupler is positioned between the two stops (4) on the HVAC housing. Make sure the three retaining tabs on each actuator coupler are fully engaged to the inside surface of the HVAC housing.






NOTE: Dual zone system with two blend doors shown. Single zone system with one blend door similar.

NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.

2. Install the blend air door(s) (2), as equipped, onto the actuator coupler(s) (3). Align the keyway in the blend air door pivot shaft with the key on the actuator coupler.






NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.

3. Install the mode air doors (1 and 2) and the center partition (3), if equipped, to the rear half of the HVAC housing (4). Align the keyways in the mode air door pivot shafts with the keys on the actuator couplers (5). Align the dowel pins on the center partition to the holes in the HVAC housing.





4. Align the pivot shafts of the air doors to the holes in the HVAC housing halves (2 and 4).
5. Align the dowel pins on the rear half of the HVAC housing to the holes in the front half of the HVAC housing and install the two halves of the housing together.
6. Carefully engage the fourteen retaining tabs (3). Make sure the retaining tabs are fully engaged.

NOTE: If the foam seals on top of the HVAC housing are deformed or damaged, they must be replaced.

7. Inspect the foam seals (1), especially along the parting line (5) and replace as required.





8. Install the blend and mode door actuators (3, 4 and 6) onto the HVAC housing (5). If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those on the actuator coupler.
9. Install the screws that secure the blend and mode door actuators to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).
10. Install the evaporator temperature sensor (2) onto the HVAC housing.
11. Connect the HVAC wire harness (1) to the evaporator temperature sensor and the blend and mode door actuators.
12. Install the HVAC wire harness onto the HVAC housing. Make sure the wiring harness is routed correctly and is fully engaged to the retaining clips.






NOTE: If the foam seals on the heater core are deformed or damaged, they must be replaced.

13. Inspect the foam seals on the heater core (4) and replace as required.
14. Carefully install the heater core into the front of the HVAC housing (2).
15. Position the flange (1) onto the front of the HVAC housing. Make sure the retaining tab is fully engaged.
16. Install the two screws (3) that secure the flange to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).






NOTE: If the foam seal is deformed or damaged, the seal must be replaced.

17. Install the foam seal (1) onto the flange (2) at the front of the HVAC housing.





18. If equipped with dual zone system, install the blend door actuator (3) onto the front of the HVAC housing (1). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the actuator coupler.
19. Install the screws (4) that secure the blend door actuator to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).
20. Connect the HVAC wire harness connector (2) to the blend door actuator.






NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

21. Inspect the foam insulator on the A/C evaporator (1) and replace as required.
22. Carefully install the A/C evaporator into the blower motor and evaporator housing (2).





23. Carefully install the blower motor and evaporator housing (6) onto the HVAC housing (3). Align the dowel pins to the holes in the housing.
24. Carefully engage the nine retaining tabs (1 and 4). Make sure the retaining tabs are fully engaged.
25. Install the three screws (2 and 5) that secure the blower motor and evaporator housing to the HVAC housing. Tighten the screws to 1.1 Nm (10 in. lbs.).





26. Remove the tape or plugs from the evaporator tube fittings.
27. Lubricate new O-ring seals with clean refrigerant oil and install them onto the evaporator tube fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
28. Install the A/C expansion valve (5) onto the evaporator tube tapping block (3).
29. Install the two bolts (4) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 Nm (97 in. lbs.).

NOTE: If the foam seal is deformed or damaged, the seal must be replaced.

30. Install the foam seal (1) onto the HVAC housing (2).





31. Connect the HVAC wiring harness (1) to the recirculation door actuator (2), power module or blower resister (3) (depending on application) and the blower motor (4).
32. Engage the HVAC wiring harness to the two retaining clips (5). Make sure the wire harness is fully engaged to the retaining clips.
33. Install the HVAC housing HVAC Housing - Installation.

NOTE: If the heater core is being replaced, flush the cooling system Service and Repair .

34. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system [1][2]Capacity Specifications. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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