2002 DODGE RAM battery

instrument panel just inboard of the glove box. Vehi-
cles equipped with a manual transmission have a
lighted storage bin installed on the instrument panel
in place of the fold-down cup holder.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. 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 DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the storage bin unit onto the instru-
ment panel (Fig. 10).
(2) Engage the illumination lamp and hood
retainer clip to the back of the instrument panel stor-
age bin unit.
(3) Raise and position the top of the storage bin to
the instrument panel.
(4) Install and tighten the two screws that secure
the top of the storage bin unit to the instrument
panel. Tighten the screws to 2.2 N´m (20 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, 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 PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1)
Disconnect and isolate the battery negative cable.
(2) Remove the Airbag Control Module (ACM) and
bracket from the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - REMOVAL).
(3) Remove the trim from the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - REMOVAL).
(4) Remove the steering column opening cover
from the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(5)
Remove the two screws that secure the inside
hood latch release handle to the instrument panel lower
reinforcement and lower the release handle to the floor.
(6)Disconnect the clockspring pigtail wire connector
from the instrument panel wire harness connector
located on the instrument panel lower reinforcement.
(7) If the vehicle is so equipped, disconnect the
overdrive lockout switch pigtail wire connector from
the instrument panel wire harness connector near
the instrument panel lower reinforcement.
(8) Remove the steering column from the vehicle,
but do not remove the driver airbag, the steering
wheel, or the switches from the column. Be certain
that the steering wheel is locked and secured from
rotation to prevent the loss of clockspring centering.
(Refer to 19 - STEERING/COLUMN - REMOVAL).
(9) From under the driver side of the instrument
panel, perform the following:
(a) Disengage the park brake release handle
linkage rod from the park brake mechanism on the
Fig. 10 Instrument Panel Storage Bin Remove/Install
1 - SCREWS
2 - STORAGE BIN (RAISED)
3 - STORAGE BIN (LOWERED)
BR/BEINSTRUMENT PANEL SYSTEM 23 - 115
STORAGE BIN (Continued)

wire harness connectors from the heater-A/C housing
wire harness connectors.
(15) With the aid of an assistant, remove the tem-
porary hook and lift the instrument panel assembly
off of the roll-down bracket screws and remove it
from the vehicle.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT BELT TENSIONER, 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 PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS-
TEM. FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
(1)With the aid of an assistant, load the instrument
panel assembly onto the roll-down bracket screws on
the cowl side inner panels in the vehicle (Fig. 11).
Install a temporary hook in the center hole on top of the
instrument panel. Secure the other end of the hook to
the center hole in the top of the dash panel. The hook
should support the instrument panel in its rolled down
position about 46 cm (18 inches) from the dash panel.
(2) With the instrument panel supported in the
roll-down position, reconnect the instrument panel
wire harness connectors to the heater-A/C housing
wire harness connectors.
(3) Remove the temporary hook from the instru-
ment panel and roll the instrument panel up to its
installed position against the dash panel.
(4) Install and tighten the five screws that secure
the top of the instrument panel to the top of the dash
panel. Tighten the screws to 3.2 N´m (28 in. lbs.).
(5) Tighten the right and left instrument panel
cowl side roll-down bracket screws. Tighten the
screws to 11.9 N´m (105 in. lbs.).
(6) From under the passenger side of the instru-
ment panel, reconnect the two halves of the radio
antenna coaxial cable connector.
(7) From under the driver side of the instrument
panel, perform the following:
(a) Engage the park brake release handle link-
age rod with the park brake mechanism on the left
cowl side inner panel. (Refer to 5 - BRAKES/PARK-
ING BRAKE/RELEASE - INSTALLATION).
(b) Reconnect the instrument panel wire harness
connector to the park brake switch on the park
brake mechanism.(c) Reconnect the three connectors (one from the
body wire harness, and two from the headlamp and
dash wire harness) to the three connector recepta-
cles located closest to the dash panel on the back of
the Junction Block (JB).
(d)
Reconnect the headlamp and dash wire harness
to instrument panel wire harness bulkhead connector
and tighten the screw in the center of the connector.
Tighten the screw to 3.5 N´m (31 in. lbs.).
(e) Reconnect the instrument panel wire harness
to door wire harness connector located directly
below the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(f) If the vehicle is equipped with the Infinity
sound system option, reconnect the Infinity wire
harness connector to the instrument panel wire
harness connector that is secured to the outboard
side of the instrument panel wire harness to head-
lamp and dash wire harness bulkhead connector.
(g) Reconnect the instrument panel wire harness
connector to the stop lamp switch.
(h) Reconnect the heater-A/C housing vacuum
harness connector to the heater-A/C control vac-
uum harness connector located near the left end of
the heater-A/C housing.
(8) Reinstall the steering column into the vehicle.
Be certain that the steering wheel was locked and
secured from rotation to prevent the loss of clock-
spring centering. (Refer to 19 - STEERING/COL-
UMN - INSTALLATION).
(9) If the vehicle is so equipped, reconnect the
overdrive lockout switch pigtail wire connector to the
instrument panel wire harness connector near the
instrument panel lower reinforcement.
(10) Reconnect the clockspring pigtail wire connec-
tor to the instrument panel wire harness connector
at the instrument panel lower reinforcement.
(11) Position the inside hood latch release handle
to the instrument panel lower reinforcement.
(12) Install and tighten the two screws that secure
the inside hood latch release handle to the instru-
ment panel lower reinforcement. Tighten the screws
to 2.8 N´m (25 in. lbs.).
(13) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(14) Reinstall the trim onto the left and right cowl
side inner panels. (Refer to 23 - BODY/INTERIOR/
COWL TRIM COVER - INSTALLATION).
(15) Reinstall the Airbag Control Module (ACM)
and bracket onto the floor panel transmission tunnel.
(Refer to 8 - ELECTRICAL/RESTRAINTS/AIRBAG
CONTROL MODULE - INSTALLATION).
(16) Reconnect the battery negative cable.
BR/BEINSTRUMENT PANEL SYSTEM 23 - 117
INSTRUMENT PANEL ASSEMBLY (Continued)

