Chevrolet Suburban Service Manual

Section 1
HVAC
Heating, Ventilation and Air Conditioning ...1-5 Blower Switch Replacement ......................... 1-38
Specifications....................... ............. ......... ...... 1-5 Temperature Control Cable Replacement .....1-39
Fastener Tightening Specifications .................1-5 Air Inlet Assembly Replacement................... 1-40
GM SPO Group Numbers............... ....... ........ 1-5 Blower Motor Resistor Replacement .............1-41
Schematic and Routing Diagrams.................. 1-6 Blower Motor and Fan Replacement ............1-41
Heater Blower Controls Schematic Air Distributor Duct Replacement ......... ........1-43
References ........ ................. ................... .......1-6 Air Outlet Replacement - Floor ----- .............1-43
Heater Blower Controls Schematic Icons........1-6 Air Outlet Replacement - Rear Floor............1-44
Heater Blower Controls Schematics ................1-7 IP Air Outlet Ducts Replacement................. ..1-45
Component Locator............ ......................... . 1-10
Air Outlet Duct Replacement - Left Lap .......1-46
Heater Blower Controls Components............ 1-10
Heater Hoses Replacement
Heater Blower Controls Component Views .... 1-13
(Inlet Hose- 4.3L,5.0L,5.7,7.4L) ..... ............1-47
Heater Blower Controls Connector
End Views ........................... .................... — 1-17 Heater Hoses Replacement
(Outlet Hose- 7.4L) .......... ........ ..................1-48
Diagnostic Information and Procedures.......1-20
Function Test...................... ..... ....... ...............1-20 Heater Hoses Replacement
(Outlet Hose- 4.3L, 5.0L, 5.7L) .................. 1-49
Heater Blower Controls System Check .........1-21
Air Delivery Improper..................................... 1-21 Heater Hoses Replacement
(Inlet Hose- Diesel).... ................................ 1-49
Blower Motor Inoperative at Any Speed ....... 1-21
Blower Motor Inoperative at Any Speed - Heater Hoses Replacement
Auxiliary ............................................. ......... 1-22 (Outlet Hose- Diesel) ............... ......... ......... 1-51
Blower Motor Inoperative Hot Water Bypass Valve Replacement ......... 1-51
at High Speed Only............................. ...... 1-23 Heater Core Replacement....... ...... ................ 1-52
Blower Motor High Speed Inoperative - Control Switch Replacement - Auxiliary
Auxiliary ....................... ............................... 1-24 (Suburban- IP Cluster) ................................ 1-55
Blower Motor Medium Speed Inoperative - Control Switch Replacement - Auxiliary
Auxiliary ................. ...... ................... ....... . ..1-25 (Suburban- Front Overhead) ......................1-56
Blower Motor Inoperative Control Switch Replacement - Auxiliary
at Low Speed Only ................. .................. 1-25 (Suburban- Center Overhead)....................1-56
Blower Motor Low Speed Inoperative - Heater Hoses Replacement - Auxiliary
Auxiliary ...................................... .................1-26 (Suburban- Front) ............ ......... ................. 1-57
Blower Motor Inoperative Med-1 ....................1-27 Heater Hoses Replacement - Auxiliary
Blower Motor Inoperative Med-2..... ..............1-27 (Suburban- Rear).........................................1-61
Blower Motor Operates Heater Hoses Replacement - Auxiliary
at High Speed Only............ ....................... 1-28 (Diesel- R ear)..............................................1-62
Blower Motor Operates Blower Motor Replacement - Auxiliary ........ ..1-66
at High Speed Only - Auxiliary .................. 1-28
Heater Core Replacement - Auxiliary ............1-67
Blower Motor Always On ..... .......................1-29
Blower Motor Operates Continuously - Blower Motor Resistor Replacement -
Auxiliary .............. ................ .......................1-30 Auxiliary ........................... ...... .................... 1-69
Heater Output Temperature Check............... 1-31 Description and Operation..............................1-71
Defrosting Insufficient..................................... 1-31 Heater System Description .................... ........ 1-71
Heating Insufficient...... ........... ........................1-31 Air Distribution System Description ................1-71
Heat Excessive.... ...... ................. ......... ........1-34 Heater Core Description............ ................ ....1-71
Noise Diagnosis ..................... .........................1-34 Heater Blower Controls Circuit Description ...1-72
High or Low Temperature Control Effort.......1-36 Modes Description ........................,i,...............1-72
Repair instructions........... ............................... 1-37 Heater Description - Auxiliary ................ ........1-72
Control Assembly Replacement.....................1-37 Special Tools and Equipment........................ 1-72
HVAC System - M a n u a l................................... 1-73 Temperature Actuator Inoperative (Rear) ....1-134
Specifications .................................................... 1-73 Heating Insufficient....................................... 1-136
Fastener Tightening Specifications ............... 1-73 Defrosting Insufficient ................................... 1-137
Fitting and Line Tightening Specifications.... 1-73 Cooling Insufficient - A/C Inoperative..........1-137
Compressor Specifications .............................1-74 Noise Diagnosis............................................1-141
System Capacities .......................................... 1-74 Odor Diagnosis ............................................. 1-142
R-134a Metric Fitting Sizes............................1-74 Repair Instructions.........................................1-143
GM SPO Group Numbers ..............................1-74 Refrigerant Recovery and Recharging ........1-143
Schematic and Routing Diagrams ................ 1-75 Compressor Oil Level Check....................... 1-143
HVAC Schematic References........................ 1-75 Compressor Replacement
HVAC Schematic Icons.................................. 1-75 (4.3L, 5.0L, 5.7L) ............... ...................... 1-144
HVAC Blower Control Schematics.................1-76 Compressor Replacement (7.4L) ................1-145
HVAC Compressor Control Schematics........1-79 Compressor Replacement (Diesel) ..... ....... 1-146
HVAC Air Delivery Schematics...................... 1-81 Compressor Clutch Plate and
Component Locator.......................................... 1-85 Hub Assembly Removal ........ ...................1-147
HVAC Components.........................................1-85 Clutch Rotor and/or Bearing Removal ........ 1-147
HVAC Component Views ............................... 1-89 Compressor Clutch Coil Removal............... 1-149
HVAC Connector End Views......................... 1-96 Compressor Shaft Seal Removal........... .....1-150
Diagnostic Information and Procedures .....1-103 Compressor Pressure Relief Valve
Functional Check ............. .......... .................1-103 Removal .................. ............................. .,..1-152
HVAC Blower Controls System Check........1-103 Compressor Control Switches Removal......1-152
HVAC Compressor Controls Compressor Clutch Plate/Hub
System Check ............................................1-104 Assembly Install........................................1-153
HVAC Air Delivery System Check.............. 1-104 Clutch Rotor and/or Bearing Install............. 1-154
HVAC Compressor Clutch Compressor Clutch Coil Install .................... 1-156
Circuit Diagnosis (Gas) .............................1-106 Compressor Shaft Seal Install .....................1-158
HVAC Compressor Clutch Compressor Pressure Relief Valve Install .... 1-160
Circuit Diagnosis (Diesel).... ................... .1-110 Compressor Control Switches Install ..........1-161
Blower Motor Inoperative at Any Speed .... 1-113 Compressor Leak Testing ........................... 1-161
Blower Motor Low Speed Inoperative.........1-114 Compressor Pressure Relief Valve
Blower Motor Inoperative Med-1 ..... ............1-114 Replacement (7.4L) ..................................1-163
Blower Motor Inoperative Med-2..... ....... — 1-115 Compressor Pressure Relief Valve
Noise Diagnosis ............................................ 1-115 Replacement (All Except 7.4L) ................. 1-164
Compressor Sealing Washers
Blower Motor Operates
Replacement.......................... .................... 1-164
at High Speed O nly..................................1-116
Blower Motor High Speed Inoperative ........1-116 O-Ring Replacement - Dual ........................ 1-165
Blower Motor Always O n ..............................1-117 Compressor Hose Assembly Replacement
(Gasoline Engines) ................................... 1-166
Blower Motor Inoperative
Compressor Hose Assembly Replacement
at Any Speed - Auxiliary..................... ..... 1-118
(Diesel Engines) ............... ...... ................. 1-167
Blower Motor Low Speed Inoperative -
Auxiliary................................. ................... .1-119 Condenser Tube Replacement ....................1-169
Blower Motor Medium Speed Inoperative - Evaporator Tube Extension Replacement .....1-170
Auxiliary..................... .................................1-120 A/C Hose Replacement - Auxiliary ............ .1-171
Blower Motor High Speed Inoperative - Evaporator Tube Replacement .................... 1-173
Auxiliary.............................................. ....... 1-121 Thermal Expansion Valve Replacement......1-174
Blower Motor Operates Continuously - Expansion (Orifice) Tube
Auxiliary.... ......... ....................................... 1-122 Replacement (C 60)...................... .............1-174
Blower Motor Operates Expansion (Orifice) Tube
at High Speed Only - Auxiliary ............... 1-122 Replacement (C69) ....................................1-175
Vacuum System ............................................. 1-123 Condenser Replacement ..............................1-176
System Performance Test Accumulator Replacement........................... 1-178
(Dual Range Temperatures)........... ......... 1-124 Blower Motor Relay Replacement ...............1-179
Refrigerant System Checks.............. ......... .1-125 Blower Motor Resistor Replacement...........1-180
Leak Testing.................................................1-125 Blower Motor and Fan Replacement .......... 1-180
CCOT A/C System Diagnosis ................... ...1-127 Evaporator Core Replacement..................... 1-182
Mode Actuator Inoperative (Front) ............... 1-130 Heater Core Replacement........................... 1-185
Mode Actuator Inoperative (Rear) ............. 1-131 Heater Hoses Replacement.......... ..............1-185
Air Inlet Actuator Inoperative .......................1-132 Heater Water Valve Replacement ..............1-185
Temperature Actuator Inoperative (Front) .... 1-133 Control Assembly Replacement...................1-186
Blower Switch Replacement........................ 1-187 Temperature Actuator Replacement -
Mode Actuator Replacement ....................... 1-188 Auxiliary...................................................... 1-206
Temperature Actuator Replacement............ 1-189 Mode Actuator Replacement - Auxiliary..... 1-207
Air Distributor Duct Replacement.................1-190 Thermal Expansion Valve Replacement -
Control Assembly Replacement - Auxiliary............... .................................. ...1-207
Front Auxiliary A/C ................................... 1-191 Description and Operation ............................1-208
Control Assembly Replacement -
A/C System Description ............................... 1-208
Auxiliary (Suburban) ................................. 1-191
Air Distribution System Description............. 1-209
Control Assembly Replacement -
Refrigeration System Description.................1-209
Auxiliary (4-Door Utility) ..................... ...... 1-192
Expansion (Orifice) Tube Replacement - Heater System Description.......................... 1-211
Auxiliary...................................................... 1-193 Handling Refrigerant R-134a ....................... 1-211
Compressor/Condenser Hose Handling of Refrigerant Lines
Replacement - Auxiliary (5.7L) .................1-194 and Fittings ................................................1-211
Compressor/Condenser Hose Maintaining Chemical Stability ..................... 1-212
Replacement - Auxiliary (7.4L) .................1-195 Thermal Expansion Valve Description......... 1-212
Compressor/Condenser Hose Expansion (Orifice) Tube Description.......... 1-212
Replacement - Auxiliary (6.5L) .................1-197
Evaporator Description ..................... ............1-213
Evaporator Core Replacement -
Auxiliary (Suburban) ................................. 1-198 Condenser Description ................................. 1-213
Evaporator Core Replacement - Accumulator Description............................... 1-213
Auxiliary (4-Door Utility) ............................1-200 Heater Core Description...............................1-214
Evaporator Tube Replacement - Compressor Description ............................... 1-214
Auxiliary...................................................... 1-201 High Pressure Relief Valve Description .... .1-214
Blower Motor Resistor Replacement - Control Assembly Description...................... 1-215
Auxiliary (Suburban) ................................. 1-202 Relays and Sensors Description..................1-215
Blower Motor Resistor Replacement -
O-Ring/Flat Washer Description...................1-216
Auxiliary (4-Door Utility) ............................1-202
Blower Motor and Fan Replacement - HVAC Blower Controls
Auxiliary (Suburban) ................................. 1-203 Circuit Description..................................... 1-216
Blower Motor and Fan Replacement - HVAC Compressor Controls
Auxiliary (4-Door Utility) ............................1-204 Circuit Description..................................... 1-218
Blower Motor Relay Replacement - HVAC Air Delivery Circuit Description ........1-218
Auxiliary...................................................... 1-206 Special Tools and Equipm ent...................... 1-220
BLANK
Heating, Venti lation and Air Conditioning
Specifications
Fastener Tightening Specifications
Specification
Application Metric :, English .
Air Inlet Valve-to-Instrument Panel Screw 1.9 N-m 17 ib in
Alternator Bracket Mounting Screws 30 N-m 22 lb ft
Auxiliary Heater Module Mounting Bolts 1.5 N-m 13 lb in
Auxiliary Heater Module Mounting Nuts 10 N-m 89 Ib in
Blower Motor Mounting Screw 2 1 N-m 20 Ib in
Blower Motor Resistor Mounting Screw 1.4 N-m 12 1b in
Control Assembly Mounting Screw 1 6 N-m 14 Ib in
Cowl Panel-to-Heater Case Mounting Screw 1.9 N-m 171b in
Defroster Nozzle Mounting Screw 1.9 N-m 171b in
Defroster Nozzle-to-Heater Case Mounting Screw 14 N-m 121b in
Distributor Duct Mounting Screw 1.9 N-m 171b in
Floor Air Outlet Duct Screw 1.9 N-m 17 Ib in
Front Auxiliary Hose-to-Frame Mounting Screw 17 N-m 131b ft
Heater Case-to-Cowl Panel Mounting Nut 28Nm 25 Ib in
Heater Case-to-Cowl Panel Mounting Screw 11 N-m 97 Ib in
Rear Auxiliary Hose Clip-to-Frame Mounting Bolts 17 N-m 131b ft
Right Vent Cable-to-Heater Case 1 4 N-m 12 1b in
GM SPO Group Numbers

Application GM SPO Group Number
Air - Outlet Defogger 9.779 !
Air - Outlet Duct 9 7/S
Air Distributor - Duct 9.282
Blower - Motor and Fan 9 786
Blower Motor - Rear Auxiliary 8 855
Blower Motor - Resistor 8 855
Blower Motor - Resistor Auxiliary 8.85b
Control - Heater Assembly 9 2?3
Control Switch - Auxiliary 9 ?/3
Heater - Case 8.854
Heater - Core 8.855
Heater - Core 8.855
Heater Case - Auxiliary 8.854
Heater Module - Auxiliary 8.855
Heater Pipe - Auxiliary Rear 8.845
Heater Pipe - Auxiliary Front 8.845
Hose - Heater 8.846
Hot Water - Valve Bypass 8.846
Schematic and Routing Diagrams
Heater Blower Controls Schematic References
Reference on Schematic Section Number - Subsection Name
Ground Distribution Cell 14 8 — Wiring Systems
HVAC Air Delivery Controls Cell 65 1 — HVAC - AC-Manual
Power Distribution Cell 10 8 — Wiring Systems
Heater Blower Controls Schematic Icons

Icon Icon Definition
Refer to E S D N o tic e in Cautions and Notices.
19384
HVAC_________________________________________________________________________________
|Hot At All Times 1 fH QflnRUNl
Power <4- Underhood Power

Distribution N3 BLOWER Fuse Distribution MB JL HTR-A/C Fuse
Cell 10
J Fuse 3
M3W SO A
* Block
I
Cell 10
U
y Fuse 12
NsC 25A
r n " 141
S268 i h - -
1
i
-
Block
-
Power
Distribution
Suburban
1 BRN .141 Cell 10 0
And Utility Pickups G C2
- r ■HVAC
Blower Control
Power
5 RED 542 Switch
Module
Distribution • S110
Cell 10 High Off
3 RED 542 3 RED 542 r* C3
CONN ID
M2 Low
C1=4 BLK
3 RED 542 C2 = 8 BLK
C3=10 GRY
&P1Q1
A C203 \r —-
HJ A PTC2 1 DKQRN
71
1 ORN 52
1 LT BLU 72 1 YEL 60
Blower 1 TAN 63
Motor
Relay D B< A^ C230
High
2 YEL 60
1 ORN 52
Blower
2 TAN 63 Resistor
Blower
Motor 2 DK BLU 101 2 LT BLU 72
Front
Ground
Distribution
Ceil 14
3 BLK
1 BLK 150
5 BLK 150
& 8202
1-8 Heating, Ventilation and Air Conditioning__________________________________________________
HVAC
Auxiliary Auxiliary Auxiliary
Blower Motor Blower Motor Blower Motor
Relay, Low Relay, Medium Relay, High
__________________________________________________________________
Component Locator
Heater Blower Controls Components
Name Location Locator View Connector End View
H V A C C o n n e c to r
Auxiliary Blower Motor Behind the right rear wheelhousing H V A C C o m p o n e n t V ie w s
E n d V ie w s
Auxiliary Blower Motor On the top of the auxiliary HVAC plenum, H V A C C o n n e c to r
H V A C C o m p o n e n t V ie w s
Relay, High near the right rear wheelhousing E n d V ie w s
Relay, Low near the right rear wheelhousing E n d V ie w s
Relay, Medium near the right rear wheelhousing E n d V ie w s
Auxiliary Blower On the top of the auxiliary HVAC plenum, H V A C C o n n e c to r
Resistor near the right rear wheelhousing E n d V ie w s
Auxiliary HVAC Control On the front of the overhead console, near H V A C C o n n e c to r
Module the windshield E n d V ie w s
To the right of the IP, behind the H V A C C o n n e c to r
Blower Motor, Front H V A C C o m p o n e n t V ie w s
IP compartment box E n d V ie w s
Blower Motor Behind the IP compartment box, on the H V A C C o n n e c to r
Relay, High HVAC plenum E n d V ie w s
H V A C C o n n e c to r
Blower Resistor On top of the HVAC plenum H V A C C o m p o n e n t V ie w s
E n d V ie w s
Part of the heater controls, in the center of H V A C C o n n e c to r
HVAC Control Module H V A C C o m p o n e n t V ie w s
the IP, under the radio End V ie w s
P o w e r a n d G r o u n d in g P o w e r a n d G r o u n d in g
To the left of the IP, near the left front
IP Fuse Block C o m p o n e n t V i e w s in C o n n e c t o r E n d V i e w s in
door jamb switch
Wiring Systems Wiring Systems
Recirculation H V A C C o n n e c to r
Under the IP, on the HVAC plenum H V A C C o m p o n e n t V ie w s
Door Motor E n d V ie w s
Temperature Under the IP, on the center of the HVAC H V A C C o n n e c to r
Door Motor plenum E n d V ie w s
P o w e r a n d G r o u n d in g P o w e r a n d G ro u n d in g
In the left rear side of the engine
Underhood Fuse Block C o m p o n e n t V i e w s in C o n n e c t o r E n d V i e w s in
compartment, on the fender
Part of the engine harness to IP harness, In lin e H a r n e s s C o n n e c to r
H a r n e s s R o u t i n g V i e w s in
C100 in the left rear side of the engine E n d V i e w s in Wiring
Wiring Systems
compartment, at the bulkhead Systems
In lin e H a r n e s s C o n n e c to r
Behind the right side of the IP, near the H a r n e s s R o u t i n g V i e w s in
C203 E n d V i e w s in Wiring
heater motor, in foam wrap Wiring Systems
Systems
I n lin e H a r n e s s C o n n e c to r
C205 At the convenience center E n d V i e w s in Wiring
Wiring Systems
Systems
C221 At the convenience center E n d V i e w s in Wiring
Wiring Systems
Systems
Behind the right side of the IP, above the H a r n e s s R o u t i n g V i e w s in
HVAC evaporator housing Wiring Systems
Systems
C300 In the overhead console E n d V i e w s in Wiring
Wiring Systems
Systems
At the right rear of the vehicle, above the H a r n e s s R o u t i n g V i e w s in
auxiliary blower motor Wiring Systems
Systems
Heater Blower Controls Components (cont’d)
Inline Harness Connector
At the right rear of the vehicle, above the Harness Routing Views in
C401 auxiliary blower motor Wiring Systems
End Views in Wiring
Systems
Part of the engine harness, approximately
D104 (4.3L, 5.0L, 5.7L) 20 cm (8 in) from the A/C compressor — —
clutch connector
D104 (6.5L) 28 cm (11 in) from the A/C compressor — — .
clutch connector
D104 (7.4L) 17 cm (6.5 in) from the A/C compressor — —
clutch connector
Power and Grounding
Behind the left side of the IP, below the
G200 Component Views in —
fuse block, on the tie bar
Wiring Systems
Power and Grounding
On the right side of the instrument panel,
G202 Component Views in —
mounted to the HVAC plenum bracket
Wiring Systems
On the right side B pillar, near the door

Power and Grounding
G400 (Utility/Suburban)
striker
Component Views in —
Wiring Systems
In the right rear side of the engine Harness Routing Views in
P1.01 compartment, at the bulkhead Wiring Systems
—
Engine harness approx. 6.5 cm (2.5 in)

S102 (6.5L) from the trans connector breakout, towards — — ■■
the starter solenoid harness breakout
Engine harness, approx. 8 cm (3 in) from
S103 (4.3L, 5.0L, 5.7L) the EGR valve breakout, toward the — ■ ■
taillamp harness breakout
Engine harness, approx. 12 cm (4.7 in)
S103 (6.5L) from the starter solenoid breakout, towards ■— ■ —
the underhood lamp harness breakout
S103 (7.4L - ATT) the EGR valve harness breakout, towards — —
the ignition coil harness breakout
Engine harness, approx. 4 cm (1.5 in) from
S103 (7.4L - M/T) the fuel injector harness breakout, towards — —
the taillamp harness breakout
S107 (4.3L, 5.0L, 5.7L) the EGR valve breakout, toward the — —
Engine harness, approx. 40 cm (15 in)
S107 (6.5L, HD) from the EBCM breakout, toward the — —
transmission harness breakout
S107 (7.4L) the EBCM breakout, toward the EGR . .— — ..
harness breakout
S11.Q (4.3L, 5.0L, 5.7L) the EBCM breakout, toward the taillamp — —
harness
S110 (6.5L) the EBCM breakout, toward the taillamp — —
harness breakout
Engine harness, approx. 26 cm (10 in)
S110 (7.4L-A/T) from the EBCM breakout, near the taillamp — —
harness breakout
Heater Blower Controls Components (cont’d)
Name ■■■ : Location Locator View Connector End View
Engine harness, approx. 11 cm (4 in) into
S145 (7.4L) — —
the EGR valve breakout
S147 (Gas) the EGR valve breakout, toward the . _ —
S147 (Diesel)
the starter motor solenoid breakout ' —
S185 At Diode D104 — —

S186 At Diode D104 — —
IP harness, approx. 10 cm (4 in) from
S204
C100, towards data link connector (DLC)
— —
IP harness, approx. 8 cm (3 in) from the

S212
inflatable restraint switch breakout
—

S217 instrument cluster harness breakout, — —
toward the radio connectors breakout
S218
inflatable restraint switch breakout
— —
HVAC harness, approx. 8 cm (3 in) from

S244 the recirculation door breakout, toward the — —
high blower motor relay
IP harness, approx. 7 cm (2.5 in) into the __ '
S268
HVAC control switch harness breakout —
IP harness, approx. 24 cm (9.5 in) from the

S298 instrument cluster breakout, toward the — —
radio breakout
Rear HVAC control harness, approx.
S307 (4-Door 10 cm (4 in) from the auxiliary HVAC
Utility/Suburban) control logic module breakout, toward the
— —
front auxiliary HVAC control module
Rear HVAC control harness, approx. 5 cm
S308 (4-Door (2 in) from the auxiliary HVAC control logic
Utility/Suburban) module breakout, toward the rear auxiliary
— — .
HVAC control module
Auxiliary A/C harness, approx. 17 cm
S400 (w/Auxiliary A/C) (6.5 in) from the blower motor relays, — —
toward the blower motor
Front-to-rear body harness, approx. 37 cm
(14.5 in) from the right rear door jamb
S410 (2-door Utility)
switch breakout, toward the right rear door
— —
speaker breakout
S410 (4-Door (4.5 in) from the right rear door speaker
Utility/Suburban) breakout, toward the right rear door jamb —■ —
breakout
S440 (4-door
Utility/Suburban)
(2.5 in) from the convenience center — .. —
harness breakout
S440 (4-Door
(2.5 in) from the crossbody harness
Utility/Suburban
breakout, toward the front dome lamp
— —
w/o C69)
breakout
S441 (4-Door
Utility/Suburban)
(2 in) from the convenience center harness '— ; —
breakout
Heater Blower Controls Component Views
Auxiliary Heater Wiring
372173
Legend
(1) Auxiliary Blower Resistor (5) Front to Rear Body Harness
(2) Auxiliary Blower Relays; Low/Medium/High (6) C400
(3) Auxiliary Blower Motor Connector (7) Auxiliary Blower Motor
(4) C401
HVAC Control Module (Rear View)
376153
Legend
( 1) Dash (4) IP Harness

(2) HVAC Control Module Connector, C1 (5) HVAC Control Module Connector, C3
(3) HVAC Control Module Connector, C2 (6) HVAC Control Module (Rear View)
Front HVAC Assembly
Legend
( 1) Blower Resistor (7) Temperature Door Motor

(2) Blower Motor (8) HVAC Plenium
(3) Blower Motor Connectors (9) Mode Door Motor
(4) C230 (10) HVAC Wiring Harness
(5) C203 (11) Blower Motor Relay, High
(6) C204
Heater Blower Controls Connector Auxiliary Blower Motor Relay, Low
End Views
Auxiliary Blower Motor m m
....... ; j r
281199
Connector Part 12034003

Information • 5F M/P 630 (BLK)
Circuit
Pin Wire Color No. Function
Information 2F Metri-Pack 630 (BLK) Fuse Output - Battery -
1 RED 2
Type II Fuse
Circuit
2 BLK/WHT 51 Ground
Auxiliary Blower
3 ;— ' — Not Used
YEL 1172 Auxiliary Blower Motor
Motor Feed 4 YEL 1151
Resistor Output - Low
BLK 150 Ground
Fuse Output - Ignition 3
5 BRN 341
Type III Fuse
Auxiliary Blower Resistor
Auxiliary Blower Motor Relay,. Medium
' o '
T - I— J J
Connector Part 02977940 281199

Information 3F 56 Series (NAT) Connector Part • 12034003
Circuit Information • 5F M/P 630 SPL (BLK)
Circuit
Auxiliary Blower Pin Wire Color No. Function
LT BLU 1072 Resistor Output -
Fuse Output - Battery -
Medium 1 RED 2
Type I Fuse
Auxiliary Blower Blower Switch Output -
YEL 1152
Motor Feed 2 LT BLU 72
Medium 2
Auxiliary Blower Motor 3 — '— Not Used
YEL 1151
Output - Low________
Auxiliary Blower
4 YEL 1172
Motor Feed
5 BRN 341
Type III Fuse
Auxiliary Blower Motor Relay, High Auxiliary Heater Control Switch (cont’d)
UL 1
281199
Connector Part • 12034003 • 12064752

information Connector Part
« 5F M/P 630 SPL (BLK) Information • 6F Metri-Pack 280
Circuit Series (BLK)
Pin Wire Color No. Function Circuit
1 RED ■ 2
Type I Fuse Auxiliary HVAC Switch
DK BLU 1926
Output - Low
Blower Switch
2 ORN 52
Output-High Auxiliary HVAC Switch
RED 1925
Output - Medium_____
3 — — Not Used
Auxiliary Blower Motor
4 YEL 1152 Resistor Output - Blower Motor, Connector C1
Medium
5 BRN 341
Type III Fuse
Auxiliary Heater Control Switch
Ire!
E»S
Connector Part • 08905615
I I Information • 1F 56 Series (GRY)
Circuit
PPL 65 Power Motor Feed
Connector Part • 12064752
Information • 6F Metri-Pack 280
Series (BLK)
Circuit
GRY IP Lamp Feed
BLK 150 Ground
Not Used
Auxiliary HVAC Switch
D WHT 1924
Output - High________
Blower Motor, Connector G2 Blower Resistor
73208
Connector Part • 12004267 Connector Part • 12064877

Information • 1F 56 Series (BLK) Information • 4F Metri-Pack 680
: Series (BLK)
Circuit
Pin Wire Color No. Function Circuit
BLK 150 Ground
Blower Switch
YEL 60
Output - Low
. . . . . . «. i. . . . «i. . . . .
Blower Motor Relay, High DK BLU 101 Blower Resistor Output

Blower Switch Output •
TAN 63
Medium 1
Blower Switch Output •
LT BLU 72
J Medium 2
w n HVAC Control Module Connector C2

(Blower Switch)
d
H - ■M N
[ 1 fi i c
281201
j
12110541
Connector Part
Information 6F Metri-Pack 280 Series
Flexlock (BLK) D
Circuit rJALi r li Li r J? i [ JDLi
Pin Wire Color No, Function
A1 BLK 150 Ground
Fuse Output Battery -
A2 RED 542 62469
Type II Fuse
B1 Not Used Connector Part • 12064998
Blower Resistor Output Information • 8F Metri-Pack 280
B2 DK BLU 101
Series (BLK)
G1 PPL 65 Blower Motor Feed Circuit
Blower Switch Pin Wire Color No. Function
C2 ORN 52
Output- High Blower Switch Output -
A LT BLU 72
Medium 2
Blower Switch Output -
B TAN 63
Medium 1
Blower Switch
C YEL 60
Output - Low
A/C Selector Switch
D DKGRN 71
Output
HVAC Control Module Connector C2 Diagnostic Information and
(Blower Switch) (cont’d)
Procedures
Function Test
J' Before beginning the function test of the heater
_ 3 c system, idle the vehicle with the coolant hot and the
thermostat open. The coolant temperature should
b j be approximately 90°C (194°F). During the function
test, evaluate the operating efforts of the mode rotary
~> knob and the temperature rotary knob. If you find a
condition during any intermediate step of the function
rJALir JBLi r l? n J? i test, complete the test before starting the repair.
F Use the Tech II in order to verify the temperature.
1
1. Cycle the temperature knob to the extreme ends
of travel on the control assembly dial.
62469
Verify that the cable is properly adjusted.
• 12064998 2. Move the mode rotary knob to the VENT position.
Connector Part
Series (BLK) • Air should come from the instrument panel
outlets at nearly the same temperature as
Circuit the outside air.
• Air should not come from the following outlets:
E-F — — Not Used
- The floor outlets
G BRN 141 - The defroster nozzles
Type III Fuse
Blower Switch - The side window defogger outlets
H ORN 52
Output - High 3. Move the mode rotary knob to the HEATER
position.
• Most of the air should come from the floor
outlets.
• Air should not come from the instrument panel
outlets.
• The remainder of the air should come out of the
defroster nozzles and the defogger outlets.
4. Move the rotary knob from the HEATER position
to the DEFROST position.
• Most of the air should be discharged onto the
windshield from the defroster nozzles.
• A small amount of air should be discharged
from the floor outlets.
5. Move the temperature rotary knob back to the full
COLD position.
6. Ensure that the air temperature returns to
approximately the temperature of the outside air.
7. Slwly turn the blower switch toward OFF. Stop
briefly at each intermediate blower speed position.
• Note the force of the airflow coming from the
instrument panel center outlets.
The airflow should reduce noticeably at each
blower speed position.
• Note the sound of the blower.
The blower noise should reduce noticeably at
each blower speed position.
Heater Blower Controls System Check
Step Action Normal Result(s) Abnormal Result(s)*
1. Turn the ignition switch to RUN The blower motor operates in all • Blower Motor Inoperative at
position. positions. Any Speed
2. Rotate the HVAC control • Blower Motor Inoperative at Low
module blower switch through Speed Only
all speeds: • Blower Motor inoperative Med-1
1
• Low • Blower Motor Inoperative Med-2
• Med 1 • Blower Motor Inoperative at High
• Med 2 Speed Only
• High • Blower Motor Operates at High
Speed Only
Turn the blower switch to the OFF The blower motor shuts off. Blower Motor Always On
2 position.
1. Turn the ignition switch to RUN The auxiliary blower motor operates • Blower Motor Inoperative at Any
position. in all positions. Speed - Auxiliary
2. Rotate the Auxiliary HVAC • Blower Motor Low Speed
control module blower switch Inoperative - Auxiliary
through all speeds: • Blower Motor Medium Speed
3
• Low Inoperative - Auxiliary
• Med • Blower Motor High Speed
• High Inoperative - Auxiliary
• Blower Motor Operates at High
Speed Only - Auxiliary
Turn the auxiliary blower switch to The auxiliary blower motor shuts off. Blower Motor Operates Continuously
4 the OFF position. - Auxiliary
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.
Air Delivery Improper If the cause of the condition is not discovered,

disconnect the control cable at the valve.
If the Function Test or other diagnosis indicates
improper air delivery or a failure in the shifting of Inspect the system for the following items:
modes when moving the mode rotary knob. Inspect the • Improper air control valve travel and effort
attachment of the affected control cable at the • Improper control cable travel at the heater module
heater module. end while moving the mode rotary knob is
1. Ensure that the cable loop connects to the moving.
actuator. • If the cable does not move, inspect for a broken
2. Ensure that the cable sheath is retained. cable or control assembly part.
3. Remove the instrument panel storage • An unattached cable end at the control assembly
compartment. • A sharp kink in the control cable sheath that
4. Observe the action of the control cable. may cause severe binding.
Blower Motor Inoperative at Any Speed
Step Action Value(s) Yes No
Was the Heater Blower Controls System Check performed? Go to Heater
1 : _■ Blower Controls
Go to Step 2 System Check
1. Remove the blower motor relay high.
2 2. Connect a J 39200 between pin Cl and B2 of — ' ■■
the relay.
Is there continuity? Go to Step 4 Go to Step 3
Replace the blower motor relay high. Refer to Blower Motor Go to Heater
3 Relay Replacement. — Blower Controls —
Is the repair complete? System Check
1. Disconnect the connectors at the blower motor.
4 2. Connect a J 39200 between the blower motor —
connector C2, cavity B to ground.
Blower Motor Inoperative at Any Speed (cont’d)
Connect a J 3 9 2 0 0 between the blower motor
connector C1, cavity A and cavity C1 of the blower motor
5 relay high. —
Is there continuity? Go to S te p 6 Go to S te p 9
1. Reconnect the blower motor connectors.
6 2. Connect a fused jumper wire between cavities A2 —
and C1 of the blower motor relay high, socket.
Does the motor spin freely? Go to S te p 1 0 Go to S te p 7
Replace the blower motor. Refer to B lo w e r M o to r a n d F a n Go to H e a t e r
7 R e p la c e m e n t — B lo w e r C o n tro ls —
Is the repair complete? S y s te m C h e c k
Repair the open in CKT 150 (BLK) between the blower
motor and ground G202. Refer to W irin g R e p a ir s ] n Wiring Go to H e a t e r
8 Systems. —■ —
B lo w e r C o n tro ls
Repair the open in CKT 65 (PPL) between the blower
motor relay high and the blower motor. Refer to W irin g Go to H e a t e r
9 R e p a ir s in Wiring Systems. — —
1. Disconnect the HVAC control module connector C2.
2. Turn the ignition switch to the RUN position.
10 3. Connect a J 3 9 2 0 0 between cavity G2 of the HVAC —
control module connector and ground.
Is battery voltage present? Go to S te p 1 2 Goto S t e p 11
Repair the open in CKT 141 (BRN) between the
instrument panel (IP) fuse block and the HVAC control Go to H e a t e r
11 module. Refer to W irin g R e p a ir s in Wiring Systems. — .—
Replace the HVAC control module. Refer to C o n tr o l Go to H e a t e r
12 A s s e m b ly R e p la c e m e n t — .. B lo w e r C o n tro ls —
Blower Motor Inoperative at Any Speed - Auxiliary

Has the Heater Blower Controls System Check been Go to H e a t e r
1 performed? — B lo w e r C o n tro ls
Go to S te p 2 S y s te m C h e c k
1. Disconnect the auxiliary HVAC control module, front
switch.
2 2. Connect a J 3 9 2 0 0 (continuity) between cavity B of . — ,.
the switch connector and ground.
Is continuity present? Go to S te p 4 Goto S t e p 3
Locate and repair the open in CKT 150 (BLK) between the
auxiliary HVAC control module, front switch and ground Go to H e a t e r
3 G200. Refer to W irin g R e p a ir s in Wiring Systems. .. — .
Connect a J 3 9 2 0 0 (continuity) between pin B and
pin E, F and D while rotating the blower switch through
4 Low, Med, and High. —
Is continuity present in all modes? Go to S te p 6 Go to S te p 5
Replace the auxiliary HVAC control module, front switch.
Refer to C o n tr o l S w itc h R e p la c e m e n t - A u x ilia r y Go to H e a t e r
5 ( S u r b u r b a n - F r o n t O v e r h e a d ). —■ —
Blower Motor Inoperative at Any Speed - Auxiliary (cont’d)
1. Disconnect the auxiliary blower resistor connector.
2. Disconnect the auxiliary blower motor connector.
6 3. Connect a J 3 9 2 0 0 (continuity) between cavity B of —
the resistor connector and cavity A of the blower
motor connector.
Is continuity present? Go to S te p 8 Go to S te p 7
Locate and repair the open in CKT 1172 (YEL) between
splice S402 and the blower motor. Refer to W irin g R e p a ir s Go to H e a t e r
7 in Wiring Systems. — —
Connect a J 3 9 2 0 0 (continuity) between cavity B of the
8 blower motor connector and ground. —
Is continuity present? Go to S te p 9 Go to S te p 1 0
Replace the auxiliary blower motor. Refer to B lo w e r M o to r Go to H e a t e r
9 R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tr o ls —
blower motor and ground G400. Refer to W irin g R e p a ir s in Go to H e a t e r
10 Wiring Systems. — —
Blower Motor Inoperative at High Speed Only