Heater Diagnosis
3. Incorrect engine
coolant temperature.3. Check the performance and operation of the engine
cooling system including: thermostat, water pump, fan
drive, accessory drive belt, coolant flow (plugged radiator
or heater core, plugged or kinked coolant hoses), air flow
(missing or improperly installed radiator air seals or fan
shroud). Refer to Cooling for the procedures.
4. Blend door actuator
inoperative or defective.4. (Refer to Controls/Blend Door Actuator) in this group.
5. Blend door not
operating properly.5. Check for a damaged, obstructed or improperly
installed blend door or seals. (Refer to Controls/Blend
Door Actuator) in this group.
6. Insufficient air flow
through heater housing.6. Remove foreign material or obstructions from cowl air
intake.
7. Improper blower motor
operation.7. (Refer to Distribution/Blower Motor/ Diagnosis and
Testing) in this group.
STANDARD PROCEDURE - DIODE
REPLACEMENT
(1) Disconnect the battery negative cable and iso-
late it.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 3).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery negative cable, and test
affected systems.
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle BR/BE - Ram
Pickup
System R134a w/orifice
tube
Compressor Sanden SD7H15 SP-20 PAG oil
Freeze±up
ControlA/C Low
Pressure Switchaccumulator
mounted
Low psi Control opens < 22-24
psi resets >
37-43 psi
High psi Control switch - opens >
450 - 490 psi,
resets < 270 -
330 psimounted on
discharge line,
near
compressor
A/C Heater
Control Headmanual type
Mode Door vacuum actuator
Blend Door electric actuator
Recirculation
Doorvacuum actuator
Fig. 3 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
BR/BEHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

LOCATING VACUUM LEAKS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect the vacuum harness connector
located between the a/c heater control and the HVAC
housing under the instrument panel.
(2) Connect the test set vacuum hose probe to each
port in the HVAC housing half of the vacuum har-
ness connector, one port at a time, and pause after
each connection (Fig. 2). The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each connection is made. If OK, replace the faulty a/c
heater control. If not OK, go to step Step 3.(3) Determine the vacuum line color of the vacuum
circuit that is leaking. To determine the vacuum line
colors, see the Vacuum Circuits chart (Fig. 3).
(4) Disconnect and plug the vacuum line from the
component (fitting, actuator, valve, switch, or reser-
voir) on the other end of the leaking circuit. Instru-
ment panel disassembly or removal may be necessary
to gain access to some components. Refer to Instru-
ment Panel System for the procedures.
(5) Connect the test set hose or probe to the open
end of the leaking circuit. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each connection is made. If OK, replace the faulty
disconnected component. If not OK, go to Step 6.
(6) To locate a leak in a vacuum line, leave one
end of the line plugged and connect the test set hose
or probe to the other end of the line. Run your fin-
gers slowly along the line while watching the test set
gauge. The vacuum reading will fluctuate when your
fingers contact the source of the leak. To repair the
vacuum line, cut out the leaking section of the line.
Then, insert the loose ends of the line into a suitable
length of 3 millimeter (0.125 inch) inside diameter
rubber hose.
A/C COMPRESSOR CLUTCH
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil, a hub bearing and pul-
ley assembly, and a clutch plate (Fig. 4). The
electromagnetic coil unit and the hub bearing and
pulley assembly are each retained on the nose of the
compressor front housing with snap rings. The clutch
plate is mounted to the compressor shaft and secured
with a nut.
Fig. 2 VACUUM CIRCUIT TEST
BR/BECONTROLS 24 - 11
CONTROLS (Continued)