2 2. Connect a J 3 9 2 0 0 between pin C2 and pin A1 of the —
blower motor relay high.
Replace the blower motor relay high. Refer to B lo w e r Go to H e a t e r
3 M o to r R e la y R e p la c e m e n t — B lo w e r C o n tro ls —
1. Connect a jumper wire between the blower motor
relay high and pin C2 and B+.
4 relay high and pin A1 and ground. —
3. Connect a J 3 9 2 0 0 between pin A2 and pin C1 of the
Connect a J 3 9 2 0 0 between the blower motor relay high
5 cavity A1 and ground. —
Is there continuity? Go to S te p 7 Go to S te p 6
blower motor relay high and ground G202. Refer to W irin g Go to H e a t e r
Connect a J 3 9 2 0 0 between the blower motor relay high
7 cavity A2 and ground. —
Is battery voltage present? Go to S te p 9 Go to S te p 8
Locate and repair the open in CKT 542 (RED) between the
underhood block and the blower motor relay high. Refer to Go to H e a t e r
8 W irin g R e p a ir s in Wiring Systems. — —
Blower Motor Inoperative at High Speed Only (cont’d)
1. Disconnect connector C2 at the HVAC control
module.
2. Connect a J 3 9 2 0 0 (continuity) between the HVAC
9 control module connector C2, cavity H and cavity G. —
3. Turn the HVAC control module to the HIGH position.
Is there continuity? Go to S te p 1 0 Go to S te p 11
Locate and repair the open in CKT 52 (ORN) between the
HVAC control module and the blower motor relay high. Go to H e a t e r
10 Refer to W irin g R e p a ir s in Wiring Systems. —
11 A s s e m b ly R e p la c e m e n t. — . B lo w e r C o n tro ls —
Blower Motor High Speed Inoperative - Auxiliary

1 performed? — . B lo w e r C o n tro ls
1. Remove the auxiliary blower motor relay, high.
2 2. Connect a fused jumper wire between cavity 1 and —
cavity 4 of the relay socket.
Does the blower motor run? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower motor relay, high. Refer to Go to H e a t e r
3 B lo w e r M o to r R e la y R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tro ls —
1. Remove the auxiliary HVAC control module, front.
2. Connect a J 3 9 2 0 0 (continuity) between pin B and
4 pin D of the switch. —
3. Rotate the switch to the HIGH position.
Replace the auxiliary HVAC control module, front. Refer to
C o n tr o l S w itc h R e p la c e m e n t - A u x ilia r y (S u r b u r b a n - F r o n t Go to H e a t e r
5 O v e r h e a d ). — —
1. Remove the auxiliary blower motor connector.
2. Connect a J 3 9 2 0 0 (continuity) between cavity 4 of
6 the high relay socket and cavity A of the blower —
connector.
Locate and repair the open in CKT YEL (1172) between
the auxiliary blower relay, high and splice S402. Refer to Go to H e a t e r
7 W irin g R e p a ir s in Wiring Systems. . . — —
Connect a J 3 9 2 0 0 (volts) between cavity 1 of the high
8 relay socket and ground. —
Is battery voltage present? Go to S te p 1 0 Go to S te p 9
Locate and repair the open in CKT 542 (RED) between
cavity 1 of the auxiliary blower relay, high and splice S401. Go to H e a t e r
9 Refer to W irin g R e p a ir s in Wiring Systems. , — —
Locate and repair the open in CKT 1924 (WHT) between
the auxiliary blower motor relay, high and the auxiliary
10 HVAC control module, front. Refer to W irin g R e p a ir s in — . . Go to H e a t e r —
Wiring Systems. B lo w e r C o n tro ls
Blower Motor Medium Speed Inoperative - Auxiliary
Step Action Vaiue(s) Yes No
Has the Heater Blower Controls System Check been Go to Heater
1 performed? — Blower Controls
1. Remove the Auxiliary Blower Motor Relay, Medium.
2 2. Connect a fused jumper wire between cavities 1 and 4 —
of the relay socket.
Does the blower motor run? Go to Step 3 Go to Step 4
Replace the auxiliary blower motor relay, medium. Refer to Go to Heater
3 Blower Motor Relay Replacement - Auxiliary. — Blower Controls —
2. Connect a J 39200 (continuity) between pin B and
■ 4 pin F of the switch. —
3. Rotate the switch to the Med position.
Is continuity present? Go to Step 6 Go to Step 5
Control Switch Replacement - Auxiliary (Surburban- Front Go to Heater
5 Overhead). — —
Blower Controls
1. Remove the auxiliary blower resistor connector.
6 2. Connect a J 39200 (continuity) between pin A and
pin B of the resistors connector.
Replace the auxiliary blower resistor. Refer to Blower Motor Go to Heater
7 Resistor Replacement - Auxiliary. — Blower Controls —
Connect a J 39200 (volts) between cavity 1 of the high relay
8 socket and ground. — ■
Is battery voltage present? Go to Step 10 Go to Step 9
cavity 1 of the auxiliary blower relay, medium and Goto Heater
9 splice S401. Refer to Wiring Repairs in Wiring Systems. — . —
Blower Controls
auxiliary blower motor relay, medium and the auxiliary
10 HVAC control module, front. Refer to Wiring Repairs in —. Go to Heater —
Wiring Systems. Blower Controls
Blower Motor Inoperative at Low Speed Only

1. Place the ignition switch in the RUN position.
2. Place the blower switch in the LOW position.
3. Disconnect the connector at the blower motor
2 resistor. —-
4. Connect a J 39200 (volts) between the blower motor
resistor connector cavity A and ground.
Replace the blower motor resistor. Refer to Blower Motor Go to Heater
3 Resistor Replacement. — Blower Controls —
Blower Motor Inoperative at Low Speed Only (cont’d)
2. Turn the blower switch to the LOW position.
4 3. Connect a J 3 9 2 0 0 (continuity) between pin C and ■
pin G of the HVAC control module.
is continuity present? Go to S te p 5 Go to S te p 6
Repair the open in CKT 60 (YEL) between the HVAC
control module connector 2, cavity C and the blower motor
5 resistor, cavity A. Refer to W irin g R e p a ir s in Wiring — . Go to H e a t e r —
Systems. B lo w e r C o n tro ls
6 A s s e m b ly R e p la c e m e n t — B lo w e r C o n tro ls
Blower Motor Low Speed Inoperative - Auxiliary

1. Remove the auxiliary blower motor relay, low.
2 2. Connect a fused jumper wire between cavity 1 and —
cavity 4 of the relay socket.
Does the blower motor run? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower motor relay, low. Refer to Go to H e a t e r
3 B lo w e r M o to r R e la y R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tro ls —
2. Connect a J 3 9 2 0 0 (continuity) between pin B and
4 pin E of the switch. —
3. Rotate the switch to the Low position.
C o n tr o l S w itc h R e p la c e m e n t - A u x ilia r y (S u r b u r b a n - F r o n t Go to H e a t e r
5 O v e r h e a d ). . — —
6 2. Connect a J 3 9 2 0 0 (continuity) between pin C and —
pin B of the resistors connector.
Replace the auxiliary blower resistor. Refer to B lo w e r Go to H e a t e r
7 M o to r R e s is to r R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tro ls —■ :
cavity 1 of the auxiliary blower relay, low and splice S401. Go to H e a t e r
9 Refer to W irin g R e p a ir s in Wiring Systems. —
Locate and repair the open in CKT 1926 (DK BLU)
between the auxiliary blower motor relay, low and the
10 auxiliary HVAC control module, front. Refer to W irin g — Go to H e a t e r —
R e p a ir s in Wiring Systems. B lo w e r C o n tro ls
Blower Motor Inoperative Med-1
1 performed? Blower Controls
2. Place the blower switch in the M1 position, next to
the LO position.
2 3. Disconnect the connector at the blower resistor. —
4. Connect a J 39200 (volts) between the blower
resistor connector, cavity C, and ground.
module.
2. Connect a J 39200 (continuity) between pins B and G
3 of the HVAC control module connector C2. —
3. Turn the blower switch to the Med1 position (next to
the Low position).
Replace the blower motor resistor. Refer to Blower Motor Go to Heater
4 Resistor Replacement ; -~ Blower Controls
Replace the HVAC control module. Refer to Control Go to Heater
5 Assembly Replacement — Blower Controls —
Locate and repair the open in CKT 63 (TAN) between the
HVAC control module and the blower resistor. Refer to Go to Heater
6 Wiring Repairs in Wiring Systems. —
Blower Controls

2. Place the blower switch in the Med2 position (next to
the HI position).
resistor connector, cavity D, and ground.
module.
2. Connect a J 39200 (continuity) between pins G and A
the HI position).
Replace the blower resistor. Refer to Blower Motor Go to Heater
4 Resistor Replacement — Blower Controls — ■
Replace the HVAC control module. Refer to Control Go to Heater
Locate and repair the open in CKT 72 (LT BLU) between
the HVAC control module and the blower resistor.
6 — Go to Heater —
Refer to Wiring Repairs in Wiring Systems. Blower Controls
Blower Motor Operates at High Speed Only
2 2. Connect a J 3 9 2 0 0 (continuity) between —
pins B2 and C1 of the relay.
Is continuity present? Go to S te p 4 Goto S te p 3
Replace the blower motor relay high. Refer to B lo w e r Go to H e a t e r
3 M o to r R e la y R e p la c e m e n t B lo w e r C o n tro ls —.
resistor.
4 2. Connect a J 3 9 2 0 0 (continuity) between the blower —
motor resistor connector cavity B and the blower
motor relay high, cavity B2.
Locate and repair the open in CKT 101 (DK BLU) between
the blower motor resistor and the blower motor relay high. Go to H e a t e r
5 Refer to W irin g R e p a ir s in Wiring Systems. — —
2. Rotate the blower switch through all speeds while
using a J 3 9 2 0 0 (continuity) checking for continuity
6 between pin G and the remaining pins of —
connector C2 (see schematic for appropriate pin to
speed callout).
Is continuity present in all modes? Go to S te p 7 Go to S te p 8
Replace the blower motor resistor* Refer to B lo w e r M o to r Go to H e a t e r
7 R e s is t o r R e p la c e m e n t — B lo w e r C o n tro ls —
8 A s s e m b ly R e p la c e m e n t — B lo w e r C o n tro ls —
Blower Motor Operates at High Speed Only - Auxiliary

1. Disconnect the auxiliary blower resistor.
2. Connect a jumper wire between cavities A and B of
2 the resistor connector.
—
3. Rotate the auxiliary HVAC control module switch to
the Med position.
Does the auxiliary blower motor spin? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower resistor. Refer to B lo w e r Go to H e a t e r
3 M o t o r R e s is to r R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tro ls
1. Disconnect the auxiliary blower motor.
2. Connect a J 3 9 2 0 0 (continuity) between cavity B of
4 the resistor connector and cavity A of the blower
connector.
Blower Motor Operates at High Speed Only - Auxiliary (cont’d)
Step Action Vaiue(s) Yes M o
the resistor connector and splice S402. Refer to W irin g Go to H e a te r
5 R e p a irs in Wiring Systems. — —
1. Remove the auxiliary HVAC control module front

switch.
6 2. Connect a J 3 9 2 0 0 (continuity) between cavities B
and E with the switch in Low, and cavities B and F
with the switch in Med.
Is continuity present in both positions? Go to S te p 8 Go to Step 7
Replace the auxiliary HVAC control module front switch.
Refer to C o n tro l S w itc h R e p la c e m e n t - A u x ilia ry Go to H e a te r
7 (S u rb u rb a n - F ro n t O ve rh e a d ). —
1. Connect all disconnect components test to this point.

2. Remove both the low and medium auxiliary blower
motor relays.
of both socket relays with the blower switch in Low
and Med.
Does the auxiliary blower motor operate in both positions? Go to S te p 9 Goto Step 10
Replace both auxiliary blower motor relays. Refer to B lo w e r Go to H e a te r
9 M o to r R e la y R e p la c e m e n t - A u x ilia ry . — B lo w e r C o n tro ls ': —
Locate and repair the open the circuit(s) between cavity 2 of

the relay socket and the auxiliary HVAC control module, Go to H e a te r
10 front switch. Refer to W irin g R e p a irs in Wiring Systems. ;~ - —
Is the repair complete? S y s te m Check
Blower Motor Always On

Step Action Vafue(s) Yes No
Has the Heater Blower Controls System Check been Go to H e a te r
Go to S te p 2 S y s te m Check
1. Remove the high blower motor relay.

2 , —
3. Place the blower motor switch in the OFF position.
Does the blower motor operate? Go to S te p 3 Go to S te p 4
Locate and repair the short to voltage in CKT 65 (PPL)
between the high blower motor relay and the blower Go to H e a te r
3 motor. Refer to W irin g R e p a irs in Wiring Systems. — —
Is the repair complete? S y s te m C h e ck
Connect a J 3 9 2 0 0 (continuity) between pins C1 and A2 of

4 the relay. -
Replace the high blower motor relay. Refer to B lo w e r Go to H e a te r
5 M o to r R e la y R e p la c e m e n t — B lo w e r C o n tro ls —

6 2. Connect a J 3 9 2 0 0 (volts) between cavity C2 of the 1 volt
high blower motor relay socket and ground.
Is voltage above the value given? Go to S te p 7 Go to S te p 8
Blower Motor Always On (cont’d)
Locate and repair the short to voltage in CKT 52 (ORN)
between the blower switch and the blower motor relay Go to H e a t e r
7 high. Refer to W irin g R e p a ir s in Wiring Systems. — —
resistor.
8 2. Connect a J 3 9 2 0 0 (volts) between cavity B2 of the 1 volt
Is voltage above the value given? Go to S te p 9 Go to S te p 1 0
Repair the short to voltage in CKT 101 (DK BLU) between
the blower motor resistor and the high blower motor relay. Go to H e a t e r
1. With the HVAC control module connector C2
disconnected. Connect a J 3 9 2 0 0 (continuity)
between pin G and the remaining pins of the HVAC
10 control module. —
2. Ensure that the blower switch is in the OFF position.
Is continuity present between any pins expect pin D? Go to S te p 11 Go to S te p 1 2
11 A s s e m b ly R e p la c e m e n t — B lo w e r C o n tro ls —
With the blower resister and the HVAC control module
connector C2 disconnected. Connect a J 3 9 2 0 0 (volts)
12 between pins A, C and D of the blower resister connector 0.5 volts
and ground.
Is voltage reading greater than the value given? Go to S te p 1 3 Go to S te p 1 4
Locate and repair the short to voltage in the circuit related
to the pin tested. Refer to W irin g R e p a ir s in Wiring Go to H e a t e r
13 Systems. — —
Locate and repair the short to voltage within the blower Go to H e a t e r
14 resister. Refer W irin g R e p a ir s in Wiring Systems. .— B lo w e r C o n tro ls —
Blower Motor Operates Continuously - Auxiliary

1 performed? — B lo w e r C o n tr o ls
1. Remove the auxiliary blower motor relays.
2 2. Listen for the blower motor to shutoff after removing —
each relay.
Does the auxiliary blower motor stop running? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower motor relay that you last
removed. Refer to B lo w e r M o to r R e la y R e p la c e m e n t - Go to H e a t e r
3 A u x ilia ry . — —-
Connect a J 3 9 2 0 0 (volts) between cavity 4 of the high Go to H e a t e r
4 relay socket and ground. 1 volt B lo w e r C o n tro ls
Is voltage greater than the value given? Go to S te p 5 S y s te m C h e c k
Locate and repair the short to voltage in CKT 1172 (YEL)
between the auxiliary blower motor, the auxiliary blower
5 motor relay, high and the auxiliary blower resistor. Refer to — Go to H e a t e r —
W irin g R e p a ir s in Wiring Systems. B lo w e r C o n tro ls
Heater Output Temperature Check
Preparation Procedure Temperature Check Procedure
Caution: Do not remove the radiator cap while the 1. When the engine is warmed up, after
cooling system is hot. Serious personal injury approximately 20 minutes of operation, drive the
may result. Only remove the radiator cap from a vehicle.
cool engine.
2. Use an accurate thermometer in order to
1. With the engine sufficiently cool, remove the determine the temperature of the outside air.
radiator cap.
3. Use an accurate thermometer in order to
2. Start the engine.
determine the temperature of the air at the floor
Idle the engine. outlets with the vehicle being driven at 48 km/h
3. St the heater controls to the HEATER mode. (30 mph).
• Set the temperature mode fully to the 4. Compare the temperature readings with the
HOT position. minimum acceptable output temperatures.
• Set the blower motor speed mode to the
HI position.
4. When the coolant fiow in the radiator is visible
through the filler neck, install the radiator cap.
Heater Output Temperature Check
Outside Air
-18°C (CPF) -4°C (25°F) 10oC(50°F) 24°C (75°F)
Temperature
Heater Air 64°C (147°F)
54°C (130°F) 59°C (139°F) 68°C (155
Temperature
T2550
The minimum acceptable heater output temperatures additional 1.8 degrees of heater output temperature
for outside air temperatures other than the when the outside temperature is below 50 degrees.
temperatures shown may be approximated by using the Allow an additional 1.6 degrees of heater output
Fahrenheit scale and rounding off the outside air temperature for every 5 degrees of outside temperature
temperature to the nearest 5 degrees. For every when the outside temperature is above 50 degrees.
additional 5 degrees of outside temperature, allow an
Defrosting Insufficient
Condition Action
An obstruction is present in the 1. Inspect the defroster nozzle outlets.
defroster nozzle.
2. Remove any foreign objects.
3. Repair any loose instrument panel pads that block outlets.
The defroster nozzle outlet is Use pliers in order to reshape the outlet flange. If you are unable to reshape the
damaged. outlet flange, replace the air distributor.
The mode actuator is faulty. 1. inspect the operation of the defroster air valve.
2. Replace a faulty mode actuator.
The defroster is not emitting Refer to Heating Insufficient
sufficient heat.
Heating Insufficient
Diagnostic Aids
The most likely causes of insufficient heating outside
the heater system include a low coolant level, a
faulty thermostat, a partially or fully clogged heater
core or hose, an obstruction to the air circulation, or an
air leak past a faulty seal into the passenger
compartment. For the proper temperature verification,
use the Tech II.
Inspect for the following conditions:
® A leak in the cooling system
® A low coolant level
® A loose belt or a worn belt
1 ® A leaking heater hose or a kinked heater hose —
® The loss of the radiator cap pressure seal
® The proper engine temperature thermostat operation.
Does the malfunction still exist? Go to S te p 2 System OK
1. Adjust the heater controls to the following modes:

• The HEATER mode
® The blower speed control to the HI position
2 • The full WARM mode ■ —
2. With the ignition switch in the ON position, inspect
the airflow out of the floor air outlet.
3. Inspect the outlet attachment.
Is the airflow high? Go to S te p 3 Go to Step 6
3 Does the airflow change with different blower speeds? — Go to S te p 4 Go to S te p 10
Perform the heater output temperature check. Refer to
4 H e a te r O u tp u t T e m p e ra tu re Check. —
Is the heater output temperature correct? Go to S te p 5 Go to S te p 11
1. Inspect the following areas of the vehicle for cold

air leaks:
® At the cowl
® In the heater case
5 — —
® In the vents
2. Inspect under the seat for any obstructions.
3. Correct any conditions as necessary.
Is the repair complete? System OK
Perform the function test. Refer to F u n c tio n T e s t
6 —
Is the repair complete? System OK Go to S te p 7
Check the airflow from the vent outlets.
7
Is the airflow from the vent outlets high? Go to S te p 8 Go to S te p 16
Move the defroster and/or the vent valve to the
8 HEATER mode. —
Is the defroster airflow correct? Go to S te p 9 Go to S te p 17
1. Remove the floor air outlet. Refer to A ir O u tle t

R e p la c e m e n t - F loor.
9 2. Inspect for any obstructions. . —
3. Change the blower speeds.
Does the airflow change with different blower speeds? Go to S te p 8 Go to S te p 10
1. Inspect the following parts:

® The motor blower switch
® The blower motor resistor assembly
10 ® The blower motor wiring harness ' ■' — '.
2. Repair any conditions as necessary.
3. Perform the heater output temperature check. Refer
to H e a te r O u tp u t T e m p e ra tu re C heck.
Is the heater output temperature correct? Go to S te p 5 Go to S te p 11
1. Turn the temperature rotary knob to full HOT.

11 2. Inspect the temperature cable indexing. —
Is the temperature valve fully closed? Go to S te p 12 Go to S te p 21
Heating Insufficient (cont’d)
Step Action Vaiue(s) Yes: No
1. With the temperature valve in the full WARM position,
start the vehicle.
12 2. Inspect the air temperature around the heater inlet 24°C (85°F)
and the heater outlet hoses.
Is the air temperature around both hoses at least at the
specified value? Go to Step 13 Go to Step 22
1. Remove the hoses at the heater core.
13 2. Inspect the hoses for proper installation. .■ ' — , . .
Were the hoses properly installed? Go to Step 14 Go to Step 24
1. Backflush the heater core.
2. Drain and replace the coolant.
3. Start the vehicle (Retest at less than ot equal to
14 30 psi). 24°C (85°F)
4. Inspect the air temperature around both hoses.
Is the air temperature around both hoses at least at the
specified value? Go to Step 15 Go to Step 22
Replace the heater core. Refer to Heater Core
15 Replacement — —
1. Turn the mode knob to the DEFROST mode.
16 2. Inspect the airflow. — ■
Is the defroster airflow not present or low? Go to Step 17 . Go to Step 9
17 Does the airflow change with different blower speeds? — ■■ Go to Step 18 Go to Step 10
Inspect for airflow obstructions at the blower inlet and
18 plenum. —
Did you find and correct a condition? System OK Go to Step 19
1. With the blower in the HI mode, turn the temperature
rotary knob from the full HOT position to the full
19 COLD position. —
2. Listen for a change in the airflow.
Is a change in the airflow audible? Go to Step 20 Go to Step 25
Check for an airflow obstruction between the blower and
20 the system outlets. —
1. Re-index the cable.
21 2. Inspect the temperature valve adjustment, cables and — —
linkage.
Did you find and correct a condition? System OK
Check the thermostat for proper installation and sealing.
22 —
Is the thermostat properly installed and seated? Go to Step 26 Go to Step 23
Reinstall the thermostat.
23 — —
Is the repair complete? Go to Step 12
Properly reinstall the hoses.
24 — —
Inspect the following components:
• The temperature valve
25 • The control assembly — —
• The blower motor wiring harness
Replace the thermostat.
26 — —
Heat Excessive Noise Diagnosis
The most likely cause of excessive heat from the
heater system is an improperly indexed temperature
Diagnostic Aids
control cable. Other related causes include the A constant air rush noise is typical of all heater
following conditions: systems. Some systems may be louder than others.
• A slipping self-adjusting clip at the temperature If possible, inspect a similar vehicle in order to
control cable end determine whether the noise is typical or excessive.
• A loose control cable sheath retainer or bracket at
the bottom of the heater assembly
• A binding or obstructed temperature air valve
A hot air leak from the engine compartment to the
blower inlet is also a remote possibility.
Noise Diagnosis
Step Action VaSue(s) Yes No
1. Inspect all the electrical connections and the grounds
for proper connections.
1 2. If a connection is doubtful, use a voltmeter in order to — —
test for constant voltage at the blower motor.
1. Sit in the vehicle with the doors and windows closed.
2. With the ignition switch in the ON position and the
engine off, start the blower on the HI mode.
3. Select full COLD on the temperature rotary knob.
4. Cycle through the blower speeds, modes and
temperature valve positions in order to find where the
noise occurs.
5. Define the noise as one of the following types:
® An air rush
® A whine
2 • A tick/click —
® A squeal/screech
• A flutter
® A rumble
® A scrape
6. If possible, compare the noise with another vehicle of
the same model in order to determine if the noise is
typical.
Is the noise typically a flutter or a rumble that is constant
at high blower speeds in certain modes, but can be
eliminated at lower blower speeds? Go to Step 3 Go to Step 5
With the blower on HI, inspect the full HOT to the full COLD
temperature positions in all modes.
3 —
Is the noise audible in all modes and in all temperature
positions? Go to Step 4 Go to Step 7
1. Check the system for obstructions or foreign materials
between the fan and the temperature valve.
4 2. Remove, repair, or replace the fan and the temperature
valve as necessary. —
3. Recheck the system for the noise.
Is the noise audible? Go to Step 2 System OK
Noise Diagnosis (cont’d)
Feel the blower armature in order to check for vibration of
5 the motor and the fan at each blower speed. —
Is the vibration excessive? Go to Step 6 Go to Step 9
1. Examine the blower fan for wear spots, cracked
blades, or a cracked hub.
2. Examine the blower case for wear spots.
6 —
3. Repair or replace the parts as necessary.
4. Recheck the system for the blower noise.
Did you find and correct the condition? System OK Go to Step 10
Is the noise audible in all modes, but not audible in all
7 temperature positions? — Go to Step 8 Go to Step 11
1. Inspect the temperature valve seals.
2. Repair or replace the temperature valve seals as
8 necessary. — —
1. Remove the blower motor and fan assembly. Refer to
Blower Motor and Fan Replacement
2. Check for foreign material at the orifice of the
blower inlet.
9 —
3. Repair or replace the blower motor and fan assembly
as necessary.
1. Replace the blower motor and fan assembly. Refer to
10 —
1. Check the ducts of the noisy modes for obstructions.
2. Remove any obstructions.
11 3. Check the seals of the suspected mode air valves.
— —
4. Repair or replace the valves as necessary.
12 Is the noise a click/tick or a whine? Go to Step 13 Go to Step 3
Replace the blower motor with a second new
13 blower motor. —

Reinstall the original blower motor.
14 — ~
High or Low Temperature Control Effort
Diagnostic Aids
A kinked control cable, a binding valve or a faulty
control assembly are possible causes of excessive
temperature control rotary knob effort.
High or Low Temperature Control Effort
1. Check the routing of the cable for a kink, wiring
interference or instrument panel interference.
1 —
2. Repair the cable as necessary.
Did you find and correct a condition? Go to Step 2 System OK
1. Disconnect the cable from the temperature valve.
Refer to Temperature Control Cable Replacement
2 2. Manually cycle the valve. —
3. Inspect the valve for binding.
Does the valve bind? Go to Step 3 Go to Step 4
1. Inspect the valve seals for proper installation.
' 3 2. Repair the valve seals as necessary. —
Did you find and correct a condition? System OK Go to Step 7
Inspect the control for binding.
4 •—
Does the control bind? Go to Step 5 Go to Step 8
1. Disconnect the cable from the control assembly.
5 . 2. Recheck the control for binding. —
Does the control bind? Go to Step 6 Go to Step 9
Replace the control.
6 — —
1. Inspect the temperature valve for misalignment of the
shaft, a bent shaft or valve, and a warped case.
7 — —
2. Repair the temperature valve as necessary.
1. Reconnect the cable to the temperature valve.
8 2. Reinspect the clearance of the cable around the — —
instrument panel components.
Replace the cables as necessary.
9 — —
Repair Instructions
Control Assembly Replacement
Removal Procedure
1. Remove the bezel—IP cluster. Refer to Bezel — .....- .....
Replacement - IP Cluster in Instrument Panel,
Gauges and Console.
2. Remove the radio for access. Refer to Radio
Replacement in Entertainment.
3. Remove the heater control assembly by firmly
depressing and holding the retaining tabs and
then sliding the assembly away from the dash. jl& i: I
257069
4. Disconnect the temperature and mode cables

from the back of the control head.
5. Disconnect the electrical connection from the
control head.
6. Remove the control head.
482493
Installation Procedure
1. Connect the electrical connection to the
control head.
2. Connect the temperature and mode cables to the
back of the control head.
482493
3. Install the control head to the l/P carrier until a
snap is heard.
4. Install the radio. Refer to Radio R eplacem ent in
Entertainment.
5. Install the bezel—IP cluster. Refer to B ezel
Replacem ent - IP Cluster s Instrument Panel,
Gauges and Console.
257069
Blower Switch Replacement

Removal Procedure
1. Remove the instrument cluster trim plate. Refer to
IP Cluster R eplacem ent in Instrument Panel,
Gauges and Console.
2. Remove the control assembly by releasing the
snap-fit retainers using a small screwdriver.
3. Disconnect the electrical connection.
4. Disconnect the cables from the control assembly
by releasing the retainers, if equipped.
5. Remove the blower switch rotary knob and the
retaining clip from the shaft of the blower switch.
6. Remove the blower switch.
257069
1. Install the blower switch.
1.1. Hold the blower switch in position.
1.2. Install the retaining clip.
1.3. Install the blower switch rotary knob
2. Connect the cables to the control assembly.
3. Connect the electrical connection.
4. Snap the control assembly into the
instrument panel.
5. Install the instrument panel trim plate. Refer to
IP Cluster Replacem ent in Instrument Panel,
Gauges and Console.
6. Test the circuit operation.
257069
Temperature Control Cable Replacement
Removal Procedure
1. Roll the instrument panel back. Refer to IP Carrier
Replacem ent in Instrument Panel, Gauges and
Console.
2. Remove the control assembly. Refer to Control
Assem bly Replacement.
3. Disconnect the electrical connector.
4. Disconnect the temperature cable from the heater
control assembly.
5. Disconnect the temperature cable from the
temperature valve:
5.1. Release the cable from the temperature
valve by squeezing the retainer.
5.2. Squeeze the post.
5.3. Lift the cable end in order to remove
the cable.
257074
1. Perform the following steps in order to index the
cable prior to the installation.
1.1. Cycle the temperature rotary knob to the
full COLD position.
1.2. Verify that the temperature door is closed.
2. Perform the following steps in order to connect
the cable to the temperature valve:
2.1. Snap the cable onto the valve.
2.2. Secure the cable by snapping the cable into
the heater case.
3. Route the cable in the same location the cable
occupied prior to removal.
4. Connect the temperature cable to the control
assembly.
5. Connect the electrical connector.
6. Install the control assembly. Refer to Control
Assem bly Replacement.
7. Roll the instrument panel forward. Refer to
IP Carrier Replacem ent in Instrument Panel,
Gauges and Console.
A ir Inlet Assembly Replacement
Removal Procedure
Caution: Refer to SIR Service Precautions Caution
in Cautions and Notices.
1. Disable the supplemental inflatable restraint (SIR)
system. Refer to Disabling the S IR System in
Restraints.
2. Remove the passenger’s knee bolster. Refer to
K nee Bolster Replacem ent in Instrument Panel,
Console and Gauges.
3. Remove the right cowl side trim panel. Refer to
Trim P anel Replacem ent - Hinge Pillar in
Interior Trim.
4. Remove the air distributor. Refer to Air Distributor
Duct Replacement.
5. Remove the bolts that retain the air inlet assembly.
6. Remove the vacuum connector.
7. Remove the air inlet assembly from the vehicle.
8. Remove the nuts that retain the vacuum motor.
9. Remove the vacuum motor from the air inlet
assembly.
1. Install the vacuum motor to the air inlet assembly.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the nuts that retain the vacuum motor to
the air inlet assembly.
Tighten
Tighten the retaining nuts to 2 N-m (18 Ib in).
3. Install the air inlet assembly to the vehicle.
4. Install the bolts that retain the air inlet assembly
to the vehicle.
Tighten
Tighten the four bolts to 4 N-m (35 Ib in).
5. install the vacuum connector.
6. Install the air distributor assembly.
7. Install the right cowl side trim panel. Refer to Trim
P anel Replacem ent - Hinge Pillar in Interior Trim.
8. Install the passenger’s knee bolster. Refer to Knee
Bolster Replacem ent in Instrument Panel, Gauges
and Console.
9. Enable the SIR system. Refer to Disabling the
S IR System in Restraints.
Blower Motor Resistor Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Roll the instrument panel back. Refer to IP Carrier
R eplacem ent in Instrument Panel, Gauges and
Console.
3. Remove the plenum tray.
4. Disconnect the electrical connector.
5. Remove the screws.
6. Remove the resistor.
Notice: Do not allow the resistor coils to touch.
Improper operation or damage to the vehicle may
result.
1. Install the resistor.
Notice: Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install the screws.
Tighten
Tighten the screws to 1.4 N-m (12 Ib in).
4. Install the plenum tray.
I P C a r r i e r R e p l a c e m e n t in Instrument Panel,
Gauges and Console.
6. Connect the negative battery cable.
7. Verify the circuit operation.

Removal Procedure
2. Remove the instrument panel (IP) storage
compartment. Refer to I P C a r r i e r R e p l a c e m e n t in
Instrument Panel, Gauges and Console.
3. Remove the front screw from the right door
sill plate.
4. Remove the right hinge pillar trim plate. Refer to
T r im P a n e l R e p l a c e m e n t - H i n g e P i l l a r in
Interior Trim.
5. Disconnect the electrical connectors from the
blower motor, as necessary.
6. Remove the bolt from the right lower IP support.
7. Remove the blower motor cover.
8. Remove the motor cooling tube.
9. Remove the blower motor flange screws and
ferrules.
10. Perform the following steps in order to remove the
blower motor:
• Carefully pull the blower motor forward in order
to avoid distorting the blower motor fan.
• If necessary, pry back the right side of the IP.
11. Inspect the blower motor terminals for distortion.
12. Clean corrosion from the terminals as necessary.
13. Replace the blower motor as necessary.
14. Inspect the flange of the blower motor for damage
or distortion that may cause an air leak.
15. Repair the flange as necessary.
16. Inspect the blower fan for any damage and
distortion.
installation Procedure
1 . Guide the blower motor and blower fan into
position.
Be careful in order not to catch the blower fan on
any protruding components.
Notice:-Refer to Fastener Notice in Cautions and
Notices.
2. Install the blower motor flange ferrules and
screws.
Tighten
Tighten the blower motor mounting screws to
2.1 N-m (20 Ib in).
3. Install the blower motor cooling tube.
4. Install the blower motor cover.
5. Install the bolt to the right lower IP support.
6. Install the electrical connectors to the blower
motor, as necessary.
7. Install the right hinge pillar trim panel. Refer to
Trim Panel Replacement - Hinge Pillar in
Interior Trim.
8. Install the front screw into the door sill plate.
9. Install the instrument panel storage compartment.
Refer to IP Carrier Replacement in Instrument
Panel, Gauges and Console.
10. Install the negative battery cable.
Air Distributor Duct Replacement
Removal Procedure
2. Remove the instrument cluster trim plate. Refer to
IP C arrier Replacem ent in Instrument Panel,
Gauges and Console.
3. Remove the radio. Refer to R adio Replacem ent in
Entertainment.
4. Tilt back the instrument panel. Refer to IP Carrier
R eplacem ent in Instrument Panel, Gauges and
Console.
5. Remove the duct mounting screws.
6. Release the duct from the instrument panel by
squeezing the retainer.
7. Remove the duct.
257092
1. Install the duct to the instrument panel.
Notices.
2. Install the duct mounting screws.
Tighten
Gauges and Console.
4. Install the radio. Refer to Radio Replacem ent in
Entertainment.
5. Install the instrument cluster trim plate. Refer to
Gauges and Console.
Air Outlet Replacement - Floor

Removal Procedure
1. Remove the screw from the floor air outlet duct.
2. Remove the floor air outlet duct.
1. Install the floor air outlet duct.
Notices.
2. Install the screw to the floor air outlet duct.
Tighten
Tighten the screw to 1.9 N-m (17 Ib in).
Air Outlet Replacement - Rear Floor

Removal Procedure
1. Remove the seats. Refer to one of the following
procedures in Seats:
• S eat Replacem ent - Bench
• S eat Replacem ent - Split Bench
• S eat Replacem ent - Front Bucket or S eat
Replacem ent - Front Bucket
2. Remove the floor storage compartment. Refer to
Com partment Replacem ent - IP in Instrument
3. Remove the grilles from the outlet ducts.
4. Remove the front carpet section. Refer to Carpet
R eplacem ent - Front (Pickup), Carpet
R eplacem ent - Front (Suburban), or C arpet
R eplacem ent - Front (Utility) in Interior Trim.
5. Remove the retaining tape.
6. Remove the locating tab from the floor pan.
7. Remove the ducts by lifting the rear section of the
ducts and by gently pulling backward.
1. Install the ducts by lifting the rear section of the
ducts and by gently pushing forward.
2. Install the locating tab to the floor pan.
3. Install the retaining tape.
4. Install the front carpet section. Refer to C arpet
R eplacem ent - Front (Pickup), C arpet
R eplacem ent - Front (Suburban), or C arpet
R eplacem ent - Front (Utility) in Interior Trim.
5. Install the grilles to the outlet ducts.
6. Install the floor storage compartment. Refer to
Com partm ent Replacem ent - IP in Instrument
7. Install the seats. Refer to one of the following
procedures in Seats:
• S e a t R eplacem ent - Bench
• S e a t Replacem ent - Split Bench
• S eat Replacem ent - Front Bucket,or S e a t
R eplacem ent - Front Bucket
257103
IP Air Outlet Ducts Replacement
Removal Procedure
1. Remove the instrument panel bezel. Refer to
IP Carrier Replacement in Instrument Panel,
Gauges and Console.
2. Expand the retainers in order to remove the air
outlet duct from the bezel.
3. Remove the instrument panel storage

compartment. Refer to IP Carrier Replacement in
4. Remove the air outlet duct from the
instrument panel.
257095
1. Install the air outlet duct to the instrument
panel bezel.
2. Install the instrument panel bezel. Refer to
Gauges and Console.
3. Install the air outlet duct to the instrument panel.
Air Outlet Duct Replacement - Left Lap

Removal Procedure
1. Remove the left knee bolster. Refer to Knee
Bolster Replacement in Instrument Panel,
Gauges and Console.
2. Remove the retaining screws (6) from the
outlet duct.
3. Disconnect the duct from the air distribution
duct (2).
4. Remove the outlet duct (4) from the vehicle.
1. Install the outlet duct (4) into the vehicle.
2. Connect the duct to the air distribution duct (2).
3. Install the retaining screws (6) into the outlet duct.
4. Install the left knee bolster. Refer to Knee
Bolster Replacement in Instrument Panel, Gauges
and Console.
301635
(Inlet Hose- 4.3L,5.0L,5.7,7.4L)
Removal Procedure
Tools Required
J 38723 Heater Line Quick Connector Separator
1. Drain the engine coolant. Refer to Draining an d
Filling Cooling System in Engine Cooling.
2. Disconnect the inlet hose (1) from the generator
bracket.
3. Disconnect the inlet hose at the fender clip.
4. Loosen the hose clamp at the heater core enough
to slide the clamp away from the fitting on the
inlet hose.
5. Remove the hose clamp at the heater core, the
water shut off valve, or the tee fitting.
6. Disconnect the inlet hose from the heater core.
257108
7. Push the inlet hose (5) into the connector (1).

8. Insert the J 38723 into the connector in order to
release the locking tabs (2).
9. Pull the retainer (4) and the inlet hose from the
heater inlet connector.
10. Inspect the O-ring sealing surface on the
inlet hose.
11. When replacing the heater inlet connector,
remove the retainer from the hose.
Discard the retainer.
12. When replacing the inlet hose, but not the
connector, complete the following steps:
12.1. Remove the retainer from the inlet hose.
12.2. Reinsert the retainer in the connector.
13. When reusing the inlet hose and the container,
5
keep the retainer in place on the hose.
220038
1. Push the hose (5) into the connector (1) until the 1 2 3
retainer tabs (3) lock.
2. Pull back on the hose in order to verify for the
proper engagement.
3. Connect the inlet hose (1) to the heater core, the
water shut off valve, or the tee fitting.
4. Install the inlet hose clamp.
Notices.
5. Install the inlet hose mounting screw.
Tighten
Tighten the screw to 30 N-m (22 Ib ft).
6. Install the inlet hose to the fender clip.
7. Add the engine coolant. Refer to Draining and
8. Inspect the system for leaks.
257108

(Outlet Hose- 7.4L)
Removal Procedure
1. Drain the engine coolant. Refer to Draining and
2. Remove the outlet hose clamps.
3. Remove the outlet hose (2) from the fender clip.
4. Disconnect the outlet hose from the heater core.
5. Disconnect the outlet hose from the radiator.
257117
1. Connect the outlet hose (2) to the radiator.
2. Connect the outlet hose to the heater core.
3. Install the outlet hose to the fender clip.
4. Install the hose clamps.
5. Add the engine coolant. Refer to Draining an d
257117
(Outlet Hose- 4.3L, 5.0L, 5.7L)
Removal Procedure
2. Remove the outlet hose (2) from the fender clip.
3. Remove the outlet hose clamp from the following
components:
• heater core
• water shut off valve
• tee fitting
4. Disconnect the outlet hose from the heater core.
5. Remove the outlet hose mounting screw.
6. Remove the outlet hose from the generator
bracket.
7. Remove the outlet hose clamp from the
water pump.
8. Disconnect the outlet hose from the water pump.
1. Connect the outlet hose (2) to the water pump.
2. Install the outlet hose clamp to the water pump.
3. Install the outlet hose to the generator bracket.
Notices.
4. Install the generator bracket mounting screw.
Tighten
5. Connect the outlet hose to the heater core.
6. Install the outlet hose clamp to the heater core.
7. Install the outlet hose to the fender clip.
8. Add the engine coolant. Refer to Draining an d

(Inlet Hose- Diesel)
Removal Procedure
Tools Required
J 38723 Heater Line Quick Connector Separator
2. Remove the inlet hose (1) from the generator
bracket.
3. Remove the inlet hose mounting nuts.
4. Loosen the inlet hose clamp at the heater core
enough in order to slip the clamp away from the
fitting on the inlet hose.
5. Remove the inlet hose clamp at the heater core.
6. Disconnect the inlet hose from the heater core.
7. Push the inlet hose (5) into the connector (1).
8. Insert J 38723 into the connector in order to
release the locking tabs (2).
9. Pull the retainer (4) and the inlet hose from the
heater inlet connector.
10. Inspect the O-ring sealing surface on the
inlet hose.
11. When replacing the heater inlet connector,
remove the retainer from the hose.
Discard the retainer.
12. When replacing the inlet hose, but not the
connector, complete the following steps:
12.1. Remove the retainer from the inlet hose.
12.2. Reinsert the retainer in the connector.
13. When reusing the inlet hose and the container,
keep the retainer in place on the hose.
220038
1. Push the inlet hose (5) into the connector (1) until
the retainer tabs (3) lock.
2. Pull back on the inlet hose in order to verify for
the proper engagement.
220038
3. Connect the inlet hose (1) to the heater core.

4. Install the inlet hose clamp (7).
Notices.
5. Install the inlet hose screw.
Tighten
(Outlet Hose- Diesel)
Removal Procedure
1. Drain the coolant. Refer to Draining and Filling
Cooling System in Engine Cooling.
2. Disconnect the outlet hose (2) from the radiator
connection.
3. Disconnect the outlet hose from the heater core
connection.
4. Remove the outlet hose from the outlet hose clip.
5. Disconnect the outlet hose from the engine.
6. Remove the hose clamps from the outlet hose.
1. Install the hose clamps to the outlet hose (2).
2. Connect the outlet hose to the engine.
3. Connect the outlet hose to the radiator connection.
4. Connect the outlet hose to the heater core
connection.
5. Install the outlet hose to the outlet hose clip.
Hot Water Bypass Valve Replacement

Removal Procedure
1. Drain the engine coolant. Refer to Draining an d
2. Remove the hose clamps from the outlet pipe (6)
and from the inlet pipe (5).
3. Remove the heater inlet pipe (5) and the outlet
pipe (6) from the bypass valves (4).
4. Remove the bolts (3) that retain the valves to the
heater assembly.
5. Remove the bypass valves (4) from the heater
assembly.
280258
1. Install the bypass valves (4) to the heater
assembly.
Notices.
2. Install the bolts that retain the valves (4) to the
heater assembly.
Tighten
Tighten the bolts to 4 N-m (35 Ib in).
3. Install the heater inlet pipe (5) and the outlet
pipe (6) to the bypass valves.
4. Install the hose clamps.
5. Fill the cooling system. Refer to Draining and
6. Ensure that no leaks exist in the cooling system.
Heater Core Replacement

Removal Procedure
1. Drain the coolant. Refer to Draining and Filling
Cooling System
2. Remove the instrument panel storage
compartment. Refer to IP Carrier Replacement in
3. Disconnect the electrical connectors, as
necessary.
4. Remove the center floor air distribution duct.
5. Remove the hinge pillar trim panels. Refer to
Gauges and Console.
7. Remove the blower motor. Refer to Blower Motor
and Fan Replacement.
8. Remove the steering column. Refer to the
applicable procedure:
• In Steering Wheel and Column — Standard:
- Steering Column Replacement (All C/K
Except C 3500HD)
- Steering Column Replacement (C 3500HD)
* In Steering Wheel and Column — Tilt:
Except C 3500HD)
9. Roll back the instrument panel. Refer to IP Carrier
Replacement in Instrument Panel, Gauges and
Console.
10. Remove the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement in
Engine Cooling.
11. Remove the heater hoses. Refer to the applicable
procedure:
• H ea te r Hoses Replacem ent
(Inlet Hose- 4 .3 L ,5 .0 L ,5 .7 ,7.4L)
(Outlet Hose- 7.4L)
(Outlet Hose- 4.3L, 5.0L, 5 .7L)
• H e a te r Hoses Replacem ent
(Inlet H ose- Diesel)
• H e a te r Hoses Replacem ent
12. While holding the heater case to the cowl, remove
the screw on the interior side of the cowl, near the
evaporator pipe, if equipped.
13. On the engine side of the cowl, remove the

4 screws that hold the heater case to the cowl.
14. On the engine side of the cowl, remove the 2 nuts
that hold the heater case to the cowl.
15. Remove the heater case.
Ask an assistant for help, if necessary.
16. Remove the 7 screws that hold the heater cover
to the heater case.
17. Remove the heater cover.
18. Remove the heater core from the retainer.
257087
1. Install the heater core into the retainer.
2. Install the 7 screws that hold the heater cover to
the heater case. Replace the seals.
3. Install the heater cover.
Verify that the heater cover is properly sealed.
4. Install the heater case.
If necessary, ask an assistant for help.
5. On the engine side of the cowl, install the nuts
that hold the heater case to the cowl.
6. On the engine side of the cowl, install the
4 screws that hold the heater case to the cowl.
7. On the interior side of the cowl, install the screw.

Notices.
8. Tighten the following fasteners:
Tighten
• Tighten the screws on the engine side of the
cowl to 1.9 N-m (17 Ib in).
• Tighten the two nuts to 2.8 N-m (25 Ib in).
• Tighten the screw on the interior side of the
cowl to 11 N-m (97 Ib in).
9. Install the heater hoses. Refer to the applicable
procedure:
• H eater Hoses Replacem ent
(Inlet H ose- 4.3L,5.0L ,5.7,7.4L)
(Outlet H ose- 7.4L)
(Outlet H ose- 4.3L, 5.0L, 5.7L)
257083
(Inlet H ose- Diesel)
10. Install the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacem ent in
Engine Cooling.
11. Roll forward the instrument panel. Refer to
Gauges and Console.
12. Install the steering column. Refer to the applicable
procedure:
• In Steering Wheel and Column — Standard:
- Steering Column Replacem ent (All C /K
Except C 3 500H D )
- Steering Column Replacem ent (C 35 0 0 H D )
« In Steering Wheel and Column — Tilt:
- Steering Column R eplacem ent (All C /K
Except C 3 500H D )
- Steering Column Replacem ent (C 3 5 0 0 H D )
13. Install the blower motor. Refer to Blower Motor
and Fan Replacement.
15. Install the hinge pillar trim panels. Refer to
Gauges and Console.
16. Install the center floor air distribution duct.
17. Connect the electrical connectors, as necessary.
Control Switch Replacement - Auxiliary

(Suburban- IP Cluster)
Removal Procedure
1. Remove the instrument cluster trim. Refer to
Gauges and Console.
2. Disconnect the electrical connectors.
3. Remove the control switch from the instrument
cluster trim.
257118
1. Install the control switch to the instrument
cluster trim.
2. Connect the electrical connectors.
3. Install the instrument cluster trim. Refer to
Gauges and Console.
4. Inspect the circuit operation.
257118
(Suburban-Front Overhead)
Removal Procedure
1. Remove the overhead console. Refer to Console
Replacement - Overhead in Interior Trim.
3. Remove the control assembly from the overhead
console.
257120
1. Install the control assembly to the overhead
console.
3. Install the overhead console. Refer to Console
257120

(Suburban- Center Overhead)
Removal Procedure
1. Remove the bezel.
2. Remove the control assembly from the roof panel.
257122
2. Install the control assembly to the roof panel.
3. Install the bezel.
Heater Hoses Replacement - Auxiliary

(Suburban- Front)
Removal Procedure
1. Raise the vehicle.
Support the vehicle with suitable safety stands.
Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove the right front wheelhouse. Refer to
Fender Replacement - Front (Right) in Body
Front End.
4. Remove the bolts in the engine compartment.
5. Remove the hose (1,2) clamps in the engine
compartment.
6. Remove the bolts from the frame.
7. Remove the hose clamps from the frame.
8. Disconnect the heater inlet hose (1) from the tee

fittings.
9. Disconnect the heater outlet hose (2) at the tee
fittings.
257124
1. Connect the heater outlet hose (2) to the tee
fittings.
2. Connect the heater inlet hose (1) to the tee
fittings.

Notices.
3. Install the hose (1,2) clamp bolts in the engine
compartment.
Tighten
Tighten the bolts to 17 N-m (13 Ib ft).
4. Install the hose clamp bolts on the frame.
Tighten
5. Install the right front wheelhouse. Refer to Fender
Replacement - Front (Right) in Body Front End.
7. Lower the vehicle.
257126
(Suburban- Rear)
Removal Procedure
Tools Required
J 38723 Heater Line Quick Connect Separator
Information.
3. Remove the bolts.
4. Perform the following steps in order to disconnect
the rear hose assembly (2) from the front hose
assembly.
4.1. Push the rear hose assembly (2) into the
front hose assembly.
4.2. Insert the J 38723 into the hose in order to
release the locking tabs.
5. Perform the following steps in order to disconnect
the rear hose assembly from the auxiliary heater
core (4).
5.1. Push the rear hose assembly into the
auxiliary heater core.
5.2. Insert the J 38723 into the hose in order to
release the locking tabs.
257128
In sta lla tio n P ro c e d u re
1. Push the rear hose assembly (2) into the front
hose assembly until the retainer tabs lock in
order to connect the hose assemblies.
2. Push the rear hose assembly (2) into the auxiliary
heater core (4) until the retainer tabs lock in order
to connect the hoses with the heater core.
Notices.
3. Install the bolts.
Tighten

(Diesel- Rear)
Removal Procedure
Information.
Fender Replacement - Front (Right) in Body
Front End.
4. Remove the bolts in the engine compartment.
5. Remove the hose clamps in the engine
compartment.
309366
6. Remove the bolts from the frame.
7. Remove the hose clamps from the frame.
8. Disconnect the heater inlet (1) hose from the tee

fittings.
9. Disconnect the heater outlet (2) hose at the tee
fittings.
1. Connect the heater outlet (2) hose to the tee
fittings.
2. Connect the heater inlet (1) hose to the tee
fittings.
257124

Notices.
3. Install the hose clamp bolts in the engine
compartment.
Tighten
309356
4. Install the hose clamp bolts on the frame.
Tighten
Tighten the bolts to 17 N-m (13 Ib ft)
5. Install the right front wheelhouse. Refer to Fender
Replacement - Front (Right) in Body Front End.
257126
Blower Motor Replacement - Auxiliary
Removal Procedure
2. Remove the right rear quarter trim panel. Refer to
the applicable procedure in Interior Trim:
• Trim Panel Replacement - Rear Quarter
(Suburban)
(Utility)
necessary.
4. Position the blower motor (2) in order to remove
the blower motor fan.
6. Remove the blower motor fan retaining nut.
7. Remove the blower motor fan.
8. Remove the blower motor.
1. Install the blower motor (2).
2. Install the blower motor fan.
3. Install the blower motor fan retaining nut.
Notices.
Tighten
6. Install the right rear quarter trim panel. Refer
to the applicable procedure in Interior Trim:
(Suburban)
(Utility)
257132
Heater Core Replacement - Auxiliary

Removal Procedure
(Suburban)
(Utility)
3. Remove the right rear wheelhouse panel. Refer to
Wheelhouse Panel Replacement (Right) in
Front End.
4. Disconnect the auxiliary heater hoses from the
heater core.
necessary.
6. Remove the drain valve (3).
7. Remove the bolts (1)
8. Remove the nuts (2, 4).
9. Remove the heater module.
10. Remove the blower motor, if necessary. Refer to
Blower Motor Replacement - Auxiliary.
11. Remove the heater case cover.
12. Remove the heater core.
1. Install the heater core.
2. Install the heater case cover.
3. Install the blower motor, if necessary. Refer to
Blower Motor Replacement - Auxiliary.
4. Install the heater module.
5. Install the nuts (2, 4).
Notices.
Tighten
• Tighten the bolts to 1.5 N-m (13 Ib in).
• Tighten the nuts to 10 N-m (89 Ib in).
8. Install the drain valve (3).
10. Connect the auxiliary heater hoses to the
heater core.
11. Install the right rear wheelhouse panel. Refer to
Wheelhouse Panel Replacement (Right) in
Front End.
12. Install the right rear quarter trim panel. Refer to
(Suburban)
(Utility)
If the fluid charging system is not used, the
system must be burped to release air bubbles.
Auxiliary
Removal Procedure
(Pickup)
(Extended Cab)
(Crew Cab)
(Suburban)
(Utility)
3. Disconnect the electrical connectors,
as necessary.
4. Remove the screws (4).
5. Remove the blower motor resistor (5).
1. Install the blower motor resistor (5).
Notices.
Tighten
Tighten the screws (4) to 1.4 N-m (12 Ib in).
to the applicable procedure in Interior Trim:
(Pickup)
(Extended Cab)
(Crew Cab)
(Suburban)
(Utility)
Description and Operation
Heater System Description When the temperature rotary knob reaches the full HOT
position, the temperature control cable holds the
The heater system provides the following functions;
temperature valve in a position that diverts all of the
• Heating airflow through the heater core for the maximum heater.
• Ram air The hot coolant from the engine is directed through
• Power ventilation the heater core. When the engine is running the
• Windshield defrosting hot coolant returns to the cooling system.
The blower fan draws outside air from the plenum at Mode Valves
the base of the windshield into the heater module.
Forward movement of the vehicle forces additional The heater system provides a choice of three basic
outside air, called ram air, into the heater module. operating modes:
Within the heater module, the air heats as required. • VENT
Then, the ducts route the air to the proper outlets
for the discharge into the passenger compartment. • HEATER
A control assembly in the instrument panel allows the • DEFROST
operator control of the following items:
• The blower speed Heater Core Description
• The mode of operation
The heater core is the main component of the heater
• The temperature of the air coming from the heater system. The heater core is located inside of the
system heater and evaporator module. Engine coolant is
pumped into the heater core from the engine whenever
Air Distribution System Description the engine is operating. The heater core fins transfers
The following air valves are used in the distribution the heat from the engine coolant to the air passing
system: over the heater core. The heater core has specific inlet
• The temperature valve and outlet tubes. The placement of the heater hoses
• The vent valve should be noted prior to servicing the heater core
• The defroster valve or the heater hoses.
Within the heater module is a series of air valves. The temperature control is linked to the temperature
These air valves are hinged parts that act like doors. valve by a flexible control cable. When you rotate
The air valves direct the airflow through the various temperature control counterclockwise to the full COLD
sections of the heater module in order to provide the position, the temperature valve is held snugly
proper airflow for the selected operating mode. against the air entrance to the heater core. The
A control cable from the heater control assembly following actions occur:
actuates each air valve. • All of the airflow from the evaporator bypasses the
Temperature Valve and Heater Core heater core.
Controlling the relative amounts of warm air and cool • No heat transfer occurs.
air coming from the heater module regulates the
When you turn the temperature control away from the
temperature of the air coming from the air distribution
full COLD position, the temperature valve begins to
duct. The temperature valve governs the part of
the total airflow through the heater module that passes direct air to the heater core. This action allows
through the heater core. A control cable, working air to flow through the heater core. The farther the
through a lever on the temperature valve shaft, temperature control is rotated clockwise, the more the
operates the temperature valve. The valve defaults to temperature valve directs air through the heater
full cold with no cable attached. core. The air discharge is warmer when most of the
When the temperature rotary knob in the control airflow is heated in this manner. The air discharge
assembly is in the full COLD position, the position of is warmer because the heated and unheated air flows
the temperature valve stops all of the airflow join and mix together thoroughly beyond the
through the heater core, so that only unheated air heater core.
passes to the air distribution duct. When you rotate the temperature lever clockwise to
As the temperature rotary knob moves away from the the full HOT position, the temperature valve blocks off
full COLD position, the temperature control cable the passage that allows air to bypass the heater
opens the temperature valve in order to allow core. This action causes all of the airflow to pass
the passage of an increasing amount of air through through the heater core.
the heater core. At the same time, the temperature
valve reduces the amount of unheated air that enters
the mixture. The result is a very responsive control
of the air temperature discharged through the heater
ducts and the defroster.
Heater Blower Controls Circuit Description From the resistor assembly, the circuit moves to the
blower motor terminal in order to operate the blower
motor. A sheet metal ground wire that connects to a
ground terminal on the cowl completes the blower
motor circuit to the ground.
Modes Description
Vent Mode
When the mode rotary knob is in the VENT position,
the defroster valve and the heater valve remain closed.
As a result, the air coming from the instrument
panel vents should be approximately the same
temperature as the outside air.
Heater Mode
When the mode rotary knob is in the HEATER
position, the defroster valve remains closed. As a
result, the air from the blower fan receives heat. This
air goes to the defroster valve. The defroster valve
sends most of the airflow to the heater duct, with some
of the air going to the defroster nozzle.
257066
Defrost Mode .:
The control assembly in the instrument panel contains When the mode rotary knob is in the DEFROST
three rotary control knobs: the blower speed knob, position, the defroster control cable moves the
the mode selection knob, and the temperature defroster valve in order to fully uncover the opening to
adjustment knob. The instrument panel dimmer control the defroster nozzle. This restricts the opening to
controls the brightness of the dial illumination. the heater duct. This delivers the maximum airflow to
the defroster, with only a small amount of the
Temperature Rotary Knob airflow exiting out of the heater duct.
When the temperature rotary knob is in the full COLD
or counter clockwise position, all of the air delivered
by the ventilation system is unheated. When the
Heater Description - Auxiliary
temperature rotary control is in the full HOT or An auxiliary heater provides additional-heating for the
clockwise position, all of the air passing through the rear of the Suburban model.
heater module is heated prior to discharge. This unit operates independently of the standard
Intermediate positions of the temperature rotary knob heater. The auxiliary heater controls in the instrument
result in a mixture of heated and unheated air in panel (auxiliary heater models) or in the roof panel
order to provide more moderated air temperatures. (auxiliary heater and A/C models) regulate the auxiliary
Mode Rotary Knob heater. The auxiliary heater system consists of a
The mode rotary knob operates the defrost control separate heater core and a separate blower fan unit
cable that moves to the left end of the heater module. mounted in the rear of the vehicle.
This cable operates a crank lever and the shaft that Blower Motor Control Switch
controls the position of the an air valve in the heater The location of the auxiliary heater blower switch is in
module. The detents at 0 degrees, 90 degrees, and the instrument panel to the right of the steering
180 degrees indicate the VENT position, the FLOOR column (auxiliary heater models) or in the roof panel
position, and the DEFROST position. By placing the (auxiliary heater and A/C models).
rotary control anywhere in between the two desired
■modes, the operator can blend the air delivery.
Special Tools and Equipment
Blower Speed Control. ; ,
The blower switch provides a choice of four blower Illustration Tool Number/ Description
speeds and the OFF position. The blower switch
receives power through the HTR-A/C FUSE when the
ignition is in the ON position. In the LO position, the
circuit continues through the heater wiring harness to
the two resistors in the resistor assembly near the
blower motor. . J 38723
When the blower switch is in a medium-speed position, Heater Line Quick Connect
Separator
the circuit continues through the heater wiring harness
to the resistor assembly, but the circuit bypasses one of
the two resistors. When the blower switch is in the
HIGH position, the circuit continues through the heater
wiring harness to the resistor assembly. The circuit 234129
bypasses both resistors in order to provide full power to
the blower motor.
HVAC HVAC System - Manual 1-73
HVAC System - Manual

Specifications
Fastener Tightening Specifications
Specification
■ - Application Metric English
Accumulator Bracket Mounting Screw 6 N-m 53 Ib In
Accumulator to Front Evaporator Connection 41 N-m 30 Ib ft
Auxiliary Blower Motor Resistor Mounting Screws 1.4 N-m 121b in
Auxiliary Evaporator Hose to Auxiliary Evaporator 17N-r 131b ft
Auxiliary Evaporator to Auxiliary Compressor Hose 32 N-m 241b ft
Auxiliary Refrigerant Hose Mounting Clip Screws 6 N*m 53 Ib in
Blower Motor Mounting Screws 1.7 N-m 151b in
Blower Motor Resistor Mounting Screws 1.4 N-m 121b i n
Compressor/Condenser Hose to Accumulator 41 N-m 301b ft
Compressor/Condenser Hose to Auxiliary Compressor Hose 24 N-m 181b ft
Compressor/Condenser Hose to Compressor Bolt 34 N-m 25 Ib ft
Compressor/Condenser Hose to Condenser 24 N-m 18 1b ft
Compressor Mounting Bolts 50 N-m 37 Ib ft
Condenser Mounting Screws 4.5 N-m 40 Ib in
Control Head Mounting Screw 1.9 N-m 17 Ib i n
Defroster Nozzle Mounting Screws 1.9 N-m 17 1b in
Defroster Nozzle to Heater Case Screws 1.4 N-m 121b in
Distributor Duct Mounting Screws 9 N-m 171b in
Evaporator Tube to Auxiliary Evaporator Hose 24 N -r 181b ft
Evaporator Tube to Condenser 24 N-m 181b ft
Evaporator Tube to Front Evaporator 24 N-m 181b ft
HVAC Module Mounting Screws 1.9 N-m 17 lb in
HVAC Module to Cowl Nuts 2.8 N-m 25 Ib in
Pressure Cycling Switch to Accumulator 4.5 N-m 40 Ib in
Fitting and Line Tightening Specifications

RPO Hex Fitting Size (mm) .---..lection B/U Hex Fitting Size (mm)
Compressor/ Condenser
C60/C69 24
Hose to Condenser Inlet —
24
Evaporator Tube to —
C60/C69
Condenser Outlet
22
Evaporator Tube to Front 20
C60/C69 Evaporator
32 '
A/C Accumulator to Front 27
C60/C69 Evaporator
Compressor/ Condenser
C60/C69 32
Hose to A/C Accumulator -— '
Aux. Evaporator Hose to
C69 24 20
Evaporator Tube
22
Aux. Evaporator Hose to Aux. 16
C69 Evaporator
Aux. Compressor Hose to 22
C69 26 Aux. Evaporator
Compressor Specifications
Compressor Type Displacement
Delphi® Thermal HT6 6 Cylinder Axial 163.87 cu cm (10.0 cu in)
System Capacities
Specification
Application Metric English
Polyalkaline Glycol (PAG) Refrigerant Oil, All Vehicles with C60 240 ml 8 X| oz
Polyalkaline Glycol (PAG) Refrigerant Oil, All Vehicles with C6S 330 ml 11 flo z
Refrigerant R-134a Crew Gab/Suburban, and Four Door Utility 1.02 kg 2.25 Ib
with C60
Refrigerant R-134a Pickup with C60 0.91 kg 2 Ib
Refrigerant R-134a Suburban and Four Door Utility with C69 1.81 kg 4 Ib
R- 134a Metric Fitting Sizes

RPO Hex Fitting Size (mm) Connection B/U Hex Fitting Size (mm)
32 A/C Accumulator to Front
C60/C69 27
Evaporator
Auxiliary Compressor Hose to
C69 26 22
Auxiliary Evaporator
22 Auxiliary Evaporator Hose to
C69
Auxiliary Evaporator 16
24 Auxiliary Evaporator Hose to

C69 20
Evaporator Tube
Compressor/Condenser Hose
C60/C69 32
to A/C Accumulator —
24 . Compressor/Condenser Hose
C60/C69
to Condenser Inlet " —
24 Evaporator Tube to
G60/C69
Condenser Outlet - —
22 Evaporator Tube to Front

C60/C69 20
Evaporator
GM SPO Group Numbers

, plication GM SPO Group Number
Accumulator S.:95
Air Distributor - Duct S.786
Air Outlet - Defogger S.779
Air Outlet - Duct I/P 9.262
Air Outlet - Side Window Defogger 9.780
Blower - Impeller 9.216
Blower - Motor 3 355
Blower - Motor and Fan 8.855
Blower Motor - Rear Auxiliary 8.855
Blower Motor - Resistor 8.855
Blower Motor - Resistor Auxiliary 8.855
Blower Motor - Tube 9.218
Control Switch - Auxiliary 9.273
Evaporator - Case 8.854
Evaporator - Core 9.210
Filter 9.210
Heater - Case 8.854
Heater - Core 8.845
GM SPO Group Numbers (cont’d)
Application GM SPO Group Number
Heater - Core Rear 8.8b
Heater Case - Auxiliary 8.8 b *
Heater Module - Auxiliary 8.855
Heater Pipe - Auxiliary Rear 8.845
Heater Pipe - Auxiliary Front 8.845
Hose - Heater 8.846
Insulator - Blower Motor 9.216
Orifice 9.213
Outlet - Side Window Defogger 9.780
Outlet -l/P Center Air 9.262
Side Window Defogger Outlet 9.780
Switch - Cycling 9.172
Schematic and Routing Diagrams

HVAC Schematic References
Reference on Schematic Section Number - Subsection Name
Engine Controls Cell 20 6 — Engine Controls
Ground Distribution Cell 14 8 — Wiring Systems
Interior Lights Dimming Schematics Cell 117 8 — Lighting Systems
Power Distribution Cell 10 8 — Wiring Systems
HVAC Schematic Icons

Icon Icon Definition
Refer to ESD Notice in Cautions and Notices.
A
J jf e ix
19384
1-78 HVAC System - Manual________________________________________________________________
H V A C _________________________________________________________________________
1-78
Auxiliary Auxiliary
Biower Blower Auxiliary
Motor Motor Blower Motor
HVAC System - Manual________________________________________________________________

Relay, Relay, Relay, High
Low Medium
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E D Auxiliary HVAC
Auxiliary HVAC Low. Control
Control off*r Med Module,
Low Med
Module, Front
Rear rHigh Rear High
w/o Rear
Heat
0.8 ORN B
f L 0.8 BLK 150
1923 S307
0.8 BLK 150
| w/RearHeaT]
I
E C300 I
0.8 DKBLU 77 1
L M 0.8 BLK 150
Ground
"* Auxiliary HVAC S410 Distribution
| HVAC Air
■ Delivery < 1Control Logic Cell 14
Controls 1Module 5 BLK 150
■061165 I
L «. . \ G400
HVAC
Recirculation
□
I Hot In RUN |
r — —.
IP Fuse Door Motor
I Power
Distribution M6 t HTR-A/C J Block
Cel! 10 P Fuse 12 I
m k 25 A I 6
0.5 DKGRN 1614
F, . C230
1 BRN 141 0.5
S268 1 BRN DKGRN if**a 0.5 0.5 Plfl1
0
Power
Distribution DK GRN C200 DK GRN |x^ ? mpressor
Cell 10 1 DKGRN 141 $212 ■ ■»—--- -— —---- —IDI—|B> Low Pressure
0.5 1614 W (Diesel) 1614 Cutoff Switch
1 BRN 141 71 DKGRN 1614 p (Gas)
5 3 kC3 Ds G C2 4 C3
HVAC Air "'HVAC
Delivery Compressor Control
Controls Logic Module
Cell 65
CONN ID
C l- 4 BLK
C2=8 BLK
Mode Dial f
Defrost
7 A/C Push
Button
Switch
Ground
Distribution
Cell 14 (Gas)
Ground
Distribution
Cell 14 (Diesel)
C3=10 GRY Detent
•-L >--------- ----------- ^ ..✓
HVAC Blower Controls
Ground Cell 63
Gas
2 16T03 Only
0.8 LT GRN 66 S103 /

rSeseil -L fGasl
0.5 BLK/WHT 451 0.5 BLK/WHT 451
0.8 BLK 150

0.8 LT GRN 66
0.8LTGRNT66
b ! B
A/C Compressor I |A/C Compressor i
B
i A/C Compressor
1 BLK/WHT 451
V High Pressure Low Pressure Cycling
A/C Compressor
HVAC System
Cycling Switch Cutout Switch I ICutout Switch I I Switch 1 BLK/WHT 451
Ground
0.8 A A a '
S298 Distribution
Cell 14 DK GRN/WHT 762 Ground
0.5 DK BLU 604 0.5 DK GRN 603 Distribution
Celt 14
Ground
1 BLK 150 Distribution
25 C3 (Gas) 14 C3 30 C3 (Gas)
Cell 14 “■ Vehicle
- A/C
- Manual
Request Control 0.8
3 BLK 150 GAS Signal DIESEL Module (VCM)/ TAN/WHT 551
com id CONN ID
C1 = BLU C1 = BRN - ► A/C Compressor - ► A/C Compressor Powertrain
C2=RED C2=BRN Low Pressure Cycling Control
a1
lG200
G C3=CLEAR C3=BLU Cutout Switch Switch Module (PCM) G104 AG103
C4=BLK Input Input
1-79
1=80
pteTinWNAndCT^I
1“»Underhood
HVAC System - Manual________________________________________________________________

Power Power
Distribution A/C 0Fuse Block
Cell 10 Fuse 1
10 A 1
j
17.4 O n ly j^ 0.8 PNK | 639
mn X fimMm 0.8 PNK 639
0.8 ORN 1240 S146 0.8 PNK 639

0.8 ORN 1240 I
*
0.8 PNK 639
I Power
Distribution
Cell 10
Power
Power Distribution
Distribution Cell 10 S'"G a s ! ransn
Cell 10
1 Underhood C100
Fuse
Block
Y
0.8 LT GRN 66
C20Q
A/C Compressor
Cycling
A6
Switch
0.8 DKGRN B
0.8 DK GRN
0.8 DK GRN 603
.59 rpieSeTl rs n i S159
0.8 DKGRN
0.8 DKGRN 603
B 0.5 DKGRN j 1614 B
D104 459
(A/C A/C A/C Compressor
Compressor a!
Compressor
A/C Compressor High Pressure
□
Clutch Diode Clutch Cutoff Switch
1 AMP) Low Pressure
Cutout Switch
0.8 BLK 0.8 DK GRN/WHT 762
150 bT 1614 £P101
0.8 BLK 0.5 DK GRN
1 C3 Diesel Only
0.5 BLK 150
$m ¥- i C4<Gas) DS C3 (Diesel) C2 Cl (Diesel)
1 BLK 150 I GAS DIESEL

Vehicle Control
>
Ground CONN ID CONN ID t ■ A/C Compressor [ Module (VCM)/
S147 < Distribution C1 = BLU C1 = BRN * ’ 1 Clutch Relay Powertrain Control
Cell 14 C2 = RED M . Control
C3 = CLR
C2 = BRN Module (PCM)
C3 = BLU
3 BLK 150 5 BLK 150 C4 = BLK
Me
HVAC
Hot In RUN
Power ------- “MP Fuse

Distribution M6 I HTRA/C JBlOCk
Fuse 12 ■
V■
N5 C 25 A I
1
1
0
Power
- - - Distribution
Cell 10
1 BRN 141
GOtZQ i 1 BRN r
141 !>
L C230
1 BRN 1 4 1 s- T 1 DK GRN 71
1 BRN 141
<3 . d Ic 2 5, 3
HVAC
Control
Module
_________________________________________
> C230
493355
1-82 HVAC System - M a n u a l ____________________________________________________________
0
HVAC _________________________________________
OVAH lenueiAl - uiajsAs OVAH 178-1-
Component Locator
HVAC Components
On the front of the A/C compressor, in the HVAC Connector
A/C Compressor Clutch HVAC Component Views
left front side of the engine End Views
In the underhood fuse-relay center, in the
A/C Compressor
left rear side of the engine compartment, HVAC Component Views HVAC Connector
Clutch Relay
on the fender End Views
A/C Compressor
On the top right of the A/C accumulator, in H V A C C o n n e c to r
Cycling Switch the right side of the engine compartment, HVAC Component V i e w s End Views
on the bulkhead
A/C Compressor High On the rear of the A/C compressor, in the HVAC Component Views HVAC Connector
Pressure Cutout Switch left front side of the engine End Views
A/C Compressor Low On the top of the A/C compressor, in the HVAC Component Views HVAC C o n n e c t o r
Pressure Cutout Switch high pressure refrigerant line End Views
Auxiliary Blower Motor Behind the right rear wheelhousing HVAC Component Views HVAC Connector
E n d V ie w s
Auxiliary Blower Motor On the top of the auxiliary HVAC plenum, HVAC Connector
r*elay, High near the right rear wheelhousing HVAC Component Views End Views
Auxiliary Blower Motor On the top of the auxiliary HVAC plenum, HVAC Component Views HVAC Connector
Relay, Low near the right rear wheelhousing End Views
Auxiliary Blower Motor On the top of the auxiliary HVAC plenum, HVAC Component Views HVAC Connector
Relay, Medium near the right rear wheelhousing End Views
Auxiliary Blower On the top of the auxiliary HVAC plenum, HVAC Component Views HVAC Connector
Resi stor near the right rear wheelhousing End Views
Auxiliary Cooling Fan Cooling System Cooling System
Relay (Except 4.3 L) Left of engine compartment Component Views in Connector End Views in
Engine Cooling Engine Cooling
Auxiliary HVAC Control In the rear overhead console, behind the HVAC Connector
Logic Module controls HVAC C o m p o n e n t Views End Views
Auxiliary HVAC Control On the front of the overhead console, near HVAC Component Views HVAC Connector
Module, Front the windshield End Views
Auxiliary HVAC Control On the rear of the overhead console HVAC Component Views HVAC Connector
Module, Rear molding, in the headliner End Views
Auxiliary Mode In the auxiliary HVAC plenum, forward of HVAC Connector
Door Motor the left rear wheelhousing HVAC Component Views End Views
Auxiliary Temperature In the auxiliary HVAC plenum, near the HVAC Component Views HVAC Connector
Door Motor right rear wheelhousing End Views
Blower Motor, Front To the right of the IP, behind the HVAC Component Views HVAC Connector
IP compartment box End Views
Blower Motor Behind the IP compartment box, on the HVAC Component V i e w s HVAC Connector
Relay, High HVAC plenum End Views
Blower Resistor HVAC Component Views HVAC Connector
On top of the HVAC plenum End Views
Power and Grounding Power and Grounding
Convenience Center Under the left side of the IP, on the Component Views in Connector End Views in
bulkhead Wiring Systems Wiring Systems
Part of the heater controls, in the center of HVAC Component Views HVAC Connector
HVAC Control Module the IP, under the radio End Views
Power and Grounding Power and Grounding
IP Fuse Block To the left of the IP, near the left front Component Views in Connector End Views in
door jamb switch Wiring Systems Wiring Systems
Mode Door Motor Under the IP, on the left side of the HVAC HVAC Component Views HVAC Connector
plenum End Views
Powertrain Control Under right end of IP, above blower motor, Engine C o n t r o l s PCM Connector End
Module (PCM) (Diesel) behind IP compartment box Component Views in Views in Engine Controls
Engine Controls
HVAC Components (cont’d)
Recirculation
Under the IP, on the HVAC plenum HVAC Component Views HVAC Connector
Door Motor End Views
Temperature Under the IP, on the center of the HVAC HVAC Component Views HVAC Connector
Door Motor plenum End Views
In the left rear side of the engine Power and Grounding Power and Grounding
Underhood Fuse Block compartment, on the fender Component Views in Connector End Views in
Vehicle Control Module Engine Compartment, near EBCM Engine Controls VCM Connector
Component Views in
(VCM) (Gas)
Engine Controls End Views
Part of the engine harness to IP harness, Harness Routing Views in Inline Harness Connector
C100 in the left rear side of the engine Wiring Systems End Views in Wiring
compartment, at the bulkhead Systems
Behind the right side of the IP, near the Harness Routing Views in Inline Harness Connector
C200 heater motor, in foam wrap Wiring Systems End Views in Wiring
Systems
0203
Behind the right side of the IP, near the Harness Routing Views m Inline
End
Harness Connector
Views in Wiring
heater motor, in foam wrap Wiring Systems
Systems <
Harness Routing Views in Inline Harness Connector
C205 At the convenience center Wiring Systems End Views in Wiring
. Systems
C221 At the convenience center Harness Routing Views in Inline Harness Connector
End Views in Wiring
Wiring Systems Systems
C300 In the overhead console Wiring Systems End Views in Wiring
Systems
C400
At the right rear of the vehicle, above the Harness Routing Views in Inline Harness Connector
End Views in Wiring
auxiliary blower motor Wiring Systems Systems
C401
At the right rear of the vehicle, above the Harness Routing Views in Inline Harness Connector
End Views in Wiring
auxiliary blower motor Wiring Systems
Systems
C406 Top of the right side D pillar Wiring Systems End Views in Wiring
Systems
D104 (4.3L, 5.0L, 5.7L) 20 cm (8 in) from the A/C compressor — —
clutch connector
D104 (6.5L) 28 cm (11 in) from the A/C compressor — —
clutch connector
D104 (7.4'L) 17 cm (6.5 in) from the A/C compressor — —
clutch connector
On the right front side of the engine, near Power and Grounding
G103 (Gas)
the thermostat housing Component Views in —
Wiring Systems
Power and Grounding
G104 (4.3L, 5.0L/5.7L) Backside of the right cylinder head Component Views in —
Wiring Systems
Power and Grounding
G104 (6.5L) Top rear of the right cylinder head Component Views in
Wiring Systems
Backside of the engine block, below the Power and Grounding
G 104(7.41)
right cylinder head Component Views in —
Wiring Systems
Power and Grounding
G105 (Gas) On the right front side of the engine block Component Views in —
Wiring Systems
Right rear of the cylinder head, cylinder #7
Power and Grounding
G105 (Diesel)
intake bolt
Wiring Systems
Behind the left side of the IP, below the fuse
Power and Grounding
G200
block, on the tie bar Component Views in —
Wiring Systems
On the right side of the instrument panel,

Power and Grounding
G202
mounted to the HVAC plenum bracket
Wiring Systems
On the right side B pillar, near the door
Power and Grounding
G400 (Utility/Suburban) striker Component Views in
Wiring Systems
In the left rear side of the engine Harness Routing Views in
P100
compartment, at the bulkhead, above C100 Wiring Systems ■■ —
In the right rear side of the engine Harness Routing Views in —
P101 compartment, at the bulkhead Wiring Systems
Engine harness approx. 6.5 cm (2.5 in) from
S102 (6.5L) trans connector breakout, towards the — -
Starter Solenoid harness breakout
S103 (4.3L, 5.0L, 5.7L) EGR valve breakout, toward taillamp — . — ■
harness breakout
S103 (6.5L) starter solenoid breakout, towards the — —
underhood lamp harness breakout
S103 (7.4L-A/T) the EGR valve harness breakout, towards _ —-'
the ignition coil harness breakout
Engine Harness, approx. 4 cm (1.5 in) from
S103 (7.4L-M/T) the fuel injector harness breakout, towards — —
the taillamp harness breakout
S107 (4.3L, 5.0L, 5.7L) EGR valve breakout, toward taillamp — —
harness breakout
S107 (6.5L, HD) EBCM breakout, toward transmission — —
harness breakout
S107 (7.4L) EBCM breakout, toward the EGR harness — —
breakout
S110 (4.3L, 5.0L, 5.7L)
Engine harness, approx. 23 cm (9 in) from _ —
EBCM breakout, toward taillamp harness
S110 (6.5L) the EBCM breakout, towards the Taillamp — —
harness breakout
S110 (7.4L-A/T) EBCM breakout, near taillamp harness — —
breakout
S145 (7.4L)
Engine harness, approx. 11 cm (4 in) into —
EGR valve breakout
S147 (Gas) EGR valve breakout, toward taillamp —
harness breakout
Engine harness, approx. 4 cm (1.5 in) from — —
S147 (Diesel) starter motor solenoid breakoui:
Location Locator View.. Connector End View
S185 At Di ode D104 —
S186 At Diode D104 —
S204 C100, towards data link connector (DLC) — —
S212 inflatable restraint switch breakout — —
HVAC harness, approx. 4 cm (1.5 in) from
S243 recirculation door breakout, toward blower — —
motor relay
HVAC harness, approx. 8 cm (3 in) from
S244 recirculation door breakout, toward high — —
blower motor relay
IP harness, approx. 7 cm (2.5 in) into the ' —
S268 HVAC control switch harness breakout —
IP harness, approx. 24 cm (9.5 in) from
S298 instrument cluster breakout, toward radio —
breakout ' ■■■
Rear HVAC control harness, approx.
S307 (4-Door 10 cm (4 in) from auxiliary HVAC control
Utility/Suburban) logic module breakout, toward front —- '— '
auxiliary HVAC control module
Rear HVAC control harness, approx. 5 cm
S308 (4-Door (2 in) from auxiliary HVAC control logic
Utility/Suburban) module breakout, toward rear auxiliary ''— —
HVAC control module
Taillamp extension harness, approx. 10 cm
S324 (4 in) from G404 breakout, toward engine — " —
harness
S400 (w/Auxiliary A/C) (6.5 in) from blower motor relays, toward _ . —
blower motor
S401 (w/Auxiliary A/C) (15 in) from blower motor relays, toward _— —
blower motor
Auxiliary HVAC harness, approx. 13 cm
S401 (5 in) from blower motor relays breakout,
(w/Auxiliary HVAC) — —
toward blower motor
S402 (w/Auxiliary A/C) (2.5 in) from blower motor resistor — —■
breakout, toward blower motor relays
Auxiliary HVAC harness, approx. 7 cm
S403 (2.5 in) from blower motor resistor
(w/Auxiliary HVAC) — —
breakout, toward blower motor
S410 (2-door Utility)
(14.5 in) from right rear door jamb switch — ■■ — ■
breakout, toward right door speaker
breakout
S410 (4-Door (4.5 in) from right rear door speaker
Utility/Suburban) breakout, toward right rear door jamb — —
breakout
S440 (4-Door Front-to-rear body harness, approx. 7 cm
Utility/Suburban (2.5 in) from crossbody harness breakout, —
w/o C69 toward front dome lamp breakout
S441 (4-Door Front-to-rear body harness, approx. 5 cm
Utility/Suburban) (2 in) from convenience center harness — —
breakout
S442 (4-Door
Utility/Suburban) (6.5 in) from convenience center harness — ' ■ ■ ' —■
breakout
HVAC Component Views
A/C Accumulator and Cycling Switch (Gas)
459128
Legend
(1) Manifold Air Temperature Sensor (5) Water Valve Actuator (Suburban/Utility Only)
(2) A/C Accumulator (6) Heater Hoses
(3) A/C Cycling Switch (7) P101
(4) Underhood Lamp Harness (8) Manifold Air Flow Sensor
A/C Accumulator and Cycling Switch (Diesel)
Legend
(1) A/C Accumulator (5) Low Coolant Level Sensor Connector
(2) A/C Cycling Switch (6) Engine Harness
(3) G108 (7) Coolant Reservoir
(4) P101
A/C Low and High Pressure Cutout Switch
277982
Legend
(1) Throttle Position (TP) Sensor (5) A/C Low Pressure Cutout Switch
(2) Idle Air Control (IAC) Valve Motor (6) A/C Compressor Clutch Connector
(3) Engine Coolant Temperature Switch (7) Engine Coolant Temperature Sensor
(4) A/C High Pressure Cutout Switch (8) EGR Valve
1-92 HVAC System - Manual HVAC
Front and Rear Auxiliary HVAC Control Modules (Overhead Console)
277977
Legend
(1) Auxiliary HVAC Control Logic Module (4) Reading Lamps Overhead Console
(2) Auxiliary HVAC Control Module, Rear (5) Auxiliary HVAC Control Module, Front
(3) Universal Transmitter Switches (ZM9/UG1)
Auxiliary A/C Wiring
277976
Legend
(1) Auxiliary HVAC Blower Relays; (5) Auxiliary Blower Resistor
Low/Meduim/High (5) Auxiliary Temperature Door Motor
(2) C401 (7) Auxiliary Mode Door Motor
(3) C400
(4) Auxiliary Blower Motor
HVAC Control Module (Rear View)
Legend
(1) Dash (4) IP Harness
(2) HVAC Control Module Connector, C1 (5) HVAC Control Module Connector, C3
(3) HVAC Control Module Connector, C2 (6) HVAC Control Module (Rear View)
Front HVAC Assembly
Legend
( 1) Blower Resistor (7) Temperature Door Motor

(2) Blower Motor (8) HVAC Plenium
(3) Blower Motor Connectors (9) Mode Door Motor
(4) C230 (10) HVAC Wiring Harness
(5) C203 (11) Blower Motor Relay, High
(6 ) C204
HVAC Connector End Views A/C Compressor High Pressure
Cutoff Switch
A/C Compressor Clutch

information 2F m/P 150 (BLK)
Information 2F M/P 150 (GRY) Circuit
Circuit
Pin Wire Color No. Function DK GRN/ Air Conditioning
762
BLK- Ground WHT Request Signal
150
Air Conditioning LT GRN Air Conditioning Switch
66
DKGRN Compressor Clutch Output_______
59
Solenoid Feed
A/C Compressor Refrigerate Pressor Switch
A/C Compressor Cycling Switch

Information 2F M/P 150 (BLK)
Information 2F 150 (BLK) Circuit
Circuit
Pin Wire Color No. Function Air Conditioning
Air Conditioning Refrigerant High
DK BLU 604
Pressure Cut-Out
Refrigerant Low
DKGRN 603 Switch Output
Pressure Cut-Out
Switch Output WHT 451 Ground
BLK 451 Ground
Auxiliary Blower Motor Auxiliary Blower Motor Relay, Low
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281199
Connector Part 12129939 Connector Part • 12034003

Information Information • 5F M/P 630 (BLK)
2F Metri-Pack 630 (BLK)
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No, Function
Auxiliary Blower RED 542
YEL 1172 1
Motor Feed Type II Fuse
BLK 150 Ground 2 DKBLU 1926
Output - Low
3 ■— ' — Not Used
Auxiliary Blower Motor Resistor Auxiliary Blower Motor
4 YEL 1176
Resistor Output - Low
5 BRN 341
Type III Fuse
Auxiliary Blower Motor Relay, Medium

B
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428533

Information 3F56 Series (NAT) “.....................
Circuit
281199
Auxiliary Blower
LT BLU 1072 Resistor Output - Connector Part • 12034003
Medium Information • 5F M/P 630 SPL (BLK)
Auxiliary Blower Circuit
YEL 1172 Motor Feed Pin Wire Color No. Function
Auxiliary Blower Motor 1 RED 542
YEL 1176 Output - Low_______ Type II Fu
RED Auxiliary HVAC Switch
2 1925
Output - Medium
3 — ■— Not Used
Auxiliary Blower Motor
4 LT BLU 1072 Resistor Output -
Medium
BRN 341
5
Type III Fuse
Auxiliary Blower Motor Relay, High Auxiliary HVAC Control Module, Front
(cont’d)
f——- \ C r - 0
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62464
Connector Part © 12034003
Information • 5F M/P 630 SPL (BLK) • 12064769
Connector Part
Circuit Information ® 10F Metri-Pack 150
Pin Wire Color No. Function Series (NAT)
Fuse Output - Battery - Circuit
1 RED 542 Pin Wire Color No. Function
Type II Fuse
Auxiliary HVAC Switch Auxiliary HVAC Switch
2 WHT 1924 E RED 1925
Output - High Output - Medium
3 — — Not Used F Auxiliary HVAC
ORN 1923 Switch Feed
Auxi liary Blower Motor
4 YEL 1172 Resistor Output - G - 34-: Ignition Feed - Fused
Medium Air Temp Door Position
H LT BLU ■ 733 ' Sensor Signal
BRN 341
5
Type III Fuse J LT BLU 91 £ Front Control Heat Input
K — — Not Used
Auxiliary HVAC Control Module, Front
Auxiliary HVAC Control Module, Rear
f----
h
f C
T .... l— h
ti .r ..■....
v. q r: |- r i qsp qsp q p ...........
C v_— q « p [ - t i c j p nsp c t :
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62464
Connector Part • 12064769 62464

Series (NAT) Connector Part ® 12064769
Circuit Series (NAT)
Circuit
A GRY 8 IP Lamp Feed Pin Wire Color No. Function
B BLK 150 Ground A Gf 8 IP Lamp Feed
C DK BLU 1926 Output - Low B BLK 150 Ground
Auxiliary HVAC Switch Auxiliary HVAC Switch
D WHT 1924 C DK BLU 1926 Output — Low
Output - High
Auxiliary HVAC Control Module, Rear Auxiliary HVAC Control Logic Module
(cont’d ) _________
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[5 ] [ j t \ [5 b :5 b
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328486
62464
• 12047887
• 12064769 Connector Part • 12 Way Printed Circuit
Connector Part
Information • 10F Metri-Pack 150 Information Edgeboard Series
Series (NAT) Standard (BLK)
Circuit Circuit
Pin Wire Color No* Function Pin Wire Color No. Function
Auxiliary HVAC Switch Air Temperature Door
D WHT 1924 Output — High A LT BLU 733
Position Signal
Auxiliary HVAC Switch Air Temperature Door
E RED 1925 Output — Medium B DK BLU 1199
Motor - Feed
Auxiliary HVAC Air Temperature Door
F ORN 1923 Switch Feed C DKBLU 1646
Position Signal - Rear
G BRN 341 Ignition Feed — Fused :
D LT BLU 920 Rear Control Output
Air Temp Door Position
H LT BLU 733 Sensor Signal E LT BLU 919 Front Control Heat Input
J LT BLU 919 Front Control Heat Input F WHT 119 Mode Switch Output
K - - Not Used G — — Not Used
H BLK 150 Ground
J BRN 341 Ignition Fused Feed
K — — Not Used
L 77 A/C Select
DK BLU
Switch - Rear
A/C Select Switch
M ORN 1923 - Fror-
Auxiliary Mode Door Motor Blower Motor, Front
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Connector Part • 12040953 Connector Part 08905615

Information o 6F M/P 100 Series (BL ) information 1F56 Series (GRY)
Circuit Circuit
Pin Wire Color No, Function Pin Wire Color No. Function
5- 6 — — Not Used PPL 65 Power Motor Feed
7 BLK 150 Ground
8 WHT 119 Mode Switch Output Blower Motor Relay, High
9 ■— . — Not Used
--
341 Fuse Output - Ignition 3
10 BRN
Type III Fuse
i_j_j i
------
Auxiliary Temperature Door Motor
Cl
_ _
'N
G 3
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0 CD CD O CDCD Connector Part 12110541
Information 6F Metri-Pack 280 Series
Flexlock (BLK)
Circuit
A1 BLK 150 Ground
Connector Part • 12040953 A2 RED
Fuse Output Battery -
542
Information • 6F M/P 100 Series (BLK) Type II Fuse
Circuit B1 Not Used
Pin Wire Color No. Function B2 DK BLU 101 Blower Resistor Output
5 -6 — — Not Usee' C1 PPL 65 Blower Motor Feed
7 BLK 150 Ground Blower Switch
C2 ORN 52
Air Temperature Valve Output - High
8 DK BLU 1199
Motor Feed
9 — — Not Used
341 Fuse Output - Ignition 3
10 BRN
Type III Fuse
Blower Resistor Blower Switch, Connector C2 (cont’d)
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Connector Part 12064877 • 12064998

Connector Part
Information 4F Metri-Pack 680 Information • 8 Way F Metri-Pack 280
Series (BLK) Series (BLK)
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
Blower Switch Fuse Output -
YEL 60 G BRN 141
Output - Low Ignition 3-Type III Fuse
DK BLU 101 Blower Resistor Output Blower Switch
Blower Switch Output - H ORN 52
TAN 63 Output - High
Medium 1
Blower Switch Output - Heater Control Module, 01
LT BLU 72
Medium 2
Blower Switch, Connector C2

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62450
• 12052856
Connector Part
62469 Information ® 4 Way F Metri-Pack 280
Series (BLK)
Connector Part
• 12064998
Circuit
Information • 8 Way F Metri-Pack 280 Pin Wire Color No. Function
Series (BLK)
Battery Fused Feed
Circuit A ORN 1440 Fuse Output - Battery
Pin Wire Color No. Function -Type III Fuse
A 72 Blower Switch Output -
LT BLU
Medium 2 Ignition Fused Feed
B BRN 141 Fuse Output - Ignition 3
Blower Switch Output - - Type III Fuse
B TAN 63
Medium 1
C BLK 150 Ground
Blower Switch
0 YEL 60 Rear Defogger
Output - Low D PPL 293 Element Feed
D DK GRN 71 A/C Select Switch
Output
E- F — Not Used
Heater Control Module, C3 Mode Door Motor
[I "1 — r n
I000HE
COO OHOHCDHE
12191271 ® 12040953
Connector Part Connector Part
Information 10 Way P/C Bow Information ® 6 Way F Micro-Pack 100
Series (GRY) Series (BLK)
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
Battery Fused Feed 5- 6 Not Used
ORN Fuse Output - Battery
BLK 150 Ground
-Type III Fuse
BLK Ground WHT 454 Mode Switch Output
150
Blower Switch Not Used
DKGRN 71
Output- Off Fuse Output - Ignition 3
10 BRN 141
Rear Defogger Type III Fuse
PPL 1614
Element Feed
Fuse Output Ignition 3- Recirculation Door Motor
BRN 141
Type III Fuse
Not Used
Water Heater Control
GRY/BLU 1596
LT BLU 733
Solenoid Output
Air Temperature Valve
n n
n
n
3
Position Sensor Signal
WHT 454 Mode Sensor Output t§ • r.-. u s
10 LT GRN 66 A/C Switch Output c o o o o CDCD

Information 6 Way F Micro-Pack 100
Series (BLK)
Circuit
BRN 141 Fuse Output - Ignition 3
Type 111 Fuse
DKGRN 1614 Air Inlet Valve

Motor Feed
BLK 150 Ground
i- 10 Not Used
Temperature Door Motor Water Valve (Suburban/Utility)
h -i
—
n n n
M0 E 0 u s
CDDUEDEDDDE!
281207
• 12040953 Connector Part • 12052641

Connector Part Information
Information • 6F Micro-Pack 100 • -2F M/P 150 (BLK)
Series (BLK) Circuit
Circuit Pin Wire Color No* Function
GRY/BLK Heater Water Control
1596
5- 6 — — Not Used Solenoid Output
7 BLK 150 Ground BLK 150 Ground
Air Temperature Valve
8 LT BLU 733 Position Sensor Signal
9 — — Not Used
Fuse Output Ignition 3
10 BRN 141
Type III Fuse
Diagnostic Information and Procedures

Functional Check 2 . The same hand-felt temperature of the evaporator
inlet pipe and the accumulator surface of an
As an aid in determining whether or not the air
operating system indicates a properly charged
conditioning, electrical, air, and refrigeration systems
are operating properly use the System system.
Performance Table. 3. The operation of the air conditioning control head
1. The operation of the air conditioning blower at all in the distribution of air from the designated
speeds, in any position except the OFF position, outlets indicates proper functioning.
and the engagement of the compressor clutch
indicate that the electrical circuits are functioning
properly.
HVAC Blower Controls System Check
1. Turn the ignition switch to the The blower motor runs in all • Blower Motor Inoperative at
RUN position. positions. Any Speed
2. Rotate the front blower switch • Blower Motor Low Speed
through all fan speeds: Inoperative
• Low • Blower Motor Inoperative Med- 1
1
• Med 1 • Blower Motor Inoperative Med-2
• Med 2 • Blower Motor High Speed
• High Inoperative
• Blower Motor Operates at High
Speed Only
Turn the front blower switch to the Blower motor stops running Blower Motor Always On
2 OFF position.
HVAC Blower Controls System Check (cont’d)
Rotate the auxiliary HVAC control The auxiliary blower motor runs in all • Blower Motor Inoperative at Any
module, Front through all fan positions. Speed - Auxiliary
speeds:
• Blower Motor Low Speed
• Low Inoperative - Auxiliary
• Med • Blower Motor Medium Speed
• High Inoperative - Auxiliary
1. Turn the auxiliary HVAC control • Blower Motor High Speed
3 module, front to the rear Inoperative - Auxiliary
position. • Blower Motor Operates at High
2. Rotate the auxiliary HVAC Speed Only - Auxiliary
control module, rear through all
fan speeds:
• Low
• Med
• High
Turn the auxiliary HVAC switch to Auxiliary blower motor stops running Blower Motor Operates Continuously
4 - Auxiliary
the OFF position.
HVAC Compressor Controls System Check

1. Start the vehicle. A/C compressor clutch engages. A/C compressor clutch does not
engage.
2. Turn the blower switch to the
LOW position Refer to:
1 • H V A C C o m p r e s s o r C lu tc h C ir c u it
3. Turn the mode door switch to
the MAX A/C position. D ia g n o s is ( G a s )
• H V A C C o m p r e s s o r C lu tc h C ir c u it
D ia g n o s is ( D ie s e l)
Turn the mode door switch to the A/C compressor clutch disengages. A/C compressor clutch does not
OFF position. engage.
Refer to:
2 , • H V A C C o m p r e s s o r C lu tc h C irc u it
D ia g n o s is ( G a s )
® H V A C C o m p r e s s o r C lu tc h C irc u it
D ia g n o s is (D ie s e l)
HVAC Air Delivery System Check

1. Start the vehicle engine. • Blower motor will operate at Air flow does not change outlets:
high speed. M o d e A c tu a to r In o p e r a tiv e (F ro n t)
2. Allow vehicle to reach
operating temperature. • Air temperature will be hot.
3. Place the blower switch in the • Air flow in the defrost position is
high position. through the defrost outlets.
4. Place the temperature knob in • Air flow in the blend position is
1 the full heat (red) position. through both defrost and heater
5. Rotate the mode knob through outlets.
each of the vent positions: • Air flow in the heater position is
• Defrost through the heater outlets.
• Blend • Air flow in the vent position is
through the A/C (vent) outlets.
• Heater
• Vent
HVAC Air Delivery System Check (cont’d)
1. Place the temperature knob in • Blower motor will operate at Air temperature remains hot:
the full cold (blue) position. high speed. Temperature Actuator Inoperative
(Front)
2. Rotate the mode knob in each • Air flow will change to the
of the following positions: appropriate outlets.
2 • Defrost • Air temperature will be cooler.
• Blend
• Heater
• Vent
1. Press the A/C button. An audible change in the blower will No audible change in blower
be noticed when in either MAX A/C operation: Air Inlet Actuator
2. Place the temperature knob in or when the recirculation button is Inoperative
the MAX position. pressed.
3 3. Depress the A/C button and
turn the temperature knob to
medium/blend.
4. Press the recirculation button.
If vehicle is equipped with an • Auxiliary blower motor will • Mode Actuator
auxiliary HVAC unit perform the operate at high speed. Inoperative (Rear )
following steps:
• Air flow will be through the lower • Temperature Actuator
1. Place the front auxiliary HVAC outlets of the auxiliary unit. Inoperative (Front)
control module blower switch in
4 the high position. • Air temperature will be cold.
2. Place the mode knob in the
lower position.
3. Place the temperature knob in
the full cold (blue) position.
1. Place the front auxiliary HVAC • Auxiliary blower motor will • Mode Actuator
control module mode knob in operate at high speed. Inoperative (Rear )
the overhead position. • Air flow will be through the • Temperature Actuator
5
2. Place the temperature knob in overhead outlets of the Inoperative (Front)
the full hot (red) position. auxiliary unit.
• Air temperature will be hot.
For vehicles with rear auxiliary • Auxiliary blower motor will • Mode Actuator
HVAC control unit. operate at high speed. Inoperative (Rear )
1. Place the front auxiliary HVAC • Air flow will be through the lower • Temperature Actuator
control module blower switch in outlets of the auxiliary unit. Inoperative (Front)
the rear position.
• Air temperature will be cold.
2. Place the rear auxiliary HVAC
control module knobs in the
6 following positions:
• Blower switch in the high
position.
• Mode knob in the lower air
delivery position.
• Temperature knob in the full
cold (blue) position.
1. Place the rear auxiliary HVAC 1. Auxiliary blower motor will • Mode Actuator
control module mode knob in operate at high speed. Inoperative (Rear )
the overhead air delivery 2. Air flow will be through the • Temperature Actuator
position. overhead outlets of the Inoperative (Front)
7
2. Place the rear auxiliary HVAC auxiliary unit.
control module temperature 3. Air temperature will be hot.
knob in the full hot (red)
position.
| Hot At All Times | I Hot In Run And Start I |HoUnJRunj
Underhood J" A/C Power

IP
Power
M igne Distribution M6 «k HTR A/C 1 Fuse
Fuse-Relay , Distribution K11 L COMP
Distribution |
tion
Fuse I Block
Cell 10 /-'Fuse ■ Cell 10
Center , L12V 10 A Cell 10 G6<^ 10 A j
I NsC 25 A |
I I
Fuse Block BRN 141
Details
Cell 11
ORN 1240 7 " BRN 141
VCM
Ground BRN 141 BRN 141 C1 = BLU
Distribution B, Cl _ __5lC3_G. C2 C2 = RED
Cell 14 Ignition
—1 HVAC C3 = CLEAR
I Control C4 = BLK
PNK 639 A/C Positive
Request Vo,ta9e
Signal
Underhood
B4A A4
Fuse - Relay 874 A/C
Center Compressor
Clutch
Relay
DKGRN /
30 BLK/WHT
A6 B6
DKGRN 59
B.
A/C A/C Cycling
Compressor Evaporator/ R
Clutch Clutch B'
D104 1 Switch A/C High
A/C Ground Recirculation A Pressure
Compressor Distribution Mode Switch
Clutch Diode Cell 14
Switch
1AMP B LK
150 T DK DK 5
► I GRN/ 459 GRN/WHT 762
BLK 150 I WHT DKBLU 604 DKGRN 603
\ »- - j 1 .03 14 30 25 C3
Ground BLK 150 | A/C A/C A/C A/C | Vehicle
Distribution --- ,► , Compressor Recirculation Cycling Request. Control
Cell 14____ 1 Clutch Signal Switch Signal
BLK 150 I Relay Signal Module a
| Control (VCM) ^
190387
Circuit Description Diagnostic Aids

The VCM control of the A/C clutch improves idle If the air conditioning system seems to be operating
quality and performance by performing the following correctly at this time check the following:
conditions: • An intermittent condition caused by one of the
• Delaying clutch engagement until the idle speed is following:
increased
- Backed out terminals
• Releasing the clutch when the idle speed is
too low - improper mating
- Broken locks
• Providing additional fuel at the instant the clutch is
applied - Improperly formed or damaged terminals
The additional fuel smooths the cycling of the - Poor terminal to wire connection
compressor. - Physical damage to the wiring harness
Turning the air conditioning ON supplies battery - Corrosion
voltage through the pressure switches to the VCM.
When the VCM receives the voltage on the A/C - Moisture in the connector
request signal, the A/C enable relay circuit is • Refer to Cooling Insufficient - A/C Inoperative for
grounded. The A/C compressor clutch then engages. an insufficient cooling condition.
Test Description 15. The A/C request signal circuit consists of the
The numbers below refer to the step numbers on the HVAC Control module, the A/C high pressure
diagnostic table. cutout switch and related wiring.
1. Checks for low refrigerant as the cause for
no A/C.
HVAC Compressor Clutch Circuit Diagnosis (Gas)
Important: Before using this table confirm that the A/C Go to CCOT A/C
1 system has an adequate state of charge. — S y s te m
Does the A/C system have an adequate state of charge? G o to S te p 2 D ia g n o s is

2. Idle the engine until the normal operating temperature
is reached.
2 60 sec
3. Leave the engine at normal idle.
Go to CCOT A/C
4. Turn ON the A/C. S y s te m
Does the A/C clutch engage within the specified time? D ia g n o s is G o to S te p 3
1. Install the scan tool.

3 3. Turn ON the A/C. —
4. Monitor the A/C Request in the scan tool data list
(A/C Request should display YES).
Does the scan tool indicate a YES? G o to S te p 4 G o to S te p 1 4
1. Monitor A/C evaporator switch with the scan tool.

Does the scan tool indicate a CLOSED switch? G o to S te p 8 G o to S te p 5
1. Disconnect the A/C evaporator/cycling cutoff switch

harness connector.
2. Turn ON the ignition leaving the engine OFF.
5 — .
3. Probe pin A of the harness connector with a fused
jumper connected to a ground.
Does the scan tool indicate a CLOSED switch? G o to S te p 6 G o to S te p 2 7
Probe pin B of the harness connector with a test lamp
6 connected to B+. —
Is the test lamp ON? G o to S te p 7 G o to S te p 2 9
Replace the A/C evaporator/cycling cutoff switch.
7 — —
Is the action complete? G o to S te p 3 1
1. Turn OFF the engine.

2. Disconnect the A/C compressor clutch harness
connector.
4. Turn ON the A/C.
8 Caution: Avoid contact with moving parts and hot —
surfaces while working around a running engine in
order to prevent physical injury.
5. Probe the A/C clutch signal circuit at the A/C
compressor clutch harness connector with a test lamp
connected to a ground.
Probe the A/C clutch ground circuit at the A/C clutch
9 harness connector with a test lamp connected to B+. —
HVAC Compressor Clutch Circuit Diagnosis (Gas) (cont’d)
Repair the A/C clutch ground circuit. Refer to Wiring
10 Repairs in Wiring Systems. —
Is the action complete? Go to Step 31
Check for a poor connection at the compressor clutch
11 harness connector. —
Did you find a problem? Go to Step 12 Go to Step 13
Repair the A/C compressor clutch harness connector.
12 Refer to Wiring Repairs in Wiring Systems. — .—
Replace the A/C compressor clutch. Refer to Compressor
Clutch Plate and Hub Assembly Removal and Compressor
13 Clutch Plate/Hub Assembly Install. — —
1. Turn OFF the ignition.
2. Disconnect the VCM C3 connector.
5. Probe the VCM C3 connector pin 25 with a test lamp
connected to a ground.
Is the test lamp ON? Go to Step 28 Go to Step 15
Check for a open in the A/C request signal circuit between Go to CCOT A/C
15 the HVAC control module and the VCM. — System
Did you find a problem? Go to Step 29 Diagnosis
1. Reconnect A/C clutch harness connector.
2. Install the scan tool.
16 3. Turn ON the ignition leaving the engine OFF. —
4. Command the A/C relay ON using the scan tool.
Does the relay A/C click? Go to Step 22 Go to Step 17
1. Disconnect the A/C relay.
17 3. Probe the ignition positive voltage circuit at the —
A/C relay harness connector with a test lamp
connected a ground.
Repair the open in the A/C relay ignition positive voltage
circuit. If the fuse is blown repair the short to ground on
the circuit. A blown fuse or lack of voltage to the fuse may
18 cause other symptoms or DTCs to be present. Refer to —
Wiring Repairs in Wiring Systems.
1. Probe the A/C relay control circuit at the A/C relay
harness connector with a test lamp connected to B+.
19 —
2. Command the A/C relay ON using the scan tool.
Check for an open or short to voltage in the circuit
between the UBEC A/C relay control terminal cavity and
20 the VCM C3 connector pin 1. —
Repair the open in the circuit between the UBEC A/C relay
control terminal cavity and the VCM C3 connector pin 1.
21 Refer to Wiring Repairs in Wiring Systems. — —
HVAC Compressor Clutch Circuit Diagnosis (Gas) (cont’d)
1. Remove the A/C relay.
■22- 2. Probe the battery feed circuit at the A/C relay —
connector with a test lamp connected to a ground.
Repair the open in the A/C relay battery feed circuit.
If the fuse is blown repair the short to ground on the
circuit. A blown fuse or lack of voltage to the fuse may
23 cause other symptoms or DTC’s to be present. Refer to —
Wiring Repairs in Wiring Systems.
2. Jumper the battery feed circuit and the compressor
24 clutch circuit 59 at the relay connector with a fused —
jumper.
Does the A/C Clutch engage? Go to Step 25 Go to Step 26
Replace the A/C relay. Refer to Blower Motor Relay
25 Replacement — — '
Repair the open or short to ground in the compressor
clutch control circuit. Refer to Wiring Repairs in Wiring
26 Systems. — —
Check for an open in the A/C cycling signal circuit.
27 —
Check for a poor connection at the VCM.
28 —
Repair the circuit as necessary. Refer to Wiring Repairs in
1. Replace the VCM.
2. Program the new VCM. Refer to VCM
Replacement/Programming.
30 3. Perform the VTD Password Learn Procedure. Refer — —
to Password Learn Procedure.
4. Perform the Crankshaft Variation Learn Procedure.
Refer to CKP System Variation Learn Procedure.
is reached.
31 60 sec
3. Leave the engine at normal idle.
4. Turn ON the A/C.
Does the A/C clutch engage within the specified time? Go to Step 32 Go to Step 2
Using the scan tool, select the Capture Info and the
32 Review Info. Go to DTC List
Are any DTCs displayed that have not been diagnosed? (Domestic) System OK
Hot In RUN And START | I Hot In RUN And START I Hot In RUN I
r — — ,,p
.Power Power 4 A/C A/C , ■ Power
Distribution IGNE Distribution K11 COMP
/ v yv\_ Compressor a DistributionI M6 \ HTRA/C JFuse
Fuse Cell 10 Fuse 12
I Cell 10
I G 8> 10 A " L12{
T ID"A Fuse Clutch
Relay
I
|
Cell 10
NsC
N5 26 A I
>-I
Block
I st yf \t \ I
L. .— — — j
T brn 141
S268 Power
Underhood 0.8 PNK 639 B4 A4 B6 A6 Distribution
Fuse 1 BRN 141 Cell 10
1 BRN 141
Block 0.8 ORN
1240
5 C3 G C2 { 1 BRN 141
B Cl
■•HVAC
S186 S185 0.8 DKGRN I I Control
■i Module
10 C3
0.5
0.8 BLK
A !.„==..I B
DK GRN/WHT 459
1 LT GRN 66
D7 .0100 A
A/C Compressor 1 LT GRN 66
Clutch A JL
■" ^A/C
Ground S107 C200 S212 ' 'Compressor
Distribution <l l>- __ JCycling
CejLH__ 150 B l - - j A 1614 W 1«4 1614
A/C Compressor B ‘ Switch T O
1 BLK 150 1614 0.8 DKGRN 603
Low Cutout »■ - ‘•A/C High
S159 1 ’ Pressure
Switch Air 0.8 DKGRN 603
- h »S147 Delivery
1 'Cutout
Cell 65 0.8 GRN/WHTT762 Qy J Switch
#SP100
3 BLK 150 D5 C3 C2TC1
r —•_ — —
VCM CONN ID 1 Powertrain .
I C l-B L U C 3 - CLEAR ‘ Control '
G105 I C2=RED C4=BLK 'Module
500023
Circuit Description Diagnostic Aids

The PCM control of the A/C clutch improves idle If the air conditioning system seems to be operating
quality and performance by performing the following correctly at this time check the following:
conditions:
• An intermittent condition caused by one of the
• Delaying clutch engagement until the idle speed is following:
increased
- Backed out terminals
• Releasing the clutch when the idle speed is
too low - Improper mating
• Providing additional fuel at the instant the clutch is - Broken locks
applied
- Improperly formed or damaged terminals
The additional fuel smooths the cycling of the
compressor. - Poor terminal to wire connection
Turning the air conditioning ON supplies battery - Physical damage to the wiring harness
voltage through the high pressure and cycling switches - Corrosion
to the PCM. When the PCM receives the voltage on
the A/C request signal, the A/C enable relay circuit - Moisture in the connector
is grounded. The A/C compressor clutch then engages. • Refer to Cooling Insufficient - A/C Inoperative for
The A/C Compressor Low Cutout Switch provides a an insufficient cooling condition.
ground when the HVAC Control Module is placed
in the A/C Max. position.
Test Description 3. The A/C request signal circuit consists of the
The numbers below refer to the step numbers on the HVAC control module, the A/C high pressure
diagnostic table. cutout switch and related wiring.
1. Checks for low refrigerant as the cause for
no A/C.
HVAC Compressor Clutch Circuit Diagnosis (Diesel)
Important: Before performing the following diagnostic. Troubleshoot any DTC’s that may be stored in the PCM.
Important: Before using this table confirm that the A/C Go to C C O T A / C
1 system has an adequate state of charge. — System
Does the A/C system have an adequate state of charge? Go to Step 2 Diagnosis
is reached.
2 60 sec
- 3. Leave the engine at normal idle.
Go to C C O T A / C
4. Turn ON the A/C. System
Does the A/C clutch engage within the specified time? D ia g n o s is Go to Step 3
1.Install the scan tool.
2.Start the engine. Go to A
3.Turn ON the A/C. Powertrain On
3 — ' Board Diagnostic
4.Monitor the A/C Request in the scan tool data list (OBD) System
(A/C Request should display YES). Check in Engine
Does the scan tool indicate a YES? Go to Step 4 Controls (6.5L)
1. Disconnect connector C3 of the PCM.
4 2. Connect a fused jumper wire between cavity D5 of —
the PCM C3 and ground.
Does the A/C compressor clutch engage? Go to Step 16 Go to Step 5
1. Remove the A/C compressor clutch relay.
2. With the fused jumper still connected at the PCM.
'5 Connect a J 39200 (continuity) between cavity B6 of —
the relay socket and ground.
Locate and repair the open in CKT 459 (DK GRN/WHT) Go to HVAC
between the PCM and A/C compressor clutch relay Compressor
6 socket. Refer to Wiring R e p a i r s in Wiring Systems. — —
Controls
1. Turn the ignition switch to the Run position.
2. Connect a fused jumper wire between cavities A6
7 and A4, then A6 and B4. —
Does the A/C compressor clutch engage with both
circuits? Go to Step 8 Go to Step 9
Replace the A/C relay. Go to H V A C
Is the repair complete? Compressor
8 —. Controls —
System C h e c k
Use a J 39200 (volts) to test CKT 639 (PNK) and
CKT 1210 (ORN) between the IP Fuse Block and the relay
9 socket. Refer to Measuring Voltage in Wiring Systems. —
Is battery voltage present in both circuits? Go to Step 11 Go to Step 10
Locate and repair the open in the circuit that did not have G oto HVAC
battery voltage present. Refer to Wiring Repairs in Wiring Compressor
10 Systems. —-
Controls
HVAC Compressor Clutch Circuit Diagnosis (Diesel) (cont’d)
1. Reconnect the A/C compressor clutch relay.
2. Disconnect the compressor clutch connector.
11 —
4. Connect a J 39200 (volts) between cavities A and B
of the connector.
Replace the A/C compressor clutch. Refer to Compressor Go t o H V A C
Clutch Plate and Hub Assembly Removal. Compressor
12
Controls —
Is the repair complete?
System Check
Connect a J 39200 (continuity) between cavity A of the
13 clutch connector and ground. —
Locate and repair the open in CKT 59 (DK GRN) between Go to H V A C
the relay and the clutch. Refer to Wiring Repairs in Wiring Compressor
14 Systems. — ■—
Controls
Locate and repair the open in CKT 150 (BLK) between the Go to H V A C
clutch and ground G105. Refer to Wiring Repairs in Wiring Compressor
15 Systems. — —
Controls
1. Reconnect C3 back to the PCM.
2. Remove the A/C compressor clutch relay.
3. Connect a fused jumper wire between cavities B4
and A6 of the relay socket.
4. Connect a fused jumper wire between cavities A and B
16 of the A/C high pressure cutout switch. —
5. Turn the ignition switch to the Run position and turn on
the A/C.
6. Monitor the A/C Request in the scan tool data list
(A/C Request should display YES).
Does the scan tool indicate a YES? Go to Step 17 Go to Step 18
Replace the A/C high pressure cutout switch. Refer to Goto H V A C
Compressor Control Switches Removal. Compressor
17 — Controls —
System Check
1. Reconnect the A/C high pressure cutout switch.
2. Connect a fused jumper wire between cavities A and B
18 of the A/C compressor cycling switch. —
3. Run the same test as in step 16.
Does the scan tool indicate a YES? Go to Step 19 Go to Step 20
Replace the A/C compressor cycling switch. Refer to Go to H V A C
Compressor Control Switches Removal. Compressor
19 — Controls —
System Check
Using a J 39200 (continuity) test the applicable circuits
between the HVAC Control Module and the PCM. Refer to
20 Testing for Continuity in Wiring Systems. —
Is continiuty present within all the circuits? Go to Step 21 Go to Step 22
Replace the HVAC Control Module. Refer to Control Goto H V A C
Assembly Replacement Compressor
21 — Controls —
System Check
Locate and repair the open in the circuit(s) that did not have Go to H V A C
continuity. Refer to Wiring Repairs in Wiring Systems. Compressor
22 — Controls
System Check
Blower Motor Inoperative at Any Speed
Was the HVAC Blower Controls System Check Go to H V A C
1: performed? — Blower Controls
2 2. Connect a J 39200 between pin C1 and B2 of —
the relay.
Replace the blower motor relay high. Refer to Blower G o t o H V A C
3 Motor Relay Replacement — B lo w e r C o n tro ls —
1. Disconnect the connectors at the blower motor.
4 2. Connect a J 3 9 2 0 0 between the blower motor —
connector C2, cavity B to ground.
Is there continuity? Go to S te p 5 Go to Step 8
Connect a J 39200 between the blower motor
connector C1, cavity A and cavity C1 of the blower motor
5 relay high. —
1. Reconnect the blower motor connectors.
6 2. Connect a fused jumper wire between cavities A2 — ■■
and C1 of the blower motor relay high, socket.
Does the motor spin freely? Go to Step 10 Go to Step 7
Replace the blower motor. Refer to Blower Motor and Fan G o t o H V A C
7 Replacement —" Blower Controls ■ —
Repair the open in CKT 150 (BLK) between the blower
motor and ground G202. Refer to Wiring Repairs in Wiring Go to HVAC
8 Systems. Blower Controls
Is the repair complete? System C h e c k
Repair the open in CKT 65 (PPL) between the blower
motor relay high and the blower motor. Refer to Wiring G o to H V A C
9 Repairs in Wiring Systems. — —
Blower Controls
Is the repair complete? S y s t e m Check

10 3. Connect a J 39200 between cavity G2 of the HVAC —
control module connector and ground.
Repair the open in CKT 141 (BRN) between the
instrument panel (IP) fuse block and the HVAC control G o to HVAC
11 module. Refer to Wiring Repairs in Wiring Systems. —
Blower Controls
Replace the HVAC control module. Refer to Control Go to H V A C
12 Assembly Replacement — Blower Controls
Blower Motor Low Speed Inoperative
Has the HVAC Blower Controls System Check been Go to H V A C
2. Place the blower switch in the LOW position.
2 resistor. —
4. Connect a J 39200 (volts) between the blower motor
resistor connector cavity A and ground.
Replace the blower motor resistor. Refer to Blower Motor Go to H V A C
3 Resistor Replacement — Blower Controls —
Is the repair complete? System C h e c k
2. Turn the blower switch to the LOW position.
4 3. Connect a J 39200 (continuity) between pins C and G —
of the HVAC control module.
Repair the open in CKT 60 (YEL) between the HVAC
control module connector 2, cavity C and the blower motor
5 resistor, cavity A. Refer to Wiring Repairs in Wiring — Go to H V A C —
Systems. Blower Controls
Replace the HVAC control module. Refer to Control Go to HVAC

2. Place the blower switch in the M1 position, next to
the LO position.
resistor connector, cavity C, and ground.
module.
2. Connect a J 39200 (continuity) between pins B and G
the Low position).
Replace the blower motor resistor. Refer to Blower Motor Goto HVAC
Replace the HVAC control module. Refer to Control Go to H V A C
Locate and repair the open in CKT 63 (TAN) between the
HVAC control module and the blower resistor. Refer to Go to H V A C
6 Wiring Repairs in Wiring Systems. -- —
Blower Controls
Has the HVAC Blower Controls System Check been Go to HVAC
2. Place the blower switch in the Med2 position (next to
the HI position).
resistor connector, cavity D, and ground.
module.
2. Connect a J 39200 (continuity) between pins G and A
the HI position).
Replace the blower resistor. Refer to Blower Motor Goto HVAC
4 Resistor Replacement — Blower Controls
Replace the HVAC control module. Refer to Control G oto HVAC
5 Assembly Replacement ■ ■ - ■— Blower Controls —
Locate and repair the open in CKT 72 (LT BLU) between
the HVAC control module and the blower resistor. Go to HVAC
6 — — '
Refer to Wiring Repairs in Wiring Systems. Blower Controls
Noise Diagnosis Moans

Blower Noise Potential causes include the following conditions:
A constant air rush noise is typical of high speed • The A/C charge is not proper.
blower operation. Some systems and modes are more • Other drive components are faulty.
noisy than other systems. If possible, verify the
• A bracket is loose or is not in proper alignment.
noise using a similar vehicle in order to determine if
the noise is typical or excessive. • The lines or the hoses are in contact with
each other.
Vibration/Rattle
• The heater hoses are not correctly routed.
Important: Feel the lines, the hoses, and the brackets
during the diagnosis. Many noises stop when you Screech
contact the component. Potential causes include the following conditions:
Potential causes include the following conditions:
• The belt is serpentine.
• The belt is not in proper alignment in the
pulley groove. • The compressor bearings are faulty.
• The belt tensioner is faulty. • The compressor clutch is faulty.
• The lines or the hoses are in contact with
each other.
• The brackets are loose.
• Other drive components are faulty.
Blower Motor Operates at High Speed O nly
Step Action , Value(s) Yes m
2 2. Conect a J 39200 (continuity) between pins B2 and C1 —
of the relay.
Replace the blower motor relay high. Refer to B l o w e r M o t o r Go to H V A C
3 R e la y R e p la c e m e n t — Blower Controls
is the repair complete? System Check
1. Disconnect the connector at the blower motor resistor.
2. Connect a J 39200 (continuity) between the blower
4 motor resistor connector cavity B and the blower motor —
relay high, cavity B2.
Locate and repair the open in CKT 101 (DK BLU) between
the blower motor resistor and the blower motor relay high. Go to H V A C
5 Refer to Wiring Repairs in Wiring Systems. —
Blower Controls
2. Rotate the blower switch through all speeds while
6 using a J 39200 (continuity) checking for continuity —
between pin G and the remaining pins of connector C2
(see scnoi i laiiu for appropriate pin to speed callout).
Is continuity present in all modes? Go to Step 7 Go to Step 8
Replace the blower motor resistor. Refer to Blower Motor Go to H V A C
Replace the HVAC control module. Refer to Control Goto H V A C
Blower Motor High Speed Inoperative

2 2. Connect a J 39200 between pins C2 and A1 of the —
Replace the blower motor relay high. Refer to Blower Go to H V A C
3 Motor Relay Replacement — Blower Controls —
relay high and pin C2 and B+.
4 relay high and pin A1 and ground. —
3. Connect a J 39200 between pins A2 and C1 of the
Blower Motor High Speed Inoperative (cont’d)
Step Action Value(s) Yes Wo
Connect a J 39200 between the blower motor relay high
5 cavity A1 and ground. —■
blower motor relay high and ground G202. Refer to Wiring Go to HVAC
Blower Controls
Connect a J 39200 between the blower motor relay high
7 cavity A2 and ground. — '
underhood block and the blower motor relay high. Refer to Goto HVAC
8 Wiring Repairs in Wiring Systems. — —
Blower Controls
module.
2. Connect a J 39200 (continuity) between the HVAC
9 control module connector C2, cavities H and G. — .
3. Turn the HVAC control module to the HIGH position.
Locate and repair the open in CKT 52 (ORN) between the
HVAC control module and the blower motor relay high. Go to HVAC
10 Refer to Wiring Repairs m Wiring Systems. — —
Blower Controls
Replace the HVAC control module. Refer to Control Go to HVAC
11 Assembly Replacement. — ■■ Blower Controls —
Blower Motor Always O n

1 performed? ' — . Blower Controls
1. Remove the high blower motor relay.
2 2. Place the ignition switch in the RUN position.
—
3. Place the blower motor switch in the OFF position.
Does the blower motor operate? Go to Step 3 Go to Step 4
Locate and repair the short to voltage in CKT 65 (PPL)
between the high blower motor relay and the blower Goto HVAC
3 motor. Refer to Wiring Repairs in Wiring Systems. — —
Blower Controls
Connect a J 39200 (continuity) between pins C1 and A2 of
4 the relay. —
Replace the high blower motor relay. Refer to Blower Go to HVAC
5 Motor Relay Replacement. .. — Blower Controls —
6 2. Connect a J 39200 (volts) between cavity C2 of the 1 volt
Is voltage above the value given? Go to Step 7 Go to Step 8
Blower Motor Always On (cont’d)
Locate and repair the short to voltage in CKT 52 (ORN)
between the blower switch and the blower motor relay Go to H V A C
7 high. Refer to W irin g R e p a ir s in Wiring Systems. — —
resistor.
8 2. Connect a J 3 9 2 0 0 (volts) between cavity B2 of the 1 volt
Is voltage above the value given? Go to S te p 9 Go to S te p 1 0
Repair the short to voltage in CKT 101 (DK BLU) between
the blower motor resistor and the high blower motor relay. Go to H V A C
1. With the HVAC control module connector C2
disconnected. Connect a J 3 9 2 0 0 (continuity)
between pin G and the remaining pins of the HVAC
10 control module. —
2. Ensure that the blower switch is in the OFF position.
Is continuity present between any pins expect pin D? Go to S te p 11 Go to S te p 1 2
Replace the HVAC control module. Refer to C o n tr o l Go to H V A C
11 A s s e m b ly R e p la c e m e n t. — B lo w e r C o n tro ls —
With the blower resister and the HVAC control module
connector G2 disconnected. Connect a J 3 9 2 0 0 (volts)
12 between pins A, C and D of the blower resister connector 0.5 volts
and ground.
Is voltage reading greater than the value given? Goto S te p 1 3 Go to S te p 1 4
Locate and repair the short to voltage in the circuit related
to the pin tested. Refer to W irin g R e p a ir s in Wiring Go to H V A C
13 Systems. — —
Locate and repair the short to voltage within the blower Goto H V A C
14 resister. Refer W irin g R e p a ir s in Wiring Systems. — B lo w e r C o n tro ls —
Blower Motor Inoperative at Any Speed - Auxiliary

1 performed? — . B lo w e r C o n tro ls
Goto S t e p 2 S y s te m C h e c k
1. Disconnect the auxiliary HVAC control module, Front
switch.
2 2. Connect a J 3 9 2 0 0 (continuity) between cavity B of ■■ —
the switch connector and ground.
Locate and repair the open in CKT 150 (BLK) between
the auxiliary HVAC control module, front switch and Go to H V A C
3 ground G200. Refer to W irin g R e p a ir s in Wiring Systems. — —
Connect a J 3 9 2 0 0 (continuity) between pin B and
pins C, E, D and F while rotating the blower switch through
4 Low, Med, High and Rear. —
Is continuity present in all modes? Go to S te p 6 Go to S t e p S
Blower Motor Inoperative at Any Speed - Auxiliary (cont’d)
Replace the auxiliary HVAC control module, front switch.
Refer to Control Assembly Replacement - Front Go to HVAC
5 Auxiliary A/C. — —
Blower Controls
1. Disconnect the auxiliary blower resistor connector.
2. Disconnect the auxiliary blower motor connector.
6 3. Connect a J 39200 (continuity) between cavity B of — ■
the resistor connector and cavity A of the blower
motor connector.
splice S402 and the blower motor. Refer to Wiring Repairs Go to HVAC
7 in Wiring Systems. —
Blower Controls
Connect a J 39200 (continuity) between cavity B of the
8 blower motor connector and ground. —
Replace the Auxiliary Blower Motor. Refer to Blower Motor
and Fan Replacement - Auxiliary (Suburban), Blower Go to HVAC
9 Motor and Fan Replacement - Auxiliary (4-Door Utility) . — —
Blower Controls
blower motor and ground G400. Refer to Wiring Repairs in Go to HVAC
Blower Controls
Blower Motor Low Speed Inoperative - Auxiliary

Step Action Value(s) Yes . No
1 performed? ■ — ■ Blower Controls
1. Remove the auxiliary blower motor relay, low.
Replace the auxiliary blower motor relay, low. Refer to Goto HVAC
3 Blower Motor Relay Replacement. — Blower Controls —
1. Remove the auxiliary HVAC control modules, front
and rear.
2. Connect a J 39200 (continuity) between pins C and E
4
of both switches. —
3. Rotate the switch to Low.
Replace the auxiliary HVAC control module. Refer to
Control Assembly Replacement - Front Auxiliary A/C,
5 Control Assembly Replacement - Auxiliary (Suburban), or — Go to HVAC —'
Control Assembly Replacement - Auxiliary (4-Door Utility). Blower Controls
6 2. Connect a J 39200 (continuity) between pins C and B —
of the resistors connector.
Blower Motor Low Speed inoperative - Auxiliaryf (cont’d)
Step ction Value(s) Yes No
Replace the auxiliary blower resistor. Refer to Blower
Motor Resistor Replacement - Auxiliary (Suburban),
7 Blower Motor Resistor Replacement - Auxiliary — Go to H V A C —-
(4-Door Utility). Blower Controls
Connect a J 39200 (volts) between cavity 1 of the high
Is battery voltage present? Go to Step 10 Go to S te p 9
cavity 1 of the auxiliary blower relay, low and splice S401. Go to H V A C
Blower Controls
Locate and repair the open in CKT 1926 (DK BLU)
between the auxiliary blower motor relay, low and the
10 auxiliary HVAC control modules, front and rear. Refer to — Go to H V A C
Wiring Repairs in Wiring Systems. Blower C o n t r o l s
Blower Motor Medium Speed Inoperative - Auxiliary

Step Action "Value(s) ■ Yes No
1. Remove the auxiliary blower motor relay, medium.
2 2. Connect a fused jumper wire between cavities 1 and 4
—.
Replace the auxiliary blower motor relay, medium. Refer to Go to HVAC
3 Blower Motor Relay Replacement - Auxiliary. — Blower Controls —-
1. Remove the auxiliary HVAC control modules, front
and rear.
2. Connect a J 39200 (continuity) between pins B and E,
4 and B and F of the front switch, and F and E of the rear —'
switch.
3. Rotate the switch to Med.
Control Assembly Replacement - Front Auxiliary A/C
/Control Assembly Replacement - Auxiliary
5 (Suburban), Control Assembly Replacement - Auxiliary — —
Go to HVAC
(4-Door Utility). Blower Controls
6 2. Connect a J 39200 (continuity) between pins A and B —
of the resistors connector.
Replace the auxiliary blower resistor. Refer to Blower Motor
Resistor Replacement - Auxiliary (Suburban), Blower Motor Go to HVAC
7 Resistor Replacement - Auxiliary (4-Door Utility). — —
Blower Controls
Blower Motor Medium Speed Inoperative - Auxiliary (cont’d)
Connect a J 39200 (volts) between cavity 1 of the high
cavity 1 of the auxiliary blower relay, medium and Go to HVAC
9 splice S401. Refer to Wiring Repairs in Wiring Systems. — —
Blower Controls
the auxiliary blower motor relay, medium and the auxiliary
10 HVAC control modules. Refer to Wiring Repairs in Wiring — Go to HVAC —
Systems. Blower Controls
Blower Motor High Speed Inoperative - Auxiliary

1. Remove the auxiliary blower motor relay, high.

2- 2. Connect a fused jumper wire between cavities 1 and 4 —
Replace the auxiliary blower motor relay, high. Refer to Go to HVAC
3 Blower Motor Relay Replacement - Auxiliary. — Blower Controls —

2. Connect a J 39200 (continuity) between pins B and D
of the switch.
3. Rotate the switch to High.
4 —
4. Connect a J 39200 (continuity) between pins B and F
of the switch.
5. Rotate the switch to Rear.
Is continuity present in both positions? Goto Step 6 Go to Step 5
5 Control Assembly Replacement - Front Auxiliary A/C. — — —
1. Remove the auxiliary HVAC control module, rear.

2. Connect a J 39200 (continuity) between pins F and D
6 of the switch. —
3. Rotate the switch to High.
Replace the auxiliary HVAC control module, rear. Refer to
Control Assembly Replacement - Auxiliary (Suburban), Goto HVAC __
7 Control Assembly Replacement - Auxiliary (4-Door Utility). —
Blower Controls
1. Remove the auxiliary blower motor connector.

8 2. Connect a J 39200 (continuity) between cavity 4 of the —
high relay socket and cavity A of the blower connector.
Blower Motor High Speed Inoperative - Auxiliary (cont’d)
Locate and repair the open in CKT YEL (1172) between
the auxiliary blower relay, high and splice S402. Refer to Go to H V A C
cavity 1 of the auxiliary blower relay, high and splice S401. Go to H V A C
the auxiliary blower motor relay, high and the auxiliary
12 HVAC control modules, front and rear. Refer to W irin g — . Go to H V A C —
R e p a ir s in Wiring Systems. B lo w e r C o n tro ls
Blower Motor Operates Continuously - Auxiliary

1. Remove the auxiliary blower motor relays.
2 2. Listen for the blower motor to shut off after removing •—
each relay.
Does the auxiliary blower motor stop running? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower motor relay that you last
removed. Refer to B lo w e r M o to r R e la y R e p la c e m e n t - Go to H V A C
3 A u x ilia ry . — —
Connect a J 3 9 2 0 0 (volts) between cavity 4 of the high Go to H V A C
4 relay socket and ground. 1 volt B lo w e r C o n tro ls
Is voltage greater than the value given? Go to S te p 5 S y s te m C h e c k
Locate and repair the short to voltage in CKT 1172 (YEL)
between the auxiliary blower motor, the auxiliary blower
5 motor relay, high and the auxiliary blower resistor. Refer to — Goto H V A C —
W irin g R e p a ir s in Wiring Systems. B lo w e r C o n tro ls
Blower Motor Operates at High Speed Only - Auxiliary

1. Disconnect the auxiliary blower resistor.
2. Connect a jumper wire between cavities A and B of
2 the resistor connector.
—
3. Rotate the auxiliary HVAC control module switch to
the Med position.
Does the auxiliary blower motor spin? Go to S te p 3 Go to S te p 4
Replace the auxiliary blower resistor. Refer to B lo w e r
M o to r R e s is to r R e p la c e m e n t - A u x ilia r y (S u b u r b a n )
3 /B lo w e r M o to r R e s is to r R e p la c e m e n t - A u x ilia r y — Goto H V A C
(4 - D o o r U tility ). B lo w e r C o n tro ls
Blower Motor Operates at High Speed Only - Auxiliary (cont’d)
1. Disconnect the auxiliary blower motor.
2. Connect a J 39200 (continuity) between cavity B of
4 the resistor connector and cavity A of the blower —
connector.
the resistor connector and splice S402. Refer to Wiring Go to HVAC
Blower Controls
1. Connect all disconnect components.
2. Remove both the low and medium auxiliary blower
motor relays.
3. Connect a fused jumper wire between cavities 5
6 and 2 of both socket relays with the blower switch in —
Low and Med.
4. Switch the front auxiliary switch to Rear.
5. Rotate the rear switch to both Med and Low.
Does the auxiliary blower motor operate in all positions
tested? Go to Step 10 Go to Step 7
1. Remove both the front and rear Auxiliary HVAC
Control Modules.
2. Using a J 39200 (continuity) test each switch for
7 continuity between the ground pin and the Low and —
Med pins of the switch.
3. Check the front switch set in the Rear position.
Is continuity present on both switches? Go to Step 9 Go to Step 8
Control Assembly Replacement - Front Auxiliary A/C,
8 Control Assembly Replacement - Auxiliary (Suburban), or — Go to HVAC —
Control Assembly Replacement - Auxiliary (4-Door Utility)). Blower Controls
Locate and repair the open the circuit(s) between cavity 2 of
the relay socket and the auxiliary HVAC control modules, Go to HVAC
9 front and rear. Refer to Wiring Repairs in Wiring Systems. —
Blower Controls
Replace both auxiliary blower motor relays. Refer to Blower Go to HVAC
10 Motor Relay Replacement - Auxiliary. — Blower Controls —
Vacuum System
Condition Action
defroster nozzle.
The mode actuator is faulty. 1. inspect the operation of the defroster air valve.
The defroster is not emitting Refer to Heating Insufficient.
sufficient heat.
System Performance Test (Dual Range Temperatures)
Tools Required 20. Operate the air conditioning system for
J21213-A Four Jack Dual Range Temperature Tester 10 minutes.
1. Park the vehicle indoors or in a shaded area. 21. Record the following data:
• The outlet air temperature
2. Open the hood, the doors, and the windows in
order to ventilate the interior. • The high-side pressure
• The low-side pressure
3. Vent the engine exhaust, if necessary.
22. Turn the ignition to the OFF position.
4. Install the high and low side pressure gauges. 23. Compare the readings to the table below.
5. Route the lines over the front of the grille. 24. If you suspect a malfunction in the refrigerant
6. Close the hood completely. system due to abnormal system pressures,
7. Record the ambient temperature near the vehicle. inspect the system for the following conditions:
24.1. The outer surfaces of the radiator and the
8. Record the temperature and the relative humidity
condenser cores are blocked by dirt,
by using a psychrometer or by consulting the local
leaves, or other material.
weather bureau.
24.2. The areas between the condenser and
9. Close the doors. radiator are clogged with dirt, leaves and
10. Close all of the windows except for the front side other material.
windows. 24.3. The evaporator core, the condenser core,
11. Set the mode control to the A/C position. the hoses, the tubes and other
components are restricted or kinked.
12. Set the blower control on the HIGH position.
24.4. The system is leaking refrigerant.
13. Set the temperature control to the 24.5. The air ducts have leaks or restrictions.
FULL COLD position. 24.6. The airflow rate is low due to a restriction
14. Open the air conditioning outlets. in the evaporator core.
15. Install the J21213-A into the right center air 24.7. The compressor clutch slips.
conditioning outlet. 24.8. The drive belt tension is improper.
16. Place the transmission in park. 24.9. The accumulator is plugged.
24.10. The expansion (orifice) tube is plugged.
25. If you do not find a condition, continue with the
18. Stabilize the engine speed at 1500 RPM. CCOT A/C System Diagnosis. Refer to CCOT
19. Start the timer. A/C System Diagnosis.
System Performance Test Dual Range Temperatures)
Maximum Center
Ambient Air Maximum Low Air Outlet Maximum High
Relative Humidity Temperature Side Pressure Engine Speed Temperature Side Pressure
26.7°C 220 kPa 10.6°C 1 572 kPa
(80°F) (32 psi) (51 °F) (228 psi)
26.7°C 268 kPa 10.6°C 1 931 kPa
(90° F) (39 psi) 59°F (280 psi)
37.8°C 308 kPa 18.9°C 2 075 kPa
40%
(100°F) (44 psi) (66°F) 301 psi
43.3°C 317 kPa 23.9°C 2 255 kPa
(110°F) (46 psi) (75°F) (327 psi)
48.9°C1 310 kPa1 17.2°C1 2 530 kPa1
1500 RPM
(120°F)1 (45 psi)1 (63° F)1 (367 psi)1
21.1°C2 193 kPa2 6.1°C2 1 103 kPa2
50%
(70°F)2 (28 psi)2 (43°F)2 (160°F)2
21.1°C 234 kPa 12.2°C 1 572 kPa
(70° F) (34 psi) (54°F) (228 psi)
70%
32.2°C 324 kPa 18.3°C 2 006 kPa
(90° F) (47 psi) (65° F) 291 psi
26.7°C 268 kPa 14.4°C 1 731 kPa
80%
(80° F) 39 psi 58°F) (251 psi)
1Determine in MAX A/C with all of the windows closed.
2The compressor cycles ON and OFF.
Refrigerant System Checks Electronic Leak Detector
Perform the following test in order to determine Tools Required
whether the electrical, vacuum and refrigeration J 39400-A Electronic Leak Detector
systems operate properly.
* The electrical circuits operate properly if the
following conditions are true:
- Proper operation of the air conditioning
modes and the blower at all speeds with the
mode lever in any position except OFF
- Engagement of the compressor clutch
® The system is properly charged when the
evaporator pipe and the accumulator surface have
the same hand-felt temperature.
Leak Testing
Caution: Avoid breathing A/C Refrigerant-134a and
lubricant vapor and mist. Exposure may irritate
eyes, nose and throat. To remove R-134a from the
A/C system, use service equipment certified to
meet the requirements of SAE J2210 (R-134a
recycling equipment), if accidental system 257951
discharge occurs, ventilate work area before
resuming service. Additional health and safety This type of leak detector is the most useful tool in
information may be obtained from refrigerant and locating refrigerant leaks. The J 39400-A is a small unit
that operates on 12V DC. The J 39400-A provides
lubricant manufacturers.
an audible signal that increases in frequency as
Perform a refrigerant leak test on the system whenever R-134a is detected. Make sure the instrument is
you suspect a leak. Perform a refrigerant leak test properly calibrated in accordance with the included
instructions. Use the detector in the proper setting for
on the system following a service operation that
the type of refrigerant being tested. Place the detector
disturbs the components, the lines, or the connections.
GAS switch in the R-134a setting prior to use./
Many methods and special tools are available for
this purpose. However, no matter which tool is used,
care and diligence are the biggest keys to success.
The most common leaks are found at the refrigerant
fittings or connections. The causes of common
leaks may be the following conditions:
• Improper torque
• Damaged O-ring seals
• Dirt and debris across the O-ring seals
Even the smallest piece of lint from cotton gloves or
shop cloths can create a leak path across an
O-ring seal.
Circle each joint completely. Move the probe at

25-51 mm (1-2 in) per second. Move the tip of the
probe as close to the surface as possible, but no more
than 6 mm (0.25 in) away. Do not block the air
intake. The audible tone going from a steady
1-2 clicks per second to an a solid alarm indicates a
leak. Frequently adjust the balance knob in order
to maintain the rate of 1-2 clicks per second.
Test Procedure
Caution: Take care to prevent personal injury
which could occur due to touching a hot engine
Important: The halogen leak detectors are sensitive when testing. Tests should be done with the
to windshield washing solutions, many solvents engine “Off” and as cool as possible. Do not
and cleaners, and some adhesives used in the vehicle operate the detector in a combustible atmosphere
Prevent a false warning by making sure the surfaces since Its sensor operates at high temperature.
are clean. Also, the surfaces should be dry, because
the ingestion of liquids damages the detector. Important: Always follow the refrigerant system in a
continuous path, so that no areas of potential leaks are
The successful use of this and any other electronic missed. Always test all of the areas listed below in
leak detector depends greatly upon the scan rate. order to make sure the entire system is leak-free, even
The successful use of the detector depends upon the when one leak is already found.
carefully following the manufacturer’s instructions Use this procedure in order to test the following
regarding calibration, operation and maintenance. components and locations in the system:
• The evaporator inlet and outlet
• The accumulator inlet and outlet
• The condenser inlet and outlet
• All of the brazed and welded areas
• The areas showing signs of damage
• The hose couplings
• The compressor rear head
• The housing joints
Service Ports/Access Valves 3. Remove the blower motor resistor. Refer to
The primary seal for the service ports is the sealing Blower Motor Resistor Replacement.
cap. This cap contains a specially designed O-ring seal 4. Insert the probe of the leak detector as close to
or gasket that provides a leak-free seal. A loose or the evaporator as possible.
missing cap, or using the wrong cap, results in the loss A solid alarm indicates the discovery of a leak.
of the refrigerant charge. 5. If possible, visually inspect the core face for
Evaporator Core evidence of refrigerant oil. Use a flashlight.
Finding leaks in the evaporator core is very difficult. In Compressor Block Fitting and Shaft Seal
order to leak test the core, complete the Complete the following steps:
following steps: 1. Blow shop air behind and in front of the
1. Turn the blower fan to the HI position for compressor clutch/puller for at least 15 seconds.
15 seconds or longer. 2. Wait 1-2 minutes.
Then, turn the blower fan to the OFF position. 3. Probe the area in front of the pulley.
2. Wait 10 minutes. A solid alarm indicates the discovery of a leak.
CCOT A/C System Diagnosis
Inspect the following components of the A/C system:
• The fuses
1 • The wire connectors —
• The blower fan operation
Did you find and repair a condition? System OK Go to Step 2
2 Is the drive belt loose, missing, or damaged? — Go to Step 4 Go to Step 3
Important: The ambient temperature must be above 10°C
(50°F) for completion of this diagnostic procedure.
Inspect the compressor clutch engagement by following
these steps:
2. Idle the engine at approximately 1000 RPM.
3 —
3. Set the A/C control assembly to the NORM position.
4. Set the blower to the HIGH position.
5. Place an auxiliary fan in front of the vehicle.
6. Observe the clutch operation for a period of
5 minutes.
Does the clutch engage or cycle? Go to Step 7 Go to Step 11
4 Has the compressor seized? — ' Go to Step 5 Go to Step 6
1. Replace the compressor assembly.
2. Replace the orifice.
3. Recover the refrigerant.
5 —
4. Evacuate the system.
5. Charge the system.
Does the air conditioning system operate properly? System OK Go to Step 6
Tighten or replace the belt, as needed.
6 —
Feel the liquid line before the orifice tube.
7 —
Is the liquid line cold? Go to Step 8 Go to Step 9
1. Inspect the high side of the system for a frost spot in
order to locate a restriction.
2. Repair the restriction.
8 3. Recover the refrigerant. —
Is the air condition system operating properly? System OK Go to Step 9
CCOT A/C System Diagnosis (cont’d)
1. Feel the evaporator inlet pipe.
9. 2. Feel the evaporator outlet pipe. —
Is the inlet pipe colder than the outlet pipe? Go to Step 10 Go to Step 24
1. Conduct a leak test of the system. Refer to V a c u u m
S y s te m . :
2. Repair any leaks, as necessary.
3. If you repaired a leak, complete the following steps:
10 —
3.1. Recover the refrigerant.
3.2. Evacuate the system.
3.3. Charge the system.
1. Connect a fused jumper wire from the compressor
hot lead to the positive battery post.
11 .. —
2. Observe the compressor operation.
Does the compressor clutch engage? Go to Step 12 Go to Step 18
1. Remove the jumper.
345 kPa
12 2. Measure the pressure at the accumulator fitting. (50 psi)
Is the pressure below the specified value? Go to Step 13 Go to Step 15
Measure the refrigerant pressure on the high side of the
system. 345 kPa
13
(50 psi)
Is the pressure above the specified value? Go to S te p 14 an fn Qfep 10
2. Inspect for the following conditions:
2.1. A plugged orifice
2.2. A restriction in the high side of the system
14 3. Complete the necessary repairs, or replace the —
orifice.
Connect a fused jumper wire between the pressure switch
15 and the positive battery post. —
Does the compressor operate? Go to Step 16 Go to Step 17
Important: Do not recover the refrigerant. The fitting has a
Schrader Valve®.
16 —
Replace the pressure switch.
1. Inspect the pressure switch for an open circuit or a
broken wire.
17 —
2. Complete any necessary repairs.
is the air condition system operating properly? System OK Go to Step 7
Apply an external ground to the compressor.
18 '—
Does the compressor clutch engage? System OK Go to Step 19
Rebuild the compressor.
19 —
1. Add 0.45 kg (1 Ib) of refrigerant to the system.
20 2. Inspect the clutch cycle rate. 8 cycles/minute
Is the clutch cycle rate greater than the specified value? Go to Step 21 Go to Step 22
■CCOT A /C ;S ystem Diagin o sis '(c o n t’d)
Step Action Value(s) Yes Ho
2. Inspect the system for a plugged orifice.
3. Repair the orifice as necessary.
21 ■—
22 2. Feel the evaporator outlet pipe. —
Is the inlet pipe colder than the outlet pipe? Go to Step 23 System OK
1. Add 0.45 kg (1 Ib) of refrigerant to the system.
23 —
3. Feel the evaporator outlet pipe.
Is the inlet pipe colder than the outlet pipe? Go to Step 21 System OK
1. Install a gauge set.
2. Inspect the compressor cycling pressure. 280-350 kPa
24 (41-51 psi)
Does the compressor cycle on within the specified
value range? Go to Step 25 Go to Step 27
Does the compressor cycle off within the specified 140-190 kPa
25 value range? (20-28 psi) Go to Step 26 Go to Step 27
1. Set the A/C control assembly to the MAX position.
2. Set the temperature setting to full cold position.
3. Set the blower to the HIGH position.
4. Stabilize the engine speed for 5 minutes.
26 5. Install a thermometer in the A/C outlet. —:■
6. Perform the Performance Test. Refer to System
Performance Test (Dual Range Temperatures).
Is the temperature performance within the limits of the test
specifications? System OK Go to Step 10
Does the compressor cycle high on above the 350 kPa
27 specified value? (51 psi) Go to Step 28 Go to Step 29
Does the compressor cycle OFF below the 140 kPa
28 specified value? (20 psi) Go to Step 16 Go to Step 29
1. Disconnect the blower wire.
2. Determine when the compressor cycles OFF. 140 kPa
29 (20 psi)
Does the compressor cycle off below the specified
value range? Go to Step 16 Go to Step 30
Reconnect the blower motor wire. __
30 —
Is the wire reconnected? Go to Step 26
Observe the compressor cycling.
31 —
Does the compressor cycle ON continuously? Go to Step 32 ■ Go to Step 21
32 2. Inspect the orifice. —
Is the orifice missing? Go to Step 33 Go to Step 34
1. Install the orifice.
33 —
Inspect the suction line.
34 —
Is the suction line restricted? Go to Step 35 Go to Step 36 \
CCOT A/C System Diagnosis (cont’d]
Step Action Value(s) Yes IXio
1. Repair the suction line, as required.
35 —
1. Evacuate the system
36 2. Charge the system — —
Does the air conditioning system operate properly? System OK
Mode Actuator Inoperative (Front)

Has the HVAC Air Delivery System Check been Go to HVAC Air
1 performed? — Delivery
2. Disconnect the connector at the front mode
2 door motor.
—
3. Connect a J 39200 (volts) between the front mode
door motor connector, cavity 10, and ground.
Locate and repair the open in CKT 141 (BRN) between the
IP fuse block and the front mode door motor. Refer to Go to HVAC Air
3 Wiring Repairs in Wiring Systems. — —
Delivery
Connect a J 39200 (continuity) between the front mode
4 door motor connector, cavity 7, and ground. —
front mode door motor and splice S244. Refer to Wiring Go to HVAC Air
5 Repairs in Wiring Systems. . — —
Delivery
2. Place the blower switch on the HVAC control module
in the LO position.
3. Make sure that the front blower motor is operating.
6 4. Connect a J 39200 (volts) from the front mode door —
motor connector, cavity 8, to ground.
5. Adjust the position of the mode control dial while
observing the J 39200 response.
Is the J 39200 response a smooth, variable voltage? Go to Step 9 Go to Step 7
1. Disconect connector C3 at the HVAC control module.
2. Connect a J 39200 (volts) between pin 9 of the HVAC
7 control module, and ground.
—
3. Adjust the position of the mode control dial while
observing the J 39200 response.
Locate and repair the open or cause of resistance in
CKT 454 (WHT) between the HVAC control module and the
8 front mode door motor. Refer to Wiring Repairs in Wiring — Go to HVAC Air —
Systems. Delivery
Replace the front mode door motor. Refer to Mode Actuator Go to HVAC Air
9 Replacement — Delivery —
Replace the HVAC control module. Refer to Control Goto HVAC Air
10 Assembly Replacement — Delivery —
Mode Actuator Inoperative (Rear)
Has the HVAC Air Delivery System Cheek been Go to H V A C A i r
1 performed? — D e liv e r y
Go to S t e p 2 S y s te m C h e c k

2. Backprobe a J 3 9 2 0 0 (volts) from the auxiliary HVAC
control logic module connector, cavity F, to ground.
2 3. Adjust the mode control dial at the front and rear —
auxiliary HVAC control modules while monitoring
the J 3 9 2 0 0 .
Does the J 3 9 2 0 0 indicate a smooth, variable voltage? Go to S t e p 3 Go to S t e p 1 0
1. Turn the ignition switch to the OFF position.
2. Disconnect the connector at the auxiliary HVAC
control logic module.
3 3. Disconnect the auxiliary mode door motor connector. —
4. Connect a J 3 9 2 0 0 (continuity) between the auxiliary
HVAC control logic module connector, cavity F, and
cavity 8 of the auxiliary mode door motor connector.
Is continuity present? Go to S t e p 5 Go to S t e p 4
the auxiliary HVAC control logic module and the auxiliary
4 mode door motor. Refer to W i r i n g R e p a i r s in Wiring — Go to H V A C A i r —
Systems. D e liv e r y
Connect a J 3 9 2 0 0 (continuity) between cavity 7 of the
5 auxiliary mode door motor connector and ground. —
Is continuity present? Go to S t e p 7 Go to S t e p 6
auxiliary mode door motor and splice S403. Refer to Go to H V A C A i r
6 W i r i n g R e p a i r s in Wiring Systems. — —
D e liv e r y
Connect a J 3 9 2 0 0 (volts) between cavity 10 of the
7 auxiliary mode door motor connector and ground. —
Is battery voltage present? Go to S t e p 9 Go to S t e p 8
auxiliary mode door motor and splice S400. Refer to Go to H V A C A i r
8 W i r i n g R e p a i r s in Wiring Systems. — —
D e liv e r y
Replace the auxiliary mode door motor. Refer to M o d e Go to H V A C A i r
9 A c t u a t o r R e p la c e m e n t - A u x ilia r y . — D e liv e r y —
1. Disconnect the auxiliary HVAC control logic module.

2. Connect a J 3 9 2 0 0 (volts) between cavity J of the
10 auxiliary HVAC control logic module connector and —
ground.
Is voltage present? Go to S t e p 1 - Go to S t e p 1 1
auxiliary HVAC control logic module and splice S308. Go to H V A C / !■
11 Refer to W i r i n g R e p a i r s in Wiring Systems. — —
D e liv e r y
1. Connect a J 3 9 2 0 0 ( v o l t s ) between cavity E of the

auxiliary HVAC control logic module connector and
12 ground. —
2. Repeat the same test for cavity D.
Does the J 3 9 2 0 0 indicate a smooth, variable voltage? Go to S t e p 1 3 Go to S t e p 1 4
Mode Actuator Inoperative (Rear) (cont’d)
Replace the auxiliary HVAC control logic module. Go to H V A C A ir
13 Is the repair complete? — D e liv e r y —
S y s te m C h e c k
• If cavity E of step 12 failed complete the following test
for the front auxiliary HVAC control module.
• If cavity D of step 12 failed complete the following test
for the rear auxiliary HVAC control module.
• If both circuits failed complete the following test for
both control modules.
14 1. Backprobe a J 3 9 2 0 0 (volts) between cavity J of —
the auxiliary HVAC control module being tested
and ground.
2. Adjust the mode control dial at the auxiliary
HVAC control module while monitoring the
J 39200.
Does the J 3 9 2 0 0 indicate a smooth, variable voltage? Go to S te p 1 6 Go to S te p 1 5
Replace the auxiliary HVAC module that was tested in
step 14. Refer to C o n tro l A s s e m b ly R e p la c e m e n t - F r o n t
A u x ilia r y A /C (front)lC o n tr o l A s s e m b ly R e p la c e m e n t -
15 A u x ilia r y (S u b u r b a n ) (rear, Suburban) or C o n tr o l A s s e m b ly — —
Goto H V A C A ir
R e p la c e m e n t - A u x ilia r y ( 4 - D o o r U tility ) (rear, 4dr Utility). D e liv e r y
Locate the open or cause of resistance in CKT 920
(DK BLU) between the auxiliary HVAC control logic
module and the rear auxiliary HVAC control module and
16 the or CKT 919 (LT BLU) to the front auxiliary HVAC — —
Go to H V A C A ir
control module. Refer to W irin g R e p a ir s in Wiring Systems. D e liv e r y
Air Inlet Actuator Inoperative

Has the HVAC Air Delivery System Check been Go to H V A C A ir
1 performed? — . D e liv e r y
2. Place the blower control switch in Med 1.
2 3. Push in the recirculation button. —
4. Backprobe a J 3 9 2 0 0 (volts) between cavity 4 of the
HVAC control module and ground.
Is battery voltage present? Go to S te p 3 Go to S te p 1 0
1. Disconnect the connector at the recirculation
door motor.
3 2. Connect a J 3 9 2 0 0 (volts) between the recirculation
door motor connector, cavity 6, and ground. — ..
3. Ensure that the recirculation button is pushed in.
Repair the open in CKT 1614 (DK GRN) between the
HVAC control module and the recirculation door motor. Goto H V A C A ir
D e liv e r y
Air inlet Actuator Inoperative (cont’d]
Connect a J 3 9 2 0 0 (volts) between the recirculation door
5 motor connector, cavity 5, and the ground. —
Locate and repair the open in CKT 141 (BRN) between
splice S243 and the recirculation door motor. Refer to Go to H V A C A ir
D e liv e r y
Connect a J 3 9 2 0 0 (continuity) between the recirculation
7 door motor connector, cavity 6, and ground.
recirculation door motor and splice S244. Refer to W irin g Go to H V A C A ir
8 R e p a ir s in Wiring Systems. —■ —
D e liv e r y
1. Ensure the recirculation door flap is not binding.
Go to H V A C A ir
9 2. Replace the recirculation door motor. . — D e liv e r y —
module.
10 2. Connect a J 3 9 2 0 0 (volts) between the HVAC control —
module connector C3, cavity 5, and ground.
Is battery voltage present? Go to S te p 11 Go to S te p 1 2
Replace the HVAC control module. Refer to C o n tr o l Go to H V A C A ir
11 A s s e m b ly R e p la c e m e n t — D e liv e r y .—
Locate and repair the open in CKT 141 (BRN) between
splice S268 and the HVAC control module. Refer to W irin g Go to H V A C A ir
D e liv e r y
Temperature Actuator Inoperative (Front)

Has the HVAC Air Delivery System Check been Goto H V A C A ir
1 performed? — D e liv e r y
2. Disconnect the connector at the front temperature
door motor.
2 3. Connect a J 3 9 2 0 0 (volts) between the front — .
temperature door motor connector, cavity 10, and
ground.
IP fuse block and the front mode door motor. Refer to Goto H V A C A ir
D e liv e r y
Connect a J 3 9 2 0 0 (continuity) between the front
4 temperature door motor connector, cavity 7, and ground. —
front temperature door motor and splice S244. Refer to Go to H V A C A ir
D e liv e r y
Temperature Actuator Inoperative (Front) (cont’d)
2. Place the blower switch on the HVAC control module
in the LO position.
3. Make sure that the front blower motor is operating.
6 4. Connect a J 39200 (volts) from the front temperature —
door motor connector, cavity 8, to ground.
5. Adjust the position of the temperature control dial
while observing the J 39200 response.
module.
2. Connect a J 39200 (volts) between pin 9 of the
7 HVAC control module, and ground. —
3. Adjust the position of the temperature control dial
while observing the J 39200 response.
Locate and repair the open or cause of resistance in
CKT 454 (WHT) between the HVAC control module and
8 the front temperature door motor. Refer to Wiring Repairs ... Go to HVAC Air —
in Wiring Systems. Delivery
Replace the front temperature door motor. Refer to Go to HVAC Air
9 Temperature Actuator Replacement — Delivery
Replace the HVAC control module. Refer to Control Go to HVAC Air
10 Assembly Replacement — Delivery —
Temperature Actuator Inoperative (Rear)

Has the HVAC Air Delivery System Check been Go to HVAC Air
1 performed? Delivery
2. Backprobe a J 39200 (volts) from the auxiliary HVAC
control logic module connector, cavity B, to ground.
2 3. Adjust the temperature control dial at the front and —
rear auxiliary HVAC control modules while monitoring
the J 39200.
Does the J 39200 indicate a smooth, variable voltage? Go to Step 3 Go to Step 10
1. Turn the ignition switch to the OFF position.
2. Disconnect the connector at the auxiliary HVAC
control logic module.
3. Disconnect the auxiliary temperature door motor
3 connector. —
4. Connect a J 39200 (continuity) between the auxiliary
HVAC control logic module connector, cavity F, and
cavity 8 of the auxiliary temperature door motor
connector.
the auxiliary HVAC control logic module and the auxiliary
4 temperature door motor. Refer to Wiring Repairs in Wiring — Go to HVAC Air —
Systems. Delivery
Temperature Actuator Inoperative (Rear) (cont’d)
Connect a J (continuity) between cavity 7 of the
3 9 2 0 0
5 auxiliary temperature door motor connector and ground. ... —
auxiliary temperature door motor and splice S403. Refer to Go to H V A C A i r
Delivery
Connect a J 39200 (volts) between cavity 10 of the
7 auxiliary temperature door motor connector and ground. ' —
auxiliary temperature door motor and splice S400. Refer to _ Go to HVAC Air
Delivery
Replace the auxiliary temperature door motor. Refer to Go to H V A C A i r
9 Temperature Actuator Replacement - Auxiliary. _ Delivery —
1. Disconnect the auxiliary HVAC control logic module.
2. Connect a J 39200 (volts) between cavity J of the
10 auxiliary HVAC control logic module connector and ■ —'
ground.
Is voltage present? Go to Step 12 Go to Step 11
auxiliary HVAC control logic module and splice S308. Go to H V A C A i r
Delivery
1. Connect a J 39200 (volts) between cavity E of the
auxiliary HVAC control logic module connector and
12 ground. —
2. Repeat the same test for cavity D.
Does the J 39200 indicate a smooth, variable voltage Go to Step 13 Go to Step 14
Replace the auxiliary HVAC control logic module. Go to H V A C A i r
13 Is the repair complete? — Delivery —
System Check
• If cavity E of step 12 failed complete the following test
for the front auxiliary HVAC control module.
• If cavity D of step 12 failed complete the following test
for the rear auxiliary HVAC control module.
• If both circuits failed complete the following test for
both control modules.
14 1, Backprobe a J 39200 (volts) between cavity J of —
the auxiliary HVAC control module being tested
and ground.
2. Adjust the temperature control dial at the
auxiliary HVAC control module while monitoring
the J 3 9 2 0 0 .
Does the J 3 9 2 0 0 indicate a smooth, variable voltage? Go to Step 16 Go to Step 15
Replace the auxiliary HVAC module that was tested in
step 14. Refer to Control Assembly Replacement - Front
Auxiliary A/C (front)/Control Assembly Replacement -
15 Auxiliary (Suburban) (rear, Suburban) or Control Assembly — —
Go to H V A C A i r
Replacement - Auxiliary (4-Door Utility) (rear, 4dr Utility). Delivery
Locate the open or cause of resistance in CKT 920
(DK BLU) between the auxiliary HVAC control logic
module and the rear auxiliary HVAC control module and
16 the or CKT 919 (LT BLU) to the front auxiliary HVAC —
Go to H V A C A i r
control module. Refer to Wiring Repairs in Wiring Systems. Delivery
______Inadequate Defrosting
Problem Action
Obstruction in defroster nozzle 1. Inspect both of the defroster nozzle outlets.
3. Repair any loose instrument panel pads that block an outlet.
Damaged defroster nozzle outlet 1. Carefully reshape the outlet flange with pliers so that the outlet opening is
uniform.
2. If the outlet flange cannot be reshaped, replace the air distributor.
Faulty mode actuator 1. Inspect the operation of the defroster air valve.
2. Replace the faulty mode actuator.
Insufficient heat Refer to Insufficient Heating of Passenger Compartment in the following charts.
Inoperative Blower
Problem Action
Blown fuse Replace the fuse.
Open circuit 1. Inspect the circuit between the ignition switch and the blower motor, and the
blower motor ground circuit.
2. Repair as necessary.
Faulty blower switch Replace the faulty blower switch.
PrObl©BTI Action
Incorrect operation of controls Advise the driver of the proper operation of the controls.
Low engine coolant level 1. Add coolant as needed.
2. Inspect for coolant leaks.
3. Run the engine in order to clear any air locks.
Faulty engine thermostat 1. Inspect the thermostat.
2. Replace the thermostat if necessary.
Kinked heater hose 1. Inspect the hoses.
2. Straighten any kinks in the hoses.
3. Replace the hoses as necessary.
Obstructed heater core tubes 1. Listen for a swishing noise in the core.
2. Remove any foreign material from the core.
3. Replace the core if necessary.
Faulty blower motor or blower circuit 1. Repair or replace any faulty wires or connections.
2. Replace the faulty blower motor.
Faulty heater water valve or solenoid 1. Inspect the water valve in order to ensure that the water valve closes when you
or control circuit (if equipped) move the temperature control to the coldest setting.
2. If the water valve does not open, inspect the electrical connections between the
control head and the solenoid, and the vacuum line connections between the
engine and the solenoid, and the solenoid and the water valve.
3. Ensure that the water valve opens when you move the temperature control
several notches off of the coldest setting.
Cold Drafts on the Floor
Problem Action
Partially open air inlet valve 1. Ensure that the air inlet valve is properly closed in all modes except the
recirculation mode.
2. Repair the valve if necessary.
Side door seals damaged or missing 1. Inspect all of the door seals.
2. Repair or replace faulty seals as necessary.
Defrosting Insufficient
Condition; Action
defroster nozzle.
The mode actuator is faulty. 1. Inspect the operation of the defroster air valve.
The defroster is not emitting Refer to Heating Insufficient
sufficient heat.
Cooling Insufficient - A/C Inoperative

The compressor is a scroll compressor that matches • Check the A/C fuse and replace as necessary.
the air conditioning demand by changing the • Check the A/C blower operation and repair
compressor stroke, instead of cycling the compressor
as necessary.
clutch. A capacity control valve located in the
compressor senses the low side pressure and causes • Check the clutch coil electrical connection and
the compressor to adjust to A/C cooling demands. repair as necessary.
The compressor always runs and the system does not • Check the drive belt and replace if damaged or
cycle. However, the compressor may cycle if the missing.
cooling load is not reduced enough by the capacity
control valve. • Check the condenser for restricted air flow and
clean as necessary.
Preliminary Checks'
Refer to the following tables when you are diagnosing
• Check the proper operation of the cooling fans. insufficient cooling complaints.
• Check for system voltage above 10.5 Volts.
Cooling Insufficient - A/C Inoperative
Inspect for any stored DTCs.
1 —■
Are any DTCs stored? Go to Step 3 Go to Step 2
Connect the J 39500-B.
2 —
Are the pressures above 350 kPa (50 psi)? Go to Step 4 Go to Step 8
Correct any stored DTCs. Refer to DTC List (Domestic). _
3
Does the complaint persist? Go to Step 1 System OK
Inspect and correct for a blown Air Conditioner (A/C) fuse.
4 —
1. Disconnect the A/C clutch connector.
5 2. Inspect the A/C clutch for proper rotation. —
Does the A/C clutch rotate smoothly? Go to Step 6 System OK
Cooling Insufficient - A/C Inoperative (cont’d)
Inspect and correct for the following conditions: Go to
• Proper operation of the cooling fans. Compressor
Replacement
6 • Condenser restrictions — (7.41) or
• Radiator restrictions Compressor
Does the complaint persist? Replacement
Go to Step 7 (Diesel)
Read the DCS for Bulletins and Hints.
7 Follow the procedures indicated. —
1. Add 0.453 kg (1 Ib) of refrigerant.
8 2. Perform a leak check. Refer to Leak Testing. —
Did you find a leak? Go to Step 9 Go to Step 10
1. Repair the leak.
9 2. Inspect the system performance. Refer to System —
Performance Test (Dual Range Temperatures).
Perform an A/C Performance Check using the
following steps:
1. Ensure that the ambient temperature is at
least 6°C (43°F).
2. Ensure that the engine is idling at normal operating
temperature.
3. Turn the A/C to the ON position.
10 4. Select the coldest setting. —
5. Select the MAX blower speed.
6. Record the A/C pressures.
7. Record the A/C temperatures.
8. Refer to System Performance Test (Dual Range Go to HVAC
Temperatures). High Side vs
Does the A/C performance meet the requirement on the Low Side
Performance Chart? Go to Step 11 Pressure Table
Was the customer complaint made due to high
11 temperature and/or high humidity? —
System OK Go to Step 12
Perform a leak test. Refer to Leak Testing.
12
Did you find a leak? Go to Step 13 System OK
Evacuate and recharge the A/C system. Refer to
13 Refrigerant Recovery and Recharging. —
High Side vs. Low Side Pressure Table
689 kPa
(100 psi)
552 kPa
(80 psi)
L
0
W
414 kPa
S (60 psi)
1
D
E
P
R 276 kPa
E (40 psi)
S
S
U
R
E 138 kPa
(20 psi)
0
0 689 kPa 1378 kPa 2067 kPa 2760 kPa
(100 psi) (200 psi) (300 psi) (400 psi)
HIGH SIDE PRESSURE
247012
Gray Area Diagnosis and Service
Problem Action
Important: The clutch may cycle if the discharge pressure exceeds 2758 kPa (400 psi). or if system voltage drops
below 10.5 Volts.
improper condenser operation Improper condenser operation may result from one of the following causes:
• Extremely high ambient humidity,
® Insufficient air flow across condenser.
• Damaged or dirty condenser fins.
® Improper cooling fan operation.
High side refrigerant restriction 1. Feel liquid line before expansion tube (orifice). A cold line indicates restriction in
the high side.
2. Inspect for a frost spot in order to locate the restriction.
3. Repair the line as necessary.
Refrigerant system overcharged (high The clutch may cycle ON/OFF and cause compressor noise.
discharge and high suction Evacuate and recharge the system with the proper amount of refrigerant. Refer to
pressures) Refrigerant Recovery and Recharging.
Expansion tube (orifice) blocked 1. Discharge the system slowly using the low pressure service port to prevent
oil loss.
2. Inspect the expansion (orifice) tube for blockage. Clean or replace the tube as
required. Refer to Expansion (Orifice) Tube Replacement - Auxiliary or
Expansion (Orifice) Tube Replacement (C60).
3. Evacuate the system to a vacuum. Improper evacuation of the system prior to
recharge will cause air to remain in the system.
4. Recharge the system with the proper amount of refrigerant. Refer to R e f r i g e r a n t
R e c o v e r y a n d R e c h a rg in g .
5. Leak test the system. Refer to L e a k T e s tin g .
Air in system (High discharge and 1. Discharge the refrigerant system slowly using the low pressure service port to
high suction pressures). prevent oil loss.
required. Refer to Expansion (Orifice) Tube Replacement - Auxiliary.
4. Recharge the system with the proper amount of refrigerant. Refer to Refrigerant
Recovery and Recharging.
5. Leak test the system. Refer to Leak Testing.
Striped Area Diagnosis and Service

Problem Action
The compressor is damaged • If suction and discharge pressure are equal and do not change when the A/C
internally. mode is turned ON and OFF, the compressor may be internally damaged.
• Excess heat at the clutch surfaces or a free wheeling clutch driver are signs of
internal compressor damage.
® When replacing the compressor, Refer to Compressor Replacement (7.4L) or
Compressor Replacement (Diesel)
The expansion tube (orifice) is Feel the liquid line after the expansion tube. If the line is warm, discharge the system
missing. and inspect for proper installation of the expansion tube. If the expansion tube or
O-ring is missing, replace the expansion tube. Refer to Expansion (Orifice) Tube
Replacement - Auxiliary.
The refrigerant system is 1. The refrigerant may be undercharged when the suction pressure is below 35 psi
undercharged. during the high load test.
2. The suction line before the accumulator will be warm if the charge is low.
3. Add 1 Ib of refrigerant.
4. Recheck the pressure. Verify that the pressure is in the white area on the chart.
Then find and correct the leak.
5. Evacuate the system. Refer to Refrigerant Recovery and Recharging.
6. Charge the system with the correct amount of refrigerant.
Stri lied Area Diagnosis and Service (cont’d)
Problem Action
The expansion tube (orifice) is 1. Discharge the system slowly using the low pressure service port to prevent oil
blocked. loss. Refer to Refrigerant Recovery and Recharging.
required. Refer to Expansion (Orifice) Tube Replacement - Auxiliary or
Expansion (Orifice) Tube Replacement (C69) or Expansion (Orifice) Tube
Replacement- Auxiliary:
4. Recharge the system with the proper amount of refrigerant. Refer to Refrigerant
5. Leak test the system. Refer to Leak Testing.
NOise Diagnosis
Noise Description Source . Solution Recommendation Check
• Groundouts
• Loose Brackets Bolts
Moan (occurs at a specific RPM, less • Exhaust System Ground
Compressor • Low Belt Tension
than other speeds)
• Comp. Torq. cushion (TATC) on
HT6 Only
• Softer Hose Material
Growl (Idle) Compressor Groundouts On All A/C Lines and
Components
Growl (All Speeds) Compressor All Line Clamps and Anchor Points
(Remove and Check)
System Refrig. Charge and Oil
Chatter (Idle) Compressor (Add 1/2# R134A and 3 oz. PAG Oil,
Check Effect
1. Compressor • Pulley Brg. with A/C On and Off

Whine (All Speeds) or Grind 2. P/S Pump • Interference at All Rotating Points
of Pulley (Check with Belt On
3. Generator and Off)
1. Compressor • Belt Alignment

Squeal (All Speeds) 2. P/S Pump • Tensioner Torque
• Belt Condition (Edge Wear for
3. Generator
Rubbing)
1. Orifice Tube Occurs at A/C Shut Down (Normal
Hiss, Gurgle or Percolation Condition, Noise Subsides After Short
2. TXV (Thermal Expansion Valve) Time Period)
Occurs When A/C Cycles on
(compressor Clutch Engages or
Chirp or Thump Compressor Clutch Disengages) - Apply Anti-Seize
Compound to Clutch Face (Very Light
Coat of Moly Kote or Permatex 2000)
Knock Compressor • Loose Bracket Bolts

• Belt Tensioner
Odor Diagnosis
Problem Action
Water leaks from the body. Seal the body.
The evaporator drain is clogged. Clean the drain.
Mold or mildew is present. Clean the evaporator.
Coolant Smell
Problem Action
The anti-freeze leaks. 1. Inspect the heater core.
2. Inspect the pipes.
3. Inspect the hoses.
4. Repair or replace the components as necessary.
Refrigerant Leak
Problem Action
The refrigerant oil leaks. Inspect the evaporator core. Repair or replace the evaporator core as necessary.
Refer to Evaporator Core Replacement
Mold/Mildew Odor Problem

Under certain climate and operating conditions, a
musty odor develops from mold growth in the
evaporator core face. This odor is generally temporary.
As climate conditions change the odor will disappear
and repair automatically. If the odor persists,
remove the evaporator core. Clean the evaporator
core face with the appropriate cleaner.
Repair Instructions ■
Refrigerant Recovery and Recharging The Initial Set-Up Instruction Manual, provided with
the J 39500-B, contains specific procedures for proper
Tools Required recovery, evacuation and recharging.
• J 39500-B A/C Refrigerant Recovery, Recycling For ACR4 technical assistance in the U.S., call
and Recharging (ACR4) System
1-800-345-2233.
• J 41810 PureGuard 2
• J-41810-100A Active Flow Control 'Valve Compressor Oil Level Check
Caution; Avoid breathing the A/C Refrigerant 134a
(R-134a) and the lubricant vapor or the m ist Adding Oil
Exposure may irritate the eyes, nose, and throat The Harrison HT-6 compressor system in all C/K
Work in a well ventilated area. In order to remove models requires polyalkaline glycol (PAG) refrigerant
R-134a from the A/C system, use service oil in the quantities listed below:
equipment that is certified to meet the
requirements of SAE J 2210 (R-134a recycling • Without Aux. A/C — 240 ml (8 fl oz)
equipment). If an accidental system discharge • With Aux. A/C — 330 ml (11 fl oz)
occurs, ventilate the work area before continuing
New oil quantities must be added to the system during
service. Additional health and safety information
may be obtained from the refrigerant and lubricant component replacement. With no signs of excessive
manufacturers. leakage, add oil to the components as follows:
Caution: For personal protection, goggles and • All Compressors (drain and measure the oil)
gloves should be worn and a clean cloth wrapped - If less than 30 ml (1 fl oz) is drained, add
around fittings, valves, and connections when 60 ml (2 fl oz) to the new compressor.
doing work that includes opening the refrigerant
- If more than 30 ml (1 fl oz) is drained, add
system. If R-134a comes in contact with any part of
the body severe frostbite and personal injury the same amount that was drained to the
can result The exposed area should be flushed new compressor.
immediately with cold water and prompt medical • Accumulator — Add 105 ml (3.5 fl oz) of new oil to
help should be obtained. the replacement accumulator in order to
Notice: R-134a is the only approved refrigerant for compensate for the oil retained by the original
use in this vehicle, The use of any other refrigerant accumulator desiccant and bag assemblies. Only
may result in poor system performance or component replace the accumulator if the leaking is due
failure. to a perforation, a damaged O-ring seal seat, or
Notice; To avoid system damage use only R-134a damaged threads.
dedicated tools when servicing the A/C system. • Evaporator — Add 90 ml (3 fl oz) of new
Notice: Use only Polyalkylene Glycol Synthetic refrigerant oil.
Refrigerant Oil (PAG) for internal circulation through • Condenser — Add 30 ml (1 fl oz) of new
the R-134a A/C system and only 525 viscosity mineral refrigerant oil.
oil on fitting threads and O-rings. If lubricants other
than those specified are used, compressor failure Refrigerant Oil Loss Due to a Large Leak
and/or fitting seizure may result. If a large refrigerant leak causes the abrupt loss of
Notice: R-12 refrigerant and R-134a refrigerant must refrigerant charge, approximately 90 ml (3 fl oz)
never be mixed, even in the smallest of amounts, of refrigerant oil will be carried out of the system
as they are incompatible with each other. If the suspended in the refrigerant. Any failure that causes
refrigerants are mixed, compressor failure is likely to an abrupt refrigerant discharge will experience
occur. Refer to the manufacturer instructions included this oil loss. Failures that allow the refrigerant to seep
with the service equipment before servicing. or bleed off over time do not experience the same
The J 39500-B removes the Refrigerant-134a from the degree of oil loss.
vehicle’s A/C system. The recovery procedure uses Upon the replacement of a component that caused a
one filtering cycle. The evacuation procedure uses an large refrigerant leak, add 90 mi (3 fl oz) of new
automatic multiple pass filtering cycle. These polyalkaline glycol (PAG) refrigerant oil plus the
filtering cycles ensure a constant supply of clean, dry desired amount of oil for the particular component.
refrigerant for A/C system charging. Refer to Adding Oil.
Compressor Replacement
(4.3L, 5.0L, 5.7L)
Removal Procedure
2. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging
3. Remove the drive belt. Refer to Drive Belt
Replacem ent in Engine Mechanical — 4.3L
or Drive Belt Replacem ent in Engine
Mechanical — 5.0L, 5.7L.
4. Disconnect the refrigerant hose assembly from
the compressor. Refer to Compressor Hose
Assembly Replacem ent (Gasoline Engines).
5. Cap or plug all of the open connections.
necessary.
8. Remove the compressor from the bracket.
9. Drain the compressor oil.
10. Measure the compressor oil. Refer to Compressor
Oil Level Check.
1. Fill the compressor with oil. Refer to Compressor
Oil Level Check.
2. Install the compressor to the bracket.
Notices.
3. Install the compressor mounting bolts.
Tighten
5. Install the refrigerant hose assembly to the
compressor. Refer to Com pressor Hose Assembly
R eplacem ent (Gasoline Engines).
6. Install the drive belt. Refer to Drive Belt
R eplacem ent in Engine Mechanical 4.3L
or Drive Belt Replacem ent in Engine
Mechanical — 5.0L, 5.7L.
257965 7. Connect the negative battery cable.
8. Charge the system. Refer to Refrigerant Recovery
and Recharging.
9. Inspect the system for leaks. Refer to Leak
Testing.
Compressor Replacement (7.4L)
Removal Procedure
Replacement in Engine Mechanical — 7.4L.
Assembly Replacement (Diesel Engines). ?i?l U 1
necessary.
257966
10. Measure the compressor oil. Refer to Compressor
Oil Level Check.
1. Fill the compressor with oil. Refer to Compressor
Oil Level Check.
1 jS |N ^ 1
Notices.
Tighten
Tighten the bolts to 50 N-m (37 Ib ft). I f
compressor. Refer to Compressor Hose Assembly
Replacement (Diesel Engines).
6. Install the drive belt. Refer to Drive Belt >
Replacement in Engine Mechanical — 7.4L
7. Connect the negative battery cable. 1 V v
and Recharging. 257966

Testing.
Compressor Replacement (Diesel)
Removal Procedure
Caution: Refer to Battery Disconnect Caution In
2. Recover the refrigerant. Refer Refrigerant
Replacem ent (6.5L Drive Belt)
Assem bly Replacem ent (Diesel Engines).
necessary.
10. Measure the compressor oil.
1. Fill the compressor with oil.
Notices.
Tighten
compressor. Refer to Compressor Hose Assembly
Replacem ent (D iesel Engines).
6. Install the drive belt. Refer to Drive Belt
Replacem ent (6.5L Drive Belt).
and Recharging.
Testing.
Compressor Clutch Plate and Hub
Assembly Removal
Tools Required
• J 34992 Compressor Holding Fixture
• J 33013-B Clutch Plate and Hub Assembly
Installer-Remover
1. Clamp the J 34992 in a vise.
2. Use thumb screws in order to attach the
compressor to the holding fixture.
Notice: Do not drive or pound on the clutch hub or
shaft. Internal damage to the compressor may result.
The forcing tip on the J 33013-B remover/installer
center screw must be flat or the end of the shaft/axial
plate assembly will be damaged.
3. Ensure that the center screw forces the tip to
thrust against the end of the shaft.
4. Thread the J 33013-B into the hub.
5. While holding the body of J 33013-B of the
remover with a wrench, turn the center screw into
the remover body in order to remove the clutch
plate and hub assembly (1).
6. Remove the shaft key. Retain the shaft key for
reassembly.
Clutch Rotor and/or Bearing Removal

Tools Required
• J 6083 Snap Ring Pliers
• J 33023-A Puller Pilot
• J 41552 Pulley Puller
• J 29886 Driver Handle
• J 9398-A Bearing Remover
1. Remove the clutch plate and hub assembly. Refer
to Compressor Clutch Plate and Hub Assembly
Removal.
2. Use the J 6083 in order to remove the following
components:
• The pulley rotor (1)
• The bearing assembly retaining ring (2)
258032
3. Install the J 33023-A to the front head.
J 33023- A 4. Install the J 41552 down into the inner circle of
slots (1) in the rotor.
5. Turn the J 41552 clockwise in the slots in

the rotor.
pulley rotor and bearing assembly:
6.1. Hold the J 41552 in position.
6.2. Tighten the puller screw against the
puller guide.
6.3. Remove the pulley rotor and bearing
assembly.
258031
7. Use the following procedure in order to properly

support the rotor hub during bearing removal in
order to prevent pulley rotor damage:
7.1. Remove the forcing screw from the
J 41552.
7.2. Ensure that the puller tangs still engage in
the rotor slots.
7.3. Invert the assembly onto a solid flat surface
or blocks.
Notice: It is not necessary to remove the staking in
front of the bearing to remove the bearing, however, it
will be necessary to file away the old stake metal
for proper clearance for the new bearing to be installed
into the rotor bore or the bearing may be damaged.
8. Use the J 9398-A and the J 29886 in order to drive
the bearing out of the rotor hub.
210141
Compressor Clutch Coil Removal
Tools Required
• J 8433-1 Puller Bar
• J 33025 Clutch Coil Puller Legs
• J 8433-3 Forcing Screw
1. Remove the clutch plate and hub assembly. Refer
to Compressor Clutch Plate and Hub Assembly
Removal.
2. Use the J 6083 in order to remove the following
components:
• The bearing assembly retaining ring (2)
258032
3. Install the J 33023-A to the front head.

4. Install the J 41552 down into the inner circle of J 33023- A
slots (1) in the rotor.
5. Turn the J 41552 clockwise in the slots in

the rotor.
pulley rotor and bearing assembly:
6.1. Hold the J 41552 in position.
6.2. Tighten the puller screw against the
puller guide.
6.3. Remove the pulley rotor and bearing
assembly.
258031
7. Mark the clutch coil terminal location (1) on the
compressor front head.
8. Install the J 33023-A on the front head of the
compressor.
9. Install the J 8433-1 and the J 33025.
10. Tighten the J 8433-3 against the puller pilot in
order to remove the clutch coil (2).
Compressor Shaft Seal Removal

Seal Leak Detection
Do not change a shaft seal because of small amounts
of oil on an adjacent surface. Only replace a shaft
seal after you find actual refrigerant leakage using an
approved leak detector, such as J 39400-A or
equivalent.
Tools Required
• J 39500-B R-134a A/C Refrigerant Recovery,
Recycling and Recharging System (ACR4)
• J 23128-A Seal Seat Remover and Installer
• J 9553-01 O-Ring Remover
1. Recover the refrigerant using the J 39500-B.
2. Loosen and reposition the compressor in
the mounting brackets, if necessary.
3. Remove the clutch plate and hub assembly from
the compressor. Refer to Compressor Clutch
Plate and Hub Assembly Removal.
4. Remove the shaft seal retainer ring (1) using the
J5403.
J 5403
5. Any dirt or foreign material in the compressor may
cause damage. Thoroughly clean the following
components:
• The inside of the compressor neck area
surrounding the shaft
• The exposed portion of the seal
• The retainer ring groove
• The shaft
6. Fully engage the knurled tangs of the J 23128-A

into the recessed portion of the seal (1) by turning
the handle clockwise.
258050
7. Remove the seal (1) from the compressor using a

rotary-pulling motion. Discard the seal.
8. Securely hand-tighten the handle. Do not use a
wrench or pliers.
9. Remove and discard the seal seat O-ring (1) from
the compressor neck using the J 9553-01.
J 9553 - 01
10. Inspect the shaft and the inside of the compressor
neck for dirt or foreign material. Ensure that the
shaft and the inside of the compressor neck
are perfectly clean before installing the new parts.
11. Thoroughly clean the O-ring seal groove in
the front head.
Compressor Pressure Relief Valve

Removal
Tool s Required
J 39500-B R-134a A/C Refrigerant Recovery,
2. Remove the old pressure relief valve (5).
Compressor Control Switches Removal

Tools Required
• J 9553-01 O-Ring Remover
2. Disconnect the electrical connector from the
switch (4) in the rear head of the compressor.
3. Remove the switch retaining ring using the
J 5403.
4. Remove the switch (4) from the compressor.
5. Remove the old O-ring seal from the switch cavity
using the J 9553-01.
6. Inspect the switch cavity and the O-ring groove in
the rear head for dirt or foreign material. Clean
the components as necessary.
Compressor Clutch Plate/Hub Assembly
Install
Tools Required
J 33013-B Clutch Plate and Hub Assembly
Installer-Remover
1. Install the shaft key (4) into the hub key groove.
Allow the key to project approximately 3,2 mm
(0.125 in) out of the keyway (3). The shaft
key curves slightly in order to provide an
interference fit in the hub key groove.
2. Clean the following components:
• The clutch plate
• The clutch rotor (2)
3. Align the shaft key (4) with the shaft keyway (3).
4. Place the clutch plate and the hub assembly (1)
onto the compressor shaft.
5. Remove the forcing tip on the J 33013-B.

6. Reverse the body direction on the center screw. J 33013-B
7. Install the J 33013-B with the bearing.
8. Back off the body of the J 33013-B as necessary
in order to permit the center screw to be threaded
onto the end of the compressor shaft.
9. Hold the center screw with a wrench.
10. Tighten the hex portion of the J 33013-B body in
order to press the hub onto the shaft.
11. Tighten the body several turns.
12. Remove the installer. Ensure that the shaft key
remains in place in the keyway.
13. Install the clutch plate and hub assembly to the
final position.
Ensure that the air gap (2) between frictional
J 34992
surfaces of the clutch plate and clutch rotor
measures within 0.50-0.76 mm (0.20-0.30 in).
14. Remove the J 33013-B.
15. Verify proper positioning of the shaft key.
Ensure that the shaft key is even with or slightly
above the clutch hub.
16. Spin the pulley rotor by hand in order to verify
that the rotor does not rub against the clutch
drive plate.
Clutch Rotor and/or Bearing Install
Tools Required
• J 29886 Driver Handle
• J 21352-A Support Block
• J9481-A Bearing Installer
• J 33019 Bearing Staking Tool
• J 33017 Pulley and Bearing Assembly Installer
• J 9398-A Bearing Remover
• J 34992 Holding Fixture
Notice: Do not support the rotor by resting the pulley
rim on a flat surface during the bearing installation
or the rotor face will be bent.
1. Place the pulley rotor on the J 21352-A in order to
fully support the rotor hub during bearing
installation.
2. Use the following tools in order to align the new
bearing squarely with the hub bore.
• J 41552
• J9481-A
• J 29886
3. Drive the bearing fully into the hub.
The installer will apply force to the outer race of
the bearing, if used as shown.
4. Place the J 33019 in the hub bore.
5. Shift the rotor and bearing assembly on the
J 21352-A in order to fully support the hub
under the staking pin location.
Use a heavy-duty rubber band (1) in order to hold
the stake pin in the guide. Properly position the
stake pin in the guide after each impact on the pin.
Important: Use care in order to prevent personal injury
when striking the staking pin with a hammer.
6. Strike the staking pin with a hammer until a metal
stake, similar to the original, forms down to but
not touching the bearing.
258036
Important: Noisy bearing operation and reduced
bearing life may result if the outer bearing race is
deformed while staking. Ensure that the stake metal
does not contact the outer race of the bearing.
7. Stake 3 locations on the bearing race 120 degrees
apart as shown.
6147
8. With the compressor mounted on the J 34992,

position the pulley rotor (1) and the bearing
J 8433-1 J 8 4 3 3 -3
assembly on the front head.
9. Position the J 33017 and the J 33023-A directly I —/C _____
over the inner race of the bearing.
10. Position the J 8433-1 on the J 33023-A.
11. Assemble the 2 through bolts and the washers
through the puller bar slots.
12. Thread the through bolts into the J 34992.
Ensure that the thread of the through bolts engage
the full thickness of the J 34992.
13. Tighten the center screw in the J 8433-1 in order
to force the pulley rotor and bearing assembly
onto the compressor front head.
If the J 33017 slips off direct in-line contact with
the inner race of the bearing, perform the
following steps:
13.1. Loosen the J 8433-3.
258028
13.2. Realign the installer and the pilot in order
to ensure that the J 33017 properly clears
the front head.
14. Use the snap ring pliers in order to install the
following components:
14.1. The pulley rotor (1)
14.2. The retaining ring (2)
15. Install the clutch plate and hub assembly. Refer to
Compressor Clutch Plate/Hub Assembly Install.
Compressor Clutch Coil Install

Too ls Required
• J 33024 Clutch Coil Installer Adapter
• J 34992 Holding Fixture
• J 33017 Pulley and Bearing Assembly Installer
1. Place the clutch coil assembly (1) on the front
head. Position the terminals at the marked
location.
2. Place the J 33024 over the internal opening of the
clutch coil housing.
3. Align the J 33024 with the compressor front head.
4. Center the J 8433-1 in the counter-sunk center
hole of the J 33024.
258029 5. Install the 2 through bolts and washers through
the crossbar slots.
6. Thread the bolts into the J 34992 in order to
achieve full fixture thickness.
7. Turn the center forcing screw of the J 8433-1 in
order to force the clutch coil onto the front head.
Ensure that the clutch coil and the J 33024
remain aligned during installation.
8. When the coil is fully seated on the front head,
use a 1/8 inch diameter drift punch (2) in order to
stake the front head at 3 places 120 degrees
apart (3), in order to ensure that the clutch coil (1)
remains in position.
9. Ensure that the stake size is only one-half the

area of the punch tip. Ensure that the stake is
only approximately 0.28-0.35 mm
(0.010-0.015 in) deep.
6997
10. With the compressor mounted to the J 34992,

position the pulley rotor (1) and bearing assembly
on the front head. J 8433-1 J 8433 - 3
11. Position the J 33017 and the J 33023-A directly
over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A.
13. Assemble the 2 through bolts and washers
through the puller bar slots.
14. Thread the bolts into the J 34992. Ensure that the J 3 3 0 2 3 -A
thread of the through bolts engages the full
thickness of the J 34992.
J 33017
J 34992 J 3 3 0 2 6 -2
268028
15. Tighten the center screw in the J 8433-1 in order
to force the pulley rotor and bearing assembly
onto the compressor front head.
If the J 33017 slips off direct in-line contact with
the inner race and bearing, Perform the
following steps:
15.1. Loosen the J 8433-3.
15.2. Realign the installer and the pilot in order
to ensure that the J 33017 properly clears
the front head.
16. Use the J 6083 in order to install the following
components:
• The retainer ring (2)
Compressor Clutch Plate/Hub Assembly Install.
258032
Compressor Shaft Seal Install

Tools Required
• J 23128-A Seal Seat Remover and Installer
• J 33011 O-Ring Installer
• J 34614 Shaft Seal Protector
• J 39893 Pressure Testing Connector
Notice: Seals should not be re-used. Always use a
new specification service seal kit. Be sure that the seal
to be installed is not scratched or damaged in any
way. Make sure that the seal is free of lint and dirt that
could damage the seal surface or prevent sealing.
1. Dip the new seal seat O-ring in clean 525 viscosity
refrigerant oil. Assemble the new seal seat O-ring
onto the J 33011.
2. Insert the J 33011 into the compressor neck until
the installer bottoms.
3. Lower the moveable slide of the J 33011 in order
to release the O-ring into the seal O-ring lower
groove. Do not release the O-ring into the
compressor neck top groove.
4. Rotate the J 33011 in order to seat the O-ring.
5. Remove the J 33011.
6. Dip the new seal in clean 525 viscosity refrigerant
oil. Assemble the seal to the J 23128-A by turning
the handle clockwise.
7. Engage the knurled tangs of the J 23128-A with
the stamped steel case side of the lip seal (1) in
order to ensure that the flared-out side of the
lip seal (1) faces toward the compressor.
Notice: Handling and care of the seal protector is
important. If the seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
8. Install the seal using 1 of the 2 following methods:
258047
9. Method 1: Install the J 34614 in the seal lip.

Place the seal lip over the compressor shaft.
J 23128-A
Push the seal (1) into place using a rotary motion.
10. Method 2: Place the J 34614 over the end of the
compressor shaft.
258048
11. Slide the new seal (1) onto the shaft using a
rotary motion until the seal stops.
12. Ensure that the seal contacts the O-ring. Do not
dislodge the O-ring. Disengage the installer from
the seal.
13. Remove the J 23128-A and the J 84614.
14. Using the J 5403, install the new seal retainer
ring (1) with the flat side against the seal. Use the
J 5403 sleeve from J 33011 in order to press in the
seal retainer in order to ensure that the seal snaps
into the groove.
15. Perform a leak test using the following procedure:
15.1. Install the J 39893 on the rear head of the
compressor.
15.2. Connect the gage charging lines and the
J 39500-B.
15.3. Pressurize the suction and the high-side of
the compressor using R-134a Refrigerant.
15.4. Temporarily install a M9 x 1.25 threaded
nut on the shaft.
15.5. With the compressor in a horizontal
position, rotate the compressor shaft in
the normal direction of rotation several
turns by hand.
258064 15.6. Leak test the seal area. Correct any
leaks found.
15.7. Recover the refrigerant.
15.8. Remove the shaft nut.
16. Remove any excess oil from the shaft and from
the inside of the compressor neck.
Compressor Clutch Plate/Hub Assem bly Install.
18. Install the compressor belt. Tighten the bracket.
19. Evacuate and charge the refrigerant system.
Compressor Pressure Relief Valve Install

Tools Required
J 39500-B R-134a A/C Refrigerant Recovery,
1. Clean the valve seat area on the rear head.
2. Lubricate the O-ring of the new pressure relief
valve (5) and the O-ring assembly using new
525 viscosity refrigerant oil.
Notices.
3. Install the new pressure relief valve (5).
Tighten
Tighten the new valve to 9.0 N-m (6.1 Ib ft).
4. Evacuate and recharge the system using the
J 39500-B.
5. Leak test the system.
258039
Compressor Control Switches Install
Tools Required
J 5403 Snap Ring Pliers
Important: If you reinstall an existing control switch in
the compressor, use a new O-ring and a new
retainer ring. An O-ring and a retainer ring is included
in a new switch kit.
1. Lubricate the new O-ring using clean
refrigerant oil.
2. Install the new O-ring into the groove in the switch
cavity.
3. Lubricate the control switch housing using clean
refrigerant oil.
4. Install the switch (4) into the switch cavity until the
switch bottoms in the cavity.
5. Using the J 5403, install the switch retaining ring.
Ensure that the high point of the curved sides is
adjacent to the switch housing. Ensure that 258039
the retaining ring is properly seated in the switch
cavity retaining groove.
6. Leak test according to bench test procedure.
Compressor Leak Testing

Bench-Check Procedure
Tools Required
• J 39893 Pressure Testing Connector
• J 39500-B R134a A/C Refrigerant Recovery,
• J 34992 Compressor Holding Fixture
• J 39400-A Leak Detector
1. Install the J 39893 on the rear head of the
compressor.
2. Using the J 39500-B, attach the center hose of
the manifold gauge set on the charging station
to a refrigerant drum standing in an upright
position.
3. Connect the charging station high and low
pressure lines to the corresponding fittings on the
J 39893.
The suction port (1) (low-side) of the compressor
has a large internal opening. The discharge
port (high-side) has a smaller internal opening into
the compressor. The discharge port (2) (high-side)
also has a deeper recess.
4. Open the following controls on the charging
station in order to allow refrigerant vapor to
flow into the compressor:
• The low pressure control
• The high pressure control
• The refrigerant control
5. Use the J 39400-A in order to inspect for leaks at 18. Use a wrench in order to rotate the compressor
the following locations: crankshaft or the drive plate hub ten complete
• The pressure relief valve (5) revolutions at the speed of approximately
one-revolution per second.
• The rear head switch location
Turning the compressor at less than one-revolution
• The compressor front head seal per second can result in a lower pump-up
• The compressor rear head seal pressure. Low pump-up pressure may disqualify a
• The center cylinder seal good pumping compressor.
• The through bolt head gaskets 19. Observe the reading on the high-pressure gauge
at the completion of the tenth revolution of the
• The compressor shaft seal compressor.
6 . Turn OFF the low-pressure control and the The pressure reading for a good pumping
high-pressure control on the charging station. compressor should measure 690 kPa (100 psi) or
7. Perform the following steps if an external leak above. A pressure reading less than 620 kPa
exists: (90 psi) indicates one or more of the suction
and/or discharge valves have an internal leak or
7.1. Perform the necessary corrective measures.
an inoperative valve.
7.2. Inspect the components for leaks again in Perform the following procedure if one of the
order to verify that the leak is corrected. valves are leaking or inoperative:
8. Recover the refrigerant. 19.1. Recover the refrigerant.
9. Disconnect both hoses from the J 39893. 19.2. Disassemble the compressor.
10. Add 90 ml (3 fl oz) of new PAG lubricant to the 19.3. Inspect the compressor for the cause of
compressor assembly. the leak.
11. Slowly rotate the complete compressor assembly 19.4. Repair the compressor as necessary.
(excluding the crankshaft and the drive plate hub) 19.5. Reassemble the compressor.
several turns in order to distribute oil to all of
the cylinder and the piston areas., ■ 19.6. Repeat the pump-up test.
19.7. Test for external leaks
12. Install a M9 x 1.25 threaded nut on the
compressor crankshaft if the drive plate and clutch 20. Recover the refrigerant from the high-side.
assembly are not installed. 21 . Remove the J 39893.
13. Use a box-end wrench or socket and handle in 22. Tilt the compressor with the compressor suction
order to rotate the compressor crankshaft or port (1) and the discharge port (2) positioned
clutch drive plate on the crankshaft several turns. downward.
Performing the above action will ensure piston 23. Drain the PAG lubricant from the compressor.
assembly to cylinder wall lubrication. Allow the compressor to drain for 10 minutes.
14. Using the J 39500-B, connect the J 39893 to the 24. Refill the compressor with the proper amount of
test plate high-side connector. PAG lubricant.
15. Using the J 39500-B, connect the charging station Pour the PAG lubricant into the suction port (1).
low-pressure line to the low-pressure port of the 25. If further assembly or processing is necessary,
J 39893. install a shipping plate or the J 39893. The
Oil will drain out of the compressor suction shipping plate or the J 39893 prevents the
port (1) if the compressor is positioned with the following materials from entering the compressor
suction port downward. until the compressor is installed:
16. Attach the compressor to the J 34992. • Air
17. Mount the compressor in a vise in order to place . Dirt
the compressor in a horizontal position. • Moisture
Replacement (7.4L)
Removal Procedure

necessary.
3. Remove the compressor pressure relief valve.
4. Remove the O-ring seal.
257977
1. Coat the O-ring seal with 525 viscosity
refrigerant oil.
2. Install the new O-ring seal.
Notices.
3. Install the compressor pressure relief valve.

Tighten
Tighten the compressor pressure relief valve to
6 N-m (53 Ib in).
Replacement (AH Except 7.4L)
Removal Procedure
necessary.
3. Remove the compressor pressure relief valve.
257978
1. Coat the O-ring seal with 525 viscosity
refrigerant oil.
Notices.
3. Install the compressor pressure relief valve.
Tighten
Tighten the compressor pressure relief valve to
6 N-m (53 Ib in).
257978
Compressor Sealing Washers

R eplacem ent
Important: Take the following measures when
installing sealing washers:
• Keep dirt and foreign material from the sealing
surfaces of the washers, the hose block, and
the compressor ports.
Clean all of the sealing surfaces with a
lint-free rag.
• Do not reuse sealing washers.
• The sealing washers do not need oiling prior to
assembly.
1. Install the sealing washer onto the pilots of the
suction/discharge block fitting.
The washers must bottom against the surface of
the block fitting.
257968
2... Install the hose block to the compressor. -
Make sure the sealing washers are seated within
the compressor machined surfaces.
Notices.
3. Hold the block in place.
Tighten. .-■■■ ; . -
Tighten the bolt to 34 N-m (25 lb .in).;
O-Ring Replacem ent» Dual ■ ;

Install new O-rings whenever a fitting joint is opened.
Tools Required
J 38042 Dual O-Ring Tube Separator
Perform the following steps' in- order to service the
dual O-ring joint: . }
1. Inspect the O-ring seals and fittings for any nicks
or deformities.
Replace any damaged components in order to
prevent refrigerant leakage. r ;
2. Recover the refrigerant from the system.
3. Use the J 38042 in order to separate the joint
while loosening the female nut.
Use a nonmetallic tool when removing the O-rings
in order to prevent the chance of damaging the
seal surface.
4. Avoid any excessive stretching and twisting of the
replacement O-rings,
5. Align and completely push together the end forms
for the pilot-to-bore insertion.
6. Apply a small amount of 525 viscosity refrigerant
oil in order to ease the insertion of the O-rings.
Notices.
important: Dual O-ring fittings are different in size
from the standard A/C fitting O-rings.
7. Install the dual O-ring fittings.
Tighten
Tighten the aluminum nut to 24 N-m (18 Ib ft).
(Gasoline Engines)
Removal Procedure
Tools Required
J 38042 Dual O-Ring Separator
3. Remove the grille. Refer to Air Inlet Grille Panel
Replacement.
4. Remove the bolt.
5. Disconnect the hose assembly from the top of the
compressor.
6. Remove the sealing washers.
7. Disconnect the hose assembly from the
accumulator using the J 38042.
8. Remove the O-Ring seals from the
accumulator hose.
condenser.
10. Remove the O-ring seal from the condenser hose.
1. Coat the new O-ring seal with 525 viscosity
refrigerant oil.
2. Install the new O-ring seal to the condenser hose.
Notices.
3. Connect the hose assembly to the condenser.
Tighten
Tighten the hose assembly to 45 N-m (33 Ib ft).
4. Coat the new dual O-ring seals with 525 viscosity
refrigerant oil.
5. Install the new dual O-ring seals to the
accumulator hose.
6. Connect the hose assembly to the accumulator.
Tighten
7. Install the sealing washers.
8. Connect the hose assembly to the top of the
compressor.
9. Install the bolt.
Tighten
Tighten the bolt to 34 N-m (25 Ib ft).
10. Install the grille. Refer to A i r I n l e t G r ille P a n e l
R e p la c e m e n t.
and Recharging.
Testing.

(Diesel Engines)
Removal Procedure
Tools Required
Replacement.
4. Remove the bolt.
compressor.
accumulator using the J 38042.
8. Remove the O-Ring seals from the
accumulator hose.
257973
condenser.
10. Remove the O-ring seal from the condenser hose.
257970
refrigerant oil.
2. Install the new O-ring seal to the condenser hose
Notices.
3. Connect the hose assembly to the condenser.
Tighten
4. Coat the new dual O-ring seals with 525 viscosity
refrigerant oil.
5. Install the new dual O-ring seals to the
accumulator hose. Refer to O-Ring
Replacement - Dual.
Tighten
7. Install the sealing washers.
compressor.
Tighten
10. Install the grille. Refer to Air Inlet Grille Panel
Replacement.
and Recharging.
Testing.
Condenser Tube Replacement

Removal Procedure
3. Disconnect the auxiliary heater hose, if equipped.
Refer to Heater Hoses Replacement - Auxiliary
(Suburban- Front) in Heating and Ventilation
(Non-A/C).
Engine Cooling.
5. Disconnect the evaporator tube from the
evaporator.
257983
condenser.
9. Remove the tube from the clip.
1. Install the evaporator tube into the clip.
refrigerant oil.
Notices.
4. Connect the evaporator tube to the condenser.
Tighten
Tighten the evaporator tube to 24 N-m (18 Ib ft).
refrigerant oil.
7. Install the evaporator tube to the evaporator.
Tighten
257983 8. Install the coolant recovery reservoir. Refer to
Engine Cooling.
9. Connect the auxiliary heater hose, if equipped.
(Non-A/C).
and Recharging.
Testing.
Evaporator Tube Extension Replacement

Removal Procedure
(Non-A/C).
Engine Cooling.
evaporator.
condenser.
refrigerant oil.
Notices.
Tighten
refrigerant oil.
Tighten
8. Install the coolant recovery reservoir. Refer to 257983
Engine Cooling.
(Non-A/C).
and Recharging.
Testing.
A/C Hose Replacement - Auxiliary

Removal Procedure
2. Remove the air cleaner assembly.
3. Disconnect the evaporator tube (1) from the
auxiliary evaporator hose (3).
4. Remove the O-ring seal (2).
5. Disconnect the refrigerant hose assembly (6) from
the auxiliary compressor hose (4).
Wheel Opening Flare Replacement - Rear
(Suburban and Utility) in Exterior Trim.
8. Disconnect the auxiliary evaporator hose (4) from
the auxiliary evaporator (1).
10. Disconnect the auxiliary compressor hose (3) from
the auxiliary evaporator.
11. Remove the screws (4).
12. Remove the hose clips (1).
13. Remove the auxiliary evaporator hose (1).
14. Remove the compressor hose (2).
installation Procedure
1. Install the auxiliary compressor hose (2).
2. Install the auxiliary evaporator hose (1).
3. Install the hose clips (1).
Notice; Refer to Fastener Notice in Cautions and
Notices.
4. Install the screws (4).
Tighten
Tighten the screws to 6 N-m (53 Ib in).
5. Coat the new O-ring seal (2) for the auxiliary
compressor hose (3) with 525 viscosity
refrigerant oil.
7. Connect the auxiliary compressor hose to the
auxiliary evaporator (1).
Tighten
Tighten the auxiliary compressor hose to
32 N-m (24 Ib ft).
evaporator hose (4) with 525 viscosity
refrigerant oil.
10. Connect the auxiliary evaporator hose to the
auxiliary evaporator.
Tighten
Tighten the auxiliary evaporator hose to
17 N-m (131b ft).
11. Install the right front wheelhouse. Refer to Wheel
Opening Flare Replacement - Rear (Suburban
and Utility).
compressor hose (4) with 525 viscosity
refrigerant oil.
14. Connect the refrigerant hose assembly (6) to the
auxiliary compressor hose.
Tighten
Tighten the refrigerant hose assembly to
24 N-m (18 1b ft).
evaporator hose (3) with 525 viscosity
refrigerant oil.
18. Connect the auxiliary evaporator tube (1) to the
auxiliary evaporator hose.
Tighten
19. Install the air cleaner assembly.
and Recharging.
Testing.
Evaporator Tube Replacement
Removal Procedure
(Suburban- Front).
Coolant Recovery Reservoir Replacement.
evaporator.
condenser.
257983
refrigerant oil.
Notices.
Tighten
refrigerant oil.
Tighten
Coolant Recovery Reservoir Replacement.
(Suburban- Front).
and Recharging.
Testing.
Thermal Expansion Valve Replacement
Removal Procedure
3. Remove the evaporator core. Refer to Evaporator
Core Replacement - Auxiliary (Suburban).
4. Complete the following steps in order to remove
the TXV from the evaporator core:
• Remove the clip retaining the capillary tube to
the suction pipe.
• Remove the TXV from the evaporator
inlet pipe.
1. Install the TXV to the evaporator core by
completing the following steps:
• Install the TXV to the evaporator core
inlet pipe.
• Install the capillary tube to the suction line.
• Install the capillary tube to the retaining clip.
2. Install the evaporator core. Refer to Evaporator
Core Replacement - Auxiliary (Suburban).
3. Charge the system. Refer to Evaporator Core
Replacement.
Expansion (Orifice) Tube

Replacement (C60)
Removal Procedure
Tools Required
J 26549-E Orifice Tube Remove and Installer
Replacement.
condenser (1). Refer to Evaporator Tube
Replacement.
5. Cap or plug the open line.
258002
6. Use the J 26549-E in order to remove the
expansion (orifice) tube (3) from the condenser
outlet pipe (2).
In the event of difficulty during the removal or a
restricted or plugged expansion (orifice) tube, take
the following steps:
6.1. Remove as much of any impacted residue
as possible.
Important: Do not overheat the pipe
6.2. Carefully apply heat with a heat gun (hair
drier, epoxy drier, or similar item)
approximately 7 mm (0.25 in) from the
dimples on the inlet pipe.
6.3. While applying the heat, use the J 26549-E
in order to grip the expansion orifice tube.
6.4. Use a turning motion along with a push-pull
motion in order to loosen the impacted
expansion (orifice) tube.
Remove the tube.
1. Use the J 26549-E in order to install the expansion
tube (3) into the condenser outlet pipe (2).
2.1. Coat the O-ring seal with 525 viscosity
refrigerant oil.
2.2. Insert the short screen end of the new
orifice into the evaporator tube.
Refer to Evaporator Tube Replacement.
4. Install the grille. Refer to Air Inlet Grille Panel
Replacement.
and Recharging.
Testing.
258002
Expansion (Orifice) Tube

Replacement (C69) 1
Removal Procedure
Tools Required
J 26549-E Orifice Tube Remover and Installer
2. Remove the air cleaner assembly, if necessary.
3. Disconnect the evaporator tube (4) connection
near the junction block (6).
5. Cap or plug the open line.
6. Use the J 26549-E in order to remove the orifice
tube (1) from the evaporator tube.
258004
1. Use the J 26549-E in order to install the orifice
tube (1) into the evaporator tube (3).
2. Coat the new O-ring seal (4) with 525 viscosity
refrigeration oil.
Notices.
4. Connect the evaporator tube connection (6).
Tighten
Tighten the tube connection to 24 N-m (18 Ib ft).
and Recharging.
6. Inspect the system for- leaks. Refer to Leak
Testing.
Condenser Replacement
R em oval P ro ce d u re .. / .
2. Remove the grille. Refer to Air inlet Grille Panel
Replacement
3. Remove the hood primary latch support.
4. Remove the auxiliary cooling fan, If equipped.
Refer to Cooling Fan and Motor Replacement -
Auxiliary.
5. Disconnect the refrigerant hose from the
condenser. Refer to the appropriate procedure
from the following list:
• Compressor Hose Assembly Replacement
(Gasoline Engines)
(Diesel Engines)
condenser. Refer to Evaporator Tube
Replacement
7. Cap or plug all the open connections.
9. Remove the brackets.
10. Remove the upper insulators.
11. Bend outboard the left grille support in order to
gain clearance for the condenser removal.
Remove the condenser.
12. Remove the lower .insulators.
Installation Procedure^
1. Install the lower insulators.
2. Install the condenser.
If the condenser is being replaced, add oil. Refer
to Refrigerant Recovery and Recharging.
3. Install the upper insulators.
4. Install the brackets.
Notices.
Tighten
Tighten the bolts to 4.5 N*m (40 Ib in).
Refer to Evaporator Tube Replacement
7. Connect the refrigerant hose to the condenser.
Refer to the appropriate procedure from the
following list:
(Gasoline Engines)
(Diesel Engines)
8. Install the auxiliary cooling fan, if equipped. Ref^r
to Cooling Fan and Motor Replacement - Auxiliary.
9. Install the hood primary latch support.
10. Install the grille. Refer to A ir Inlet Grille Panel
Replacement
and Recharging.
Testing.
Accumulator Replacement
Removal Procedure
Tools Required
J 38042 Dual O-Ring Tube Separator
C a u tio n : Refer to B a tte ry D is c o n n e c t C a u tio n in
necessary.
4. Remove the pressure cycling switch.
accumulator using the J 38042. Refer to
the appropriate procedure from the following list:
(Gasoline Engines)
• ■ Compressor Hose Assembly Replacement
(Diesel Engines)
6. Disconnect the accumulator from the evaporator
using the J 38042.
Important: Cap or plug all of the open connections.
7. Remove the O-ring seals from the accumulator.
8. Remove the accumulator bracket screw.
9. Remove the accumulator.
10. Remove the upper and the lower accumulator
insulators.
1. Install the upper and lower accumulator insulators.
2. Install the accumulator.
If the accumulator is being replaced, add oil.
Refer to Refrigerant Recovery and Recharging.
Notices.
3. Install the accumulator bracket screw.
Tighten
Tighten the screw to 6 N-m (53 Ib in).
4. Coat the new O-ring seals with 525 viscosity
refrigerant oil.
5. Install the new O-ring seals.
6. Connect the accumulator to the evaporator.
Tighten
Tighten the accumulator to 41 N-m (30 Ib ft).
Refer to the appropriate procedure from the
following list:
(Gasoline Engines)
(Diesel Engines)
8. Connect the pressure cycling switch.
257998
and Recharging.
Testing.
Blower Motor Relay Replacement

Removal Procedure
2. Remove the instrument panel compartment. Refer
to Compartment Replacement - IP in Instrument
3. Disconnect the electrical connectors as necessary.
4. Remove the relay (3) from the relay bracket.
257990
1. Install the relay (3) to the relay bracket.
2. Connect the electrical connectors, as necessary,
3. Install the instrument panel compartment.
Refer to Compartment Replacement - IP in
257990
Blower Motor 'Resistor Replacement
Removal Procedure
C a u t io n : R e f e r t o B a t t e r y D is c o n n e c t C a u t io n in
C a u tio n s a n d N o tic e s .
2. Roll back the instrument panel. Refer to
Compartment Replacement - IP in Instrument
3. Remove the plenum tray.
necessary.
5 . :Remove the screws (1).
6. Remove the blower motor resistor (2).
Notices.
Tighten
Tighten the screws to 1 .4 N-m (12 Ib in).
4. Install the plenum tray.
Compartment Replacement - IP in instrument

Removal Procedure
C a u t i o n : Refer t o B a t t e r y D i s c o n n e c t C a u t i o n i n
C a u tio n s a n d N o tic e s .
2. Remove the instrument panel compartment. Refer
to Compartment Replacement - IP in Instrument
3. Remove the front screw from the right door
sill plate.
4. Remove the right hinge pillar trim panel. Refer to
Trim Panel Replacement - Hinge Pillar in
Interior Trim.
5. Disconnect the electrical connectors to the
powertrain control module (PCM), as necessary.
On diesel engines only, remove the PCM and
the mounting bracket.
6. Disconnect the electrical connectors from the
blower motor (5), as necessary.
7. Remove the bolt from the right lower instrument
panel support.
9. Remove the blower motor cooling tube.
10. Remove the blower motor flange screws (4).
the blower motor:
• Carefully pull forward, the blower motor in order
to avoid distorting the blower fan.
• Pry back the right side of the instrument panel,
as necessary.
12. Complete the following inspection steps:
• Inspect the blower motor terminals for
distortion.
Glean any corrosion from the terminals, or
replace the blower motor as necessary.
® Inspect the flange of the blower motor for any
damage or distortion that may cause an
air leak.
Repair the flange, as necessary. ;
• Inspect the blower fan for any damage or
distortion.
1. Guide the blower motor (5) and the blower fan
into position in order to install the blower motor
Use care in order to avoid catching the blower fan
on-any protruding parts.
2 . Install the blower motor flange screws (4).
3. Install the blower motor cooling tube.
5. Install the bolt to the right lower instrument panel
support.
7. Install the mounting bracket and the engine
control module (ECM).
8. Connect the electrical connectors to the ECM, as
necessary.
9. Install the right hinge pillar trim panel. Refer to
Trim Panel R eplacem ent - Hinge Pillar in
Interior Trim.
10. Install the front screw into the front door sill plate.
11. Install the instrument panel compartment. Refer
to Com partm ent R eplacem ent - IP in Instrument
Evaporator Core Replacement
Removal Procedure
Caution: Reer to Battery Disconnect Caution in
Filling Cooling System.
4. Remove the instrument panel. Refer to
5. Disconnect the electrical connectors, as necessary.
6. Remove the floor air outlet. Refer to Air Outlet
Replacement - Floor in Heating and Ventilation
(Non-A/C).
7. On diesel engines only, remove the powertrain
control module.
8. Remove the hinge pillar trim panels. Refer to Trim
Panel Replacement - Hinge Pillar in Interior Trim.
10. Remove the blower motor (5). Refer to Blower
Motor and Fan Replacement.
11. Remove the steering column. Refer to the
appropriate procedure from the following list:
• From Steering Wheel and Column — Standard:
Except C 3500HD)
• From Steering Wheel and Column — Tilt:
Except C 3500HD)
12. Tilt back the instrument panel assembly. Refer to
Actuator Replacement - Front and Rear Vertical.
Engine Cooling.
14. Disconnect the heater hoses. Refer to the
necessary procedures in Heating and Ventilation
(Non-A/C) from the following list:
• Heater Hoses Replacement (Inlet Hose-
4.3L,5.0L,5.7,7.4L)
• Heatr Hoses Replacement (Outlet Hose-
4.3L, 5.0L, 5.7L)
• Heater Hoses Replacement (Outlet Hose- 7.4L)
• Heater Hoses Replacement
(Inlet Hose- Diesel)
• Heater Hoses Replacement
• Heater Hoses Replacement - Auxiliary
(Suburban- Front)
15. Disconnect the evaporator tube. Refer to
Evaporator Tube Replacement.
16. Remove the accumulator. Refer to Accumulator
Replacement.
17. Remove the screws (1, 4).
18. Remove the nut (2).
258009
19. Remove the screw (2).

20. Remove the module assembly (2).
Ask an assistant for help in removing the module
assembly, if necessary.
21. Remove the seven screws in order to remove the
cover plate (8) on the bottom of the evaporator
case from the module assembly.
22. Remove the heater core and the seal from the
module assembly.
23. Remove the four screws in order to remove the
case cover (6) of the evaporator from the module
assembly.
24. Remove the evaporator core.
1. Install the evaporator core.
If the evaporator core is being replaced, add oil.
Refer to Refrigerant Recovery and Recharging.
2. Install the four screws that hold the case cover (6)
of the evaporator to the module assembly.
3. Install the heater core and the seal into the
module assembly.
4. Install the seven screws that hold the cover
plate (8) on the bottom of the evaporator case
to the module assembly.
5. Install the module assembly (2).
Ask an assistant for help in installing the module
assembly, if necessary.
6. Install the screw (1).
7. Install the nut (2).
8. Install the screws (1, 4).
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
Tighten
• Tighten the module mounting screw to
11N-m (97 Ib in).
• Tighten the nut (2) to 2.8 N-m (25 Ib in).
• Tighten the screws (1, 4) to 1.9 N-m (17 Ib in).
10. Install the accumulator. Refer to A c c u m u l a t o r
11. Connect the evaporator tube. Refer to E v a p o r a t o r
T u b e R e p la c e m e n t.
12. Connect the heater hoses. Refer to the necessary
procedures in Heating and Ventilation (Non-A/C)
from the following list:
® H e a t e r H o s e s R e p la c e m e n t (In le t H o s e -
4 .3 L , 5 .0 L , 5 .7 ,7 .4 L )
• H e a t e r H o s e s R e p la c e m e n t (O u tle t H o s e -
4 .3 L , 5 .0 L , 5 .7 L )
• H e a t e r H o s e s R e p la c e m e n t (O u tle t H o s e - 7 .4 L )
• H e a t e r H o s e s R e p la c e m e n t
(In le t H o s e - D ie s e l)
• H e a te r H o s e s R e p la c e m e n t
(O u tle t H o s e - D ie s e l)
• H e a t e r H o s e s R e p la c e m e n t - A u x ilia r y
(S u b u rb a n - F ro n t)
C o o l a n t R e c o v e r y R e s e r v o i r R e p l a c e m e n t in
Engine Cooling.
14. Install the instrument panel. Refer to C o m p a r t m e n t
R e p l a c e m e n t - I P in Instrument Panel, Gauges
and Console.
15. Install the steering column. Refer to the
appropriate procedure from the following list:
• From Steering Wheel and Column — Standard:
- S te e r in g C o lu m n R e p la c e m e n t (A ll C /K
Except C 3500H D )
- S te e r in g C o lu m n R e p la c e m e n t ( C 3 5 0 0 H D )
• From Steering Wheel and Column — Tilt:
- S t e e r i n g C o l u m n R e p l a c e m e n t ( A ll C / K
Except C 3500H D )
- S te e r in g C o lu m n R e p la c e m e n t ( C 3 5 0 0 H D )
16. Install the blower motor (5).
18. Install the hinge pillar trim panels. Refer to Trim
Panel Replacement - Hinge Pillar in Interior Trim.
19. Install the powertrain control module and
the mounting tray.
20. Install the floor air outlet. Refer to Air Outlet
Replacement - Floor in Heating and Ventilation
(Non-A/C).
22. Add the engine coolant.
and Recharging
Testing.
Heater Core Replacement

For the complete replacement procedure, refer to
Heater Core Replacement in Heating and Ventilation
(Non-A/C).

For the complete replacement procedure, refer to the
appropriate procedure in Heating and Ventilation
(Non-A/C) from the following list:
• Heater Hoses Replacement (Inlet Hose-
4.3L,5.0L,5.7,7.4L)
• Heater Hoses Replacement (Outlet Hose-
4.3L, 5.0L, 5.7L)
• Heater Hoses Replacement (Outlet Hose- 7.4L)
• Heater Hoses Replacement (Inlet Hose- Diesel)
• Heater Hoses Replacement (Outlet Hose- Diesel)
Heater Water Valve Replacement

Removal Procedure
1. Drain the cooling system. Refer to Draining and
2. Remove the access panel nut near the pollen
filter.
3. Remove the access panel.
4. Remove the following components from the hot
water flow control valve:
• The vacuum hose
• The remaining hose clamps
• The remaining hoses
5. Remove the hot water flow control valve.
153285
1. Install the hot water flow control valve.
2. Install the following hot water flow control valve
components;
• The hoses
• The hose clamps
• The vacuum hose
3. Install the access panel.
4. Install the access panel nut until fully seated and
not stripped.
5. Fill the cooling system. Refer to Draining and
153285
Control Assembly Replacement

Removal Procedure
1. Remove the bezel—IP cluster. Refer to Bezel
Replacement - IP Cluster
2. Remove the radio for access. Refer to Radio
Replacement
3. Remove the heater control assembly by firmly
depressing and holding the retaining tabs and
then sliding the assembly away from the dash.
Disconnect the temperature and mode cables

from the back of the control head.
Disconnect the electrical connection from the
control head.
5. Remove the control head.
1. Connect the electrical connection to the
control head
2. Connect the temperature and mode cables to the
back of the control head.
482493
3. Install the control head to the l/P carrier until a

snap is heard.
4. Install the radio. Refer to Radio Replacement in
Entertainment.
5. Install the bezel—IP cluster. Refer to Bezel
Replacement - IP Cluster in Instrument Panel,
Gauges and Console.
257069
Blower Switch Replacement

Removal Procedure
1. Remove the instrument cluster trim. Refer to
2. Remove the control assembly by completing the
following steps:
2.1. Use a small screwdriver in order to release
the retainers.
2.2. Pull the control assembly from the
instrument panel.
necessary.
257069
Installation Procedure -
1. Connect the electrical connectors as necessary.
2. Snap the control assembly to the instrument panel.
3. Install the instrument cluster trim. Refer to
Compartment Replacem ent - IP in Instrument
Mode Actuator Replacement

Removal Procedure...
1. Disconnect the negative battery cable, ■
2. Disconnect the electrical connector to the mode
actuator that is located on the left side of the air
distribution case.
4. Remove the adjuster links from the control lever.
5. Remove the mode actuator.
6. Adjust the mode actuator by completing the
following steps:
6.1. Connect the electrical connector to the
actuator.
6.2. Turn the ignition switch to the RUN position.
Allow the self-positioning of the actuator.
6.3. Turn the ignition switch to the OFF position.
6.4. Remove the actuator from the electrical
connection.
1. Install the mode actuator.
3. Install the adjuster links to the control lever.
Temperature Actuator Replacement

Removal Procedure
Compartment Replacement - /P in Instrument
3. Disconnect the electrical connector from the
temperature actuator that is located in the
passenger compartment, on the front of the
heater case.
5. Remove the actuator.
6. Adjust the actuator by completing the
following steps:
6.1. Connect the electrical connector to the
actuator.
6.2. Turn the ignition switch to the RUN position
Allow the self-positioning of the actuator.
6.3. Turn the ignition switch to the OFF position.
6.4. Remove the actuator from the electrical
connection.
1. Install the actuator
4. Install the instrument panel compartment. Refer to
258026
Air Distributor Duct Replacement

Removal Procedure
2. Remove the instrument panel bezel. Refer to
3. Remove the radio. Refer to Radio Replacement in
Entertainment.
4. Roll back the instrument panel. Refer to
5. Remove the duct mounting screws.
6. Remove the duct from the instrument panel.
258015
1. Install the duct to the instrument panel.
Notices.
2. Install the duct mounting screws.
Tighten
4. Install the radio. Refer to Radio Replacement in
Entertainment.
5. Install the instrument panel bezel. Refer to
258015
Control Assembly Replacement - Front
Auxiliary A/C
Removal Procedure
2. Remove the overhead console. Refer to Console
3. Disconnect the electrical harness from the control
assembly.
4. Remove the control assembly from the overhead
console.
257120
1. Install the control assembly to the overhead
console.
2. Connect the electrical harness to the control
assembly.
3. Install the overhead console. Refer to Console
257120
Control Assembly Replacement - Auxiliary

(Suburban)
Removal Procedure
1. Remove the bezel
3. Disconnect the electrical harness from the
control assembly.
assembly.
Control Assembly Replacement - Auxiliary

(4-Door Utility)
Removal Procedure
1. Remove the bezel
3. Disconnect the electrical harness from the
control assembly.
258041
assembly.
258041
Expansion (Orifice) Tube Replacement -
Auxiliary
Removal Procedure
evaporator.
condenser.
6. Disconnect the evaporator tube from the auxiliary
evaporator hose.
8. Remove the evaporator tube.
1. Install the evaporator tube.
refrigerant oil.
Notices.
4. Connect the evaporator tube to the auxiliary
evaporator hose.
Tighten
refrigerant oil.
Tighten
refrigerant oil.
10. Connect the evaporator tube to the evaporator.
Tighten
and Recharging.
Testing.
Replacement - Auxiliary (5.7L)
Removal Procedure
Tools Required
2. Remove the bolt.
compressor.
5. Disconnect the hose from the accumulator using
the J 38042. Refer to O-Ring/Fiat Washer
Description.
6. Disconnect the hose from the auxiliary A/C line
using the J 38042. Refer to O-Ring/Fiat Washer
Description.
7. Remove the O-ring seals from the hose.
8. Remove the hose from the clip.
condenser.
258049
refrigerant oil.
2. Install the new O-ring seals to the auxiliary
A/C hose.
Notices.
3. Connect the hose assembly to the auxiliary
A/C line.
Tighten
Tighten the hose assembly to 24 N*m (18 lb ft).
refrigerant oil.
6. Connect the hose assembly.
Tighten
refrigerant oil.
8. Install the new O-ring seals to the
accumulator hose.
Tighten
10. Install the sealing washers. Refer to Compressor
Sealing Washers Replacement
258049
compressor.
Tighten
13. Charge the system. Refer to R e f r i g e r a n t R e c o v e r y
a n d R e c h a r g in g .
14. Inspect the system for leaks. Refer to L e a k
T e s t in g .
Removal Procedure
Tools Required
J 3 8 0 4 2 Dual O-ring Separator
1. Recover the refrigerant. Refer to R e f r i g e r a n t
R e c o v e r y a n d R e c h a r g in g .
2. Remove the bolt.
compressor.
4. Remove the sealing washers. Refer to
C o m p r e s s o r S e a lin g W a s h e r s R e p la c e m e n t.
the J 3 8 0 4 2 . Refer to O - R i n g
R e p l a c e m e n t - D u a l.
using the J 3 8 0 4 2 . Refer to O - R i n g
8. Remove the hose from the clip.
condenser.
258061
refrigerant oil.
A/C hose.
Notices.
A/Cline.
Tighten
refrigerant oil.
Tighten
refrigerant oil.
accumulator hose.
Tighten
Tighten the hose assembly to 24 N-m. (18 ib ft).
10. Install the sealing washers. Refer to Compressor
Sealing Washers Replacement
compressor.
Tighten
and Recharging.
Testing.
Removal Procedure
Tools Required
J 38042 Dual O-RIng Separator
1. Recover the refrigerant. Refer to R e f r i g e r a n t
R e c o v e r y a n d R e c h a r g in g .
2. Remove the bolt.
compressor.
4. Remove the sealing washers. Refer to
C o m p r e s s o r S e a lin g W a s h e r s R e p la c e m e n t.
the J 3 8 0 4 2 . Refer to O - R i n g
using the J 3 8 0 4 2 . Refer to O - R i n g
8. Remove the hose from the bracket.
condenser.
refrigerant oil.
A/C hose.
Notices.
A/C line.
Tighten
refrigerant oil.
Tighten
refrigerant oil.
accumulator hose.
Tighten
10. Install the sealing washers. Refer to C o m p r e s s o r
S e a lin g W a s h e r s R e p la c e m e n t.
258072
compressor.
Tighten
Tighten the bolt to 34 N»m (25 Ib ft).
and Recharging
Testing.
Evaporator Core Replacement - Auxiliary

(Suburban)
Removal Procedure
3. Remove the rear quarter interior trim, as
necessary. Refer to Trim Panel Replacement -
Rear Quarter (Suburban) in Interior Trim.
Trim Panel Replacement - Rear Quarter (Utility) in
Interior Trim.
5. Remove the right rear wheelhouse. Refer to
6. Disconnect the rear heater hoses from the
auxiliary heater core (7), if equipped. Refer
to Heater Hoses Replacement - Auxiliary
(Suburban- Rear) in Heating and Ventilation
(Non-A/C).
7. Disconnect the auxiliary refrigerant hoses from the
auxiliary evaporator (6). Refer to Heater Hoses
Replacement - Auxiliary (Suburban- Front)
in Heating and Ventilation (Non-A/C).
necessary.
the heater/evaporator case cover:
9.1. Remove the case clips.
9.2. Remove the 11 screws.
9.3. Separate the case halves.
10. Remove the pipe insulator.
2. Install the pipe insulator.
3. Install the heater/evaporator case cover clips.
258121
4. Install the blower motor (2) to the case.

5. Install the auxiliary case to the vehicle.
6. Connect the auxiliary refrigerant hoses to the
auxiliary evaporator (6). Refer to Heater Hoses
Replacement - Auxiliary (Suburban- Rear) in
Heating and Ventilation (Non-A/C).
7. Connect the rear heater hoses to the auxiliary
heater core (7), if equipped. Refer to Heater
Hoses Replacement - Auxiliary (Suburban- Rear)
in Heating and Ventilation (Non-A/C).
9. Install the right rear wheelhouse. Refer to
10. Install the right rear quarter trim panel. Refer to
Trim Panel Replacement - Rear Quarter
(Suburban) in Interior Trim.
11. Install the rear quarter interior trim. Refer to Trim
Panel Replacement - Rear Quarter (Utility) in 258108
Interior Trim.
Evaporator Core Replacement - Auxiliary
(4-Door Utility)
Removal Procedure
3. Remove the rear quarter interior trim, as
necessary. Refer to Trim Panel Replacement -
Rear Quarter (Utility) in Interior Trim.
Interior Trim.
5. Disconnect the auxiliary refrigerant hoses from the
necessary.
the evaporator case cover:
7.1. Remove the screws (2) securing the case
to the rear quarter sheet metal.
7.2. Remove the blower housing (3) from the
rear of the case.
7.3. Remove the 10 case clips (6).
7.4. Separate the case halves.
8. Remove the pipe insulator.
2. Install the pipe insulator.
3. Install the clips (6) to the evaporator case cover.
4. Install the screws (2) to the evaporator
case cover.
5. Install the auxiliary case to the vehicle.
6. Connect the auxiliary refrigerant hoses to the
to Trim Panel Replacement - Rear Quarter
(Utility) in Interior Trim.
9. Install the rear quarter interior trim. Refer to Trim
Panel Replacement - Rear Quarter (Utility) in
Interior Trim.
Evaporator Tube Replacement - Auxiliary 5. Install the new O-ring seal. Coat the O-ring seal
525 viscosity refrigerant oil.
Removal Procedure 6. Install the auxiliary compressor hose to the
1. Recover the refrigerant. Refer to Refrigerant auxiliary evaporator.
Recovery and Recharging. T ig h te n
2. Remove the air cleaner assembly. Tighten the auxiliary compressor hose to
3. Remove the evaporator tube from the auxiliary 32 N-m (24 Ib ft).
evaporator hose. 7. Install the new O-ring seal. Coat the O-ring seal
4. Remove the O-ring seal. with 525 viscosity refrigerant oil.
5. Remove the refrigerant hose assembly from the 8. Install the auxiliary evaporator hose to the
auxiliary compressor hose. auxiliary evaporator.
6. Remove the O-ring seal. T ig h te n
7. Remove the right front wheelhouse panel. Refer Tighten the auxiliary evaporator hose to
to Wheelhouse Panel Replacement (Right) in 17 N-m (131b ft).
Body Front End. 9. Install the right front wheelhouse panel. Refer to
8. Remove the auxiliary evaporator hose from the Wheelhouse Panel Replacement (Right) in Body
auxiliary evaporator. Front End.
9. Remove the O-ring seal. 10. Install the new O-ring seal. Coat the O-ring seal
with 525 viscosity refrigerant oil.
10. Remove the auxiliary compressor hose from the
auxiliary evaporator. . 11. Install the refrigerant hose assembly to the
auxiliary compressor hose.
T ig h te n
Tighten the refrigerant hose assembly to
13. Remove the hose clips.
24 N-m (181b ft).
14. Remove the auxiliary evaporator hose. 12. Lower the vehicle.
15. Remove the auxiliary compressor hose. 13. Install the new O-ring seal. Coat the O-ring seal
Installation Procedure with 525 viscosity refrigerant oil.
1. Install the auxiliary compressor hose. 14. Install the evaporator tube to the auxiliary
evaporator hose.
2. Install the auxiliary evaporator hose.
T ig h te n
3. Install the hose clips.
15. Install the air cleaner assembly.
Notices.
4. Install the screws. and Recharging.
Tighten 17. Inspect the system for leaks. Refer to Leak
Tighten the screws to 6 N-m (53 Ib in). Testing.
Auxiliary (Suburban)
Removal Procedure
necessary.
4. Remove the screws (4) securing the blower motor
resistor (5).
5. Remove the blower motor resistor.
Notices.
2. Install the screws (4) in order to secure the blower
motor resistor.
T ig h te n
258108

Auxiliary (4-Door Utility)
Removal Procedure
Interior Trim.
necessary.
4. Remove the screws securing the blower motor
resistor (1).
5. Remove the blower motor resistor.
258125
1. Install the blower motor resistor ( 1).
Notices.
2. Install the screws in order to secure the blower
motor resistor.
Tighten
Blower Motor and Fan Replacement -

Auxiliary (Suburban)
R em oval P ro c e d u re
4. Remove the screws (3) securing the blower
motor (2).
5. Remove the cooling tube.
6. Remove the blower motor.
258108
7. Remove the fan cage from the motor.

1. Install the fan cage to the motor.
2. Install the blower motor (2) to the case.

Notices.
T ig h te n
4. Install the cooling tube.
8. Test the check circuit operation.
258108
Blower Motor and Fan Replacement -

Auxiliary (4-Door Utility)
Removal Procedure
Interior Trim.
4. Remove the screws (2) securing the blower
motor (3).
5. Remove the blower housing/motor assembly.
6. Remove the blower motor from the blower
housing.
7. Remove the fan cage from the motor.
In sta lla tio n P ro c e d u re

1. Install the fan cage to the motor.
2. Install the blower motor (3) to the blower housing.

3. Install the blower housing to the case.
Notices.
Tighten
8. Test the check circuit operation.
Blower Motor Relay Replacement - Temperature Actuator Replacement -
Auxiliary Auxiliary
Removal Procedure Removal Procedure
Caution: Refer to Battery Disconnect Caution in Caution: Refer to Battery Disconnect Caution In
Cautions and Notices. Cautions and Notices.
1. Disconnect the negative (-) battery cable. 1. Disconnect the negative battery cable.
2. Remove the right rear quarter trim panel. Refer to 2. Remove the right rear quarter trim panel. Refer to
the appropriate procedure in Interior Trim: the appropriate procedure in Interior Trim:
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (P ic k u p )
(P ic k u p )
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (E x te n d e d C a b )
(E x te n d e d C a b )
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (C re w C a b )
(C re w C a b ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (S u b u rb a n )
(S u b u rb a n ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r ( U t ilit y )
( U t ilit y ) 3. Disconnect the electrical connector from the
3. Disconnect the electrical connector from the temperature actuator.
blower motor relay. 4. Remove the temperature actuator from the
4. Disconnect the blower motor relay from the auxiliary A/C module.
bracket. Installation Procedure
Installation Procedure 1. Install the temperature actuator to the auxiliary
A/C module.
1. Install the blower motor relay to the bracket.
2. Install the screws that secure the temperature
2. Connect the electrical connector to the blower actuator to the auxiliary A/C module.
motor relay. 3. Connect the electrical connector to the
3. Install the right rear quarter trim panel. Refer to temperature actuator.
the appropriate procedure in Interior Trim: 4. Install the right rear quarter trim panel. Refer to
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r the appropriate procedure in Interior Trim:
(P ic k u p ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (P ic k u p )
(E x te n d e d C a b ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
• T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r (E x te n d e d C a b )
(C re w C a b ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
(C re w C a b )
(S u b u rb a n ) • T r im P a n e l R e p l a c e m e n t - R e a r Q u a rte r
(S u b u rb a n )
( U t ilit y )
( U t ilit y )
4. Connect the negative battery cable. 5. Connect the negative battery cable. Inspect the
5. Inspect the circuit operation. circuit operation.
Mode Actuator Replacement - Auxiliary Thermal Expansion Valve Replacement -
Auxiliary
Removal Procedure
1. Remove the left side rear quarter trim. Refer to Removal Procedure
T r im P a n e l R e p la c e m e n t - R e a r Q u a r t e r Caution: Refer to Battery Disconnect Caution In
( S u b u r b a n ) in Interior Trim. Cautions and Notices.
2. Disconnect the vacuum line from the vacuum 1. Disconnect the negative battery cable.
actuator. 2. Recover the refrigerant. Refer to R e f r i g e r a n t
3. Remove the vacuum actuator from the heater A/C R e c o v e r y a n d R e c h a r g in g
module. 3. Remove the evaporator core. Refer to E v a p o r a t o r
C o r e R e p la c e m e n t - A u x ilia r y (S u b u r b a n ).
Installation Procedure 4. Complete the following steps in order to remove
1. Install the vacuum actuator to the heater A/C the TXV from the evaporator core:
module. • Remove the clip retaining the capillary tube to
2. Connect the vacuum line to the vacuum actuator. the suction pipe.
3. Install the left side rear quarter trim. Refer to • Remove the TXV from the evaporator
T r im P a n e l R e p l a c e m e n t - R e a r Q u a r t e r inlet pipe.
( S u b u r b a n ) in Interior Trim. Installation Procedure
1. Install the TXV to the evaporator core by
completing the following steps:
• Install the TXV to the evaporator core
inlet pipe.
• Install the capillary tube to the suction line.
• Install the capillary tube to the retaining clip.
2. Install the evaporator core. Refer to E v a p o r a t o r
C o r e R e p la c e m e n t - A u x ilia r y (S u b u r b a n ).
3. Charge the system. Refer to E v a p o r a t o r C o r e
Description and Operatio n
A/C System Description
System Components
257927
Legend
(1) Compressor, A/C (5) Switch, Pressure Cycling
(2) Condenser, A/C (6) Bag, Dessicant
(3) Evaporator, A/C (7) Hole, Oil Bleed
(4) Accumulator, A/C (8) Orifice, A/C Condenser
The cycling clutch orifice tube (CCOT) refrigerant When an air conditioning mode is selected, the
system cycles a compressor (1) on and off in order to compressor clutch coil receives electrical energy. As
maintain the desired cooling. This cycling also the compressor reduces the evaporator pressure
prevents evaporator freeze-up. The temperature to approximately 175 kPa (25 psi), the pressure switch
selector on the control assembly maintains comfort in opens, de-energizing the compressor clutch. The
the passenger compartment comfort. system moves towards equalization and the pressure
reaches approximately 315 kPa (46 psi). Then, the
A switch that senses low side pressure as an indicator pressure switch contacts close, telling the PCM
of the evaporator pressure controls the refrigeration to recognize the clutch relay. The cycling continues
cycle, or the on and off operation of the compressor. and maintains the evaporator surface temperature at
The cycling pressure switch is the freeze protection approximately 7°C (45°F) depending on ambient
device in the system. The switch also senses refrigerant and relative humidity. Higher ambient temperature and
pressure on the suction side of the system. This switch higher humidity equal higher discharge temperature.
is located on a standard service low-side fitting. With air Some slight increases and decreases of engine
temperatures of 16-26°C (60-80°F), the increased speed/power may occur under certain conditions, due
pressures within the charged air conditioning system to the cycling. This is normal. The system cycles in
closes the contacts of the pressure switch. order to maintain maximum cooling, without evaporator
freeze-up.
Additional compressor protection results from the The sealed accumulator assembly only allows the
operating characteristics of the low-side cycling refrigerant vapor and the refrigerant oil to flow to the
pressure system. If a massive discharge occurs in the compressor.
low side of the system, or the orifice tube becomes At the bottom of the accumulator is a desiccant that
plugged, the contacts of the pressure switch may not acts as a drying agent for moisture that may enter the
close due to insufficient low-side pressures. If there system. An oil bleed hole, located near the bottom
is a low charge, insufficient cooling accompanied of the accumulator outlet pipe, provides an oil return
by rapid compressor clutch cycling is noticeable at high path to the compressor.
air temperatures. A low-side pressure service fitting is located on the
When the engine is OFF while the air conditioning accumulator. A similar service fitting is provided
system is operating, the refrigerant in the system flows for mounting the cycling pressure switch. Do not to
from the high-pressure side of the expansion tube discharge the system when replacing the switch.
(orifice) to the low pressure side until the pressure Service the accumulator only as a replacement
moves towards equalization. This may be detected as assembly.
a hissing sound for 30-60 seconds. The hissing is Compressor
normal. The Harrison HT-6 compressor is belt-driven by the
The air conditioning systems available for the vehicle engine crankshaft through the compressor clutch
are the following: pulley. The compressor pulley rotates freely, without
turning the compressor shaft, until an electromagnetic
• C60 Front Manual Controls, HVAC System
clutch coil is energized. When applied voltage
• C69 Rear, HVAC System energizes the clutch coil, a clutch plate and hub
assembly move rearward toward the compressor
Unit Repair Information clutch pulley. The magnetic force locks the clutch plate
For the bench repair procedures of the Harrison and the compressor clutch pulley together as one
HT-6 air conditioning compressor, refer to HD6/HT6 unit in order to drive the compressor shaft.
Air Conditioning Compressor Service Or Unit All the replacement compressors from the service
Repair R-134a. parts have 240 ml (8 fl oz) of oil in the crankcase.
When replacing the compressors, drain the oil from
Air Distribution System Description the old compressor into an approved container.
Note the amount drained. Drain the oil from the new
The electronically-actuated doors control airflow. At compressor. Then, fill the new compressor with new oil
various positions of the rotary knobs on the control in the same amount that was drained from the old
assembly, the mode doors mix and direct cooled, compressor.
heated, and outside air through the air
distribution duct. Handling A/C Compressor
Do not strike, drop, or turn the compressor upside
Ducts and Outlets down. If the compressor is knocked over or turned
A one-piece air distributor duct directs air to the upside down, rotate the compressor’s clutch at least
passenger compartment. The air distributor duct 6 time by hand in order to circulate the oil which
attaches to the instrument panel with snap-in style has settled in the cylinder. Sudden rotation with oil in
retainers and 3 screws. the cylinder will cause damage and adversely
affect durability.
In the case of poor air output, inspect the air distributor
duct for the following obstructions. Condenser
• Leaves The condenser assembly in front of the radiator
consists of coils that carry the refrigerant, and cooling
• Dirt fins, that provide the rapid transfer of heat. Air
• Other objects that may fall into the air distributor passing through the condenser cools the high-pressure
duct from the passenger compartment refrigerant vapor, causing condensation.
Refrigeration System Description

Accumulator
The sealed accumulator assembly connects to the
evaporator outlet pipe. The sealed accumulator
assembly functions as a liquid/vapor separator that
receives the following:
• The refrigerant vapor
• Some liquid refrigerant
• The refrigerant oil from the evaporator
Expansion (O rifice) Tube
Thermal Expansion Valve (TXV)
The rear air conditioning system uses a Thermal
Expansion Valve (TXV). The valve consists of
the following components:
• The capillary tube
• The body
• The actuating pins
• The seat
• The orifice
At the high pressure liquid inlet a fine mesh screen
prevents dirt, filings or other foreign material from
entering the valve orifice.
When the valve is connected in the system, high
pressure liquid refrigerant enters the valve through the
screen from the condenser. The high pressure
liquid refrigerant then passes to the seat and the
orifice, where the refrigerant changes into a low
pressure liquid.
82109
The low pressure liquid leaves the valve and flows
The plastic expansion tube, with the mesh screen and into the rear evaporator core, where the liquid absorbs
orifice is in the condenser outlet pipe in all the heat from the rear evaporator core. There, the liquid
models, except the models with rear air conditioning changes to a low pressure vapor and leaves the
(RPO C69). Models equipped with rear air conditioning rear evaporator core. The capillary tube is clamped to
use a Y-shaped junction block in the tube between the low pressure vapor line just below the outlet of
the condenser and the front evaporator. The junction the rear evaporator. The capillary tube is held in
block is near the right side of the radiator support. contact with the rear evaporator outlet tube by a metal
The expansion tube (2) is between the junction block clip placed near the end of the tube.
and the front evaporator. Refer to Expansion Evaporator
(Orifice) Tube Replacement - Auxiliary or HVAC The evaporator cools and dehumidifies the air before
Component Views. the air enters the vehicle. High pressure liquid
The orifice tube provides a restriction to the refrigerant flows through the orifice tube (front system)
high-pressure liquid refrigerant in the liquid line, or TXV (rear system) into the low pressure area of
metering the flow of refrigerant to the evaporator as a the evaporator. The heat in the air passing through the
low-pressure liquid. The filter screens on both the evaporator core is lost to the cooler surface of the
inlet and outlet sides protect the expansion tube and core, thereby cooling the air. When the process of heat
orifice from contamination. Service the tube only loss from the air to the evaporator core surface
takes place, any moisture in the air condenses on the
as a replacement assembly.
outside surface of the evaporator core. This
When the engine is turned OFF with the air condensed moisture drains as water.
conditioning operating, the refrigerant in the system
flows from the high-pressure side of the expansion
Heater Core
tube orifice to the low-pressure side until the pressure In any air conditioning mode, the heater core heats
moves towards equalization. This is detectable as the cool, dehumidified air in order to achieve the
a faint hissing sound for 30-60 seconds. The hissing desired temperature. The position of the control
is normal assembly temperature rotary knob determines how
much heat is added to the incoming air.
When system diagnostics indicate a restricted
expansion tube, replacement of the restricted High Pressure Relief Valve
expansion tube may not be necessary. Metal chips, The compressor has a pressure relief valve as a
flakes, or slivers found on the screen may be removed safety factor. Under certain conditions, the refrigerant
with compressed air. Reuse the expansion tube on the discharge side may exceed the designed
under the following conditions: operating pressure. Exceeding this pressure limit may
cause refrigerant loss out of the pressure relief
• The plastic frame is not broken. valve. In order to prevent refrigerant loss or
• The expansion tube is not damaged or plugged. compressor damage, the high pressure cutoff switch
opens automatically at approximately 2758 kPa:
• The screen material is not torn.
(400 psi). Opening the switch interrupts the current to
• The screen is not plugged with fine gritty material the compressor clutch. Any condition that causes
the opening of the switch keeps the compressor from
operating.
Caution; Avoid breathing A/C Refrigerant-134a and Important:
lubricant vapor and mist Exposure may irritate • Use only the approved lubricant for the R-134a
eyes, nose, and throat To remove R-134a from the system and the R-134a components. If lubricants
A/C system, use service equipment certified to other than those specified are used, compressor
meet the requirements of SAEJ2210 (R-134a failure may occur. Coat all of the fittings and
recycling equipment). If a c c id e n ta l :system the O-ring seals with a clean approved refrigerant
discharge occurs, ventilate the work area before oil. This action will provide a leak-proof seal
resuming service. Additional health and safety and to aid in assembly and disassembly.
information may be obtained from the refrigerant
• Do not store or heat the refrigerant containers
and lubricant manufacturers.
above 125°F (52°C).
Like the coolant in the engine cooling system, the • Do not heat a refrigerant container with an open
refrigerant is the substance in the air conditioning flame. If the container must be warmed, place
system that absorbs, carries, and then releases heat. the bottom of the container in a pail of warm water.
Although various substances are used as refrigerants • Do not drop, puncture, or incinerate the
in other types of refrigeration systems, some refrigerant containers.
automotive air conditioning systems use a type called
• Refrigerant will displace oxygen. Work in
Refrigerant-12 (R-12)
well-ventilated areas in order to prevent
This vehicle uses Refrigerant 134-a (R-134a). R-134a suffocation.
is a non-toxic, non-flammable, clear gas. • Do not introduce compressed air to any refrigerant
While the R-134a A/C system is very similar to an container or refrigerant component. The action
R-12 A/C system, the differences in the refrigerant, may cause the contamination of the refrigerant.
lubricants, and service equipment are important. • If it is necessary to carry a container of Dot CFR
Refrigerant -134a carries a charge of a special Refrigerant-134a in a vehicle, do not carry it in
lubricant called polyalkaline glycol (PAG) refrigerant the passenger compartment.
oil. GM PAG refrigerant oil has a slight blue tint. The oil
is hydroscopic (absorbs water from the atmosphere). Handling of Refrigerant Lines and Fittings
Store the oil in closed containers.
• Ensure that the metal lines do not exhibit the
Heater System Description following conditions.
The heater system provides the following functions: This will prevent the loss of system capacity due
to line restriction:
® Heating
- Dents
• Ram air
- Kinks
• Power ventilation
• Do not bend the flexible hose line to a radius of
• Windshield defrosting less that 4 time the diameter of the hose.
The blower fan draws outside air from the plenum at • Do not allow the flexible hose line to come within
the base of the windshield into the heater module. a distance of 63.5 mm (2 1/2 in) of the exhaust
Forward movement of the vehicle forces additional manifold.
outside air, called ram air, into the heater module.
Within the heater module, the air heats as required. • Inspect the flexible hose lines regularly.
Then, the ducts route the air to the proper outlets Replace the flexible hose line with new hose if
for the discharge into the passenger compartment. A one of the following conditions exist:
control assembly in the instrument panel allows - Leaks
the operator control of the following items: - Brittleness
• The blower speed - Deterioration
® The mode of operation • Before disconnecting any fitting in the refrigeration
• The temperature of the air coming from the heater system, discharge all of the Refrigerant-134a.
system Refer to R e f r i g e r a n t R e c o v e r y a n d R e c h a r g i n g .
• Once you open a refrigerant line to the
Handling Refrigerant R-134a atmosphere, cap or tape the line immediately.
Caution: Avoid breathing the A/C Refrigerant 134a This will prevent any of the following items from
(R-134a) and the lubricant vapor or the mist. entering the line:
Exposure may irritate the eyes, nose, and throat.
Work in a well ventilated area. In order to remove - Moisture
R-134a from the A/C system, use service - Dirt
equipment that is certified to meet the • Use the proper wrenches when you make
requirements of SAE J 2210 (R-134a recycling connections on the O-ring fittings.
equipment). If an accidental system discharge
Back-up the opposing fitting with a wrench in
occurs, ventilate the work area before continuing
order to prevent distortion of the following areas:
service. Additional health and safety information
may be obtained from the refrigerant and lubricant - The connecting lines
manufacturers. - The components
• Tighten all of the tubing connections to the ® Before recharging an A/C system that has been
specified torque. opened, properly evacuate and vacuum test
Too much or too little torque may result in the the system.
following conditions: ® Service parts are dehydrated and sealed prior to
- Loose joints shipping. Retain the parts in their sealed
packages until you are ready to use them.
- Deformed joint parts
® Ensure the parts are at room temperature before
- Refrigerant leakage
opening the packages. This prevents condensation
- An inoperative A/G system on the parts from humidity in the atmosphere.
• Ensure that the O-rings and the seats are in ® Attach the A/C service equipment quick-connects
perfect condition. as soon as possible after removing the
A burr or a piece of dirt may cause a service caps.
refrigerant leak.
® Install new O-rings that you have lubricated with Thermal Expansion Valve Description
the mineral base 525 viscosity refrigerant oil. The rear air conditioning system uses a Thermal
Do not use polyalkylene glycol (PAG) synthetic oil. Expansion Valve (TXV). The valve consists of
Do not wipe the threads with a cloth. the following components:
® Keep PAG synthetic refrigerant oil off fitting ® The capillary tube
threads. Long term contact of PAG synthetic oil on • The body
threads may cause future disassembly difficulties.
Flush threads of fitting with mineral base 525 ® The actuating pins
viscosity refrigerant oil. Do not use PAG synthetic ® The seat
oil. Do not wipe threads with a cloth. • The orifice
At the high pressure liquid inlet a fine mesh screen
Maintaining Chemical Stability prevents dirt, filings or other foreign material from
The chemical stability of the refrigeration system plays entering the valve orifice.
an important role in the efficient operation and When the valve is connected in the system, high
longevity of the A/C system. pressure liquid refrigerant enters the valve through the
When air, moisture or particulate contamination are screen from the condenser. The high pressure
introduced into the refrigeration system, the following liquid refrigerant then passes to the seat and the
results will occur: orifice, where the refrigerant changes into a low
® The chemical stability of R-134a and polyalkylene pressure liquid.
glycol (PAG) synthetic lubricant will change. The low pressure liquid leaves the valve and flows
• The pressure/temperature symmetry will change. into the rear evaporator core, where the liquid absorbs
heat from the rear evaporator core. There, the liquid
• The A/C system efficiency will be diminished.
changes to a low pressure vapor and leaves the
® Internal A/C system parts may corrode and/or rear evaporator core. The capillary tube is clamped to
wear in an abnormal manner