OPERATION
The compressor clutch assembly provides the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch into contact with the pulley and drives the
compressor shaft. When the coil is not energized, the
pulley freewheels on the clutch hub bearing, which is
part of the pulley. The compressor clutch and coil are
the only serviced parts on the compressor.
The compressor clutch engagement is controlled by
several components: the a/c heater mode control
switch, the a/c loss of charge switch, the a/c pressure
transducer, the compressor clutch relay, the evapora-
tor temperature sensor and the Powertrain Control
Module (PCM). The PCM may delay compressor
clutch engagement for up to thirty seconds(Refer to 8
- ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The battery must
be fully-charged before performing the following
tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0 to 20 volt scale) with clip-type leads for measuring
the voltage across the battery and the compressor
clutch coil.(2) With the a/c heater mode control switch in any
A/C mode, and the blower motor switch in the lowest
speed position, start the engine and run it at normal
idle.
(3) The compressor clutch coil voltage should read
within 0.2 volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch
coil feed circuit for excessive voltage drop and repair
as required. If there is no voltage reading at the
clutch coil, use a DRB IIItscan tool and (Refer to
Appropriate Diagnostic Information) for testing of the
compressor clutch circuit. The following components
must be checked and repaired as required before you
can complete testing of the clutch coil:
²Fuses in the junction block and the Power Dis-
tribution Center (PDC)
²A/C Heater mode control switch
²Compressor clutch relay
²A/C High Pressure Switch
²A/C Low Pressure Switch
²Powertrain Control Module (PCM).
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is 2.0 to 3.9
amperes with the electrical system voltage at 11.5 to
12.5 volts. This should only be checked with the work
area temperature at 21É C (70É F). If system voltage
is more than 12.5 volts, add electrical loads by turn-
ing on electrical accessories until the system voltage
drops below 12.5 volts.
(a) If the clutch coil current reading is four
amperes or more, the coil is shorted and should be
replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C Heater control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) On models with the diesel engine option,
remove the compressor from the engine. Do not
Fig. 4 COMPRESSOR CLUTCH - TYPICAL
1 - CLUTCH PLATE
2 - SHAFT KEY
3 - PULLEY
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
BR/BECONTROLS 24 - 13
A/C COMPRESSOR CLUTCH (Continued)

NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.
(12) On models with the diesel engine option,
install the compressor on the engine. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION)
(13) Connect the battery negative cable.
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The a/c compressor clutch relay is a International
Standards Organization (ISO) micro-relay. The termi-
nal designations and functions are the same as a con-
ventional ISO relay. However, the micro-relay
terminal orientation (footprint) is different, the cur-
rent capacity is lower, and the relay case dimensions
are smaller than those of the conventional ISO relay.
OPERATION
The compressor clutch relay is a electromechanical
device that switches battery current to the compres-
sor clutch coil when the Powertrain Control Module
(PCM) grounds the coil side of the relay. The PCM
responds to inputs from the a/c heater control, the a/closs of charge switch, the a/c pressure transducer and
the evaporator fin probe.
The compressor clutch relay is located in the Power
Distribution Center (PDC) in the engine compart-
ment. Refer to the PDC label for relay identification
and location.
The compressor clutch relay cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH RELAY
RELAY TEST
The compressor clutch relay (Fig. 16) is located in
the Power Distribution Center (PDC). Refer to the
PDC label for relay identification and location.
Remove the relay from the PDC to perform the fol-
lowing tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, see the Relay Circuit Test below. If not
OK, replace the faulty relay.
RELAY CIRCUIT TEST
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
Fig. 15 CHECK CLUTCH AIR GAP
1 - FEELER GAUGE
Fig. 16 COMPRESSOR CLUTCH RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BECONTROLS 24 - 17
A/C COMPRESSOR CLUTCH (Continued)

(1) The relay common feed terminal cavity (30) is
connected to fused battery feed. There should be bat-
tery voltage at the cavity for relay terminal 30 at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the compressor clutch coil. There should
be continuity between this cavity and the A/C com-
pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
to Step 4. If not OK, repair the open circuit as
required.
(4) The relay coil battery terminal (86) is con-
nected to the fused ignition switch output (run/start)
circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 17).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.(4) Unplug the compressor clutch relay from the
PDC and remove it.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C-HEATER CONTROL
DESCRIPTION
Both the heater-only and a/c heater systems use a
combination of electrical and vacuum controls. These
controls provide the vehicle operator with a number
of setting options to help control the climate and
comfort within the vehicle. Refer to the owner's man-
ual in the vehicle glove box for more information on
the features, use, and suggested operation of these
controls.
OPERATION
The heater-only or a/c heater control panel is
located to the right of the instrument cluster on the
instrument panel. The control panel contains a rota-
ry-type temperature control knob, a rotary-type mode
control switch knob, and a rotary-type blower motor
speed switch knob. On models with the optional
heated mirror system, a momentary push button
switch and indicator lamp are located near the bot-
tom of the a/c heater control panel. Refer to Heated
Mirrors for more information on this feature.
The heater-only or a/c heater control panel cannot
be repaired. If faulty or damaged, the entire unit
must be replaced. The control knobs and the illumi-
nation lamps are available for service replacement.
DIAGNOSIS AND TESTING - A/C HEATER
CONTROL
Satisfactory heater and air conditioner perfor-
mance depends upon proper operation and adjust-
ment of all operating controls and refrigeration
system components. For circuit descriptions and dia-
grams, (Refer to Appropriate Wiring Information).
These inspections, tests, and adjustments should be
used to locate the cause of a malfunction.
Operation must be tested as described in the fol-
lowing sequence:
(1) Inspect and adjust the serpentine drive bel-
t(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - DIAGNOSIS AND TESTING).
(2) Start the engine and hold the idle speed at
1,300 rpm.
Fig. 17 POWER DISTRIBUTION CENTER
1 - COVER
2 - POWER DISTRIBUTION CENTER
24 - 18 CONTROLSBR/BE
A/C COMPRESSOR CLUTCH RELAY (Continued)

(3) On vehicles with air conditioning, turn the
temperature control knob to the extreme counter
clockwise (Cool) position, and set the mode control
switch knob to the Bi-Level (A/C) position. The out-
side (recirculation) air door should be open to outside
air. If not OK, (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS - DIAGNOSIS AND TEST-
ING - VACUUM SYSTEM).
(4) Open the vehicle windows. Test the blower
motor operation in all speeds. If not OK, (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/BLOWER MOTOR - DIAGNOSIS AND TEST-
ING).
(5) On vehicles with air conditioning, the compres-
sor should be running and the air conditioning sys-
tem in operation unless the ambient air temperature
is below about -1É C (30É F). If not OK, (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE).
(6) Check the mode control switch operation. The
heater and air conditioner systems should respond as
described in the owner's manual in the vehicle glove
box to each mode selected. Reduce the engine speed
to normal idle. The vacuum will be high at low idle
and the vacuum actuators should respond quickly. If
not OK, (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - DIAGNOSIS AND TEST-
ING - VACUUM SYSTEM).
(7) If the vacuum tests, and the electrical compo-
nent and circuit tests reveal no problems, disassem-
ble the HVAC housing to inspect for mechanical
misalignment or binding of the mode doors (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - DISASSEMBLY)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Reach under the instrument panel near the
driver side of the floor panel transmission tunnel andunplug the a/c heater control to HVAC housing vac-
uum harness connector.
(3) While still reaching under the instrument
panel, disengage the retainer on the a/c heater con-
trol half of the vacuum harness from the hole in the
center distribution duct (Fig. 18).
(4) Remove the cluster bezel from the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(5) Remove the four screws that secure the a/c
heater control to the instrument panel (Fig. 19).
(6) Pull the a/c heater control assembly away from
the instrument panel far enough to access the con-
nections on the back of the control.
(7) Unplug the wire harness connector from the
back of the a/c heater control.
(8) On vehicles with heated mirrors, unplug the
heated mirror wire harness connector from the back
of the a/c heater control.
(9) Remove the a/c heater control from the instru-
ment panel.
INSTALLATION
(1) Plug the wire harness connector(s) into the
receptacle(s) on the back of the a/c heater control.
(2) Route the HVAC vacuum harness through the
hole in the reinforcement below the a/c heater control
opening of the instrument panel.
(3) Position the a/c heater control in the instru-
ment panel and secure it with four screws. Tighten
the screws to 2.2 N´m (20 in. lbs.).
Fig. 18 A/C HEATER CONTROL VACUUM HARNESS
ROUTING
1 - A/C HEATER CONTROL VACUUM HARNESS
2 - REINFORCEMENT
3 - RETAINER
4 - CENTER DISTRIBUTION DUCT
BR/BECONTROLS 24 - 19
A/C-HEATER CONTROL (Continued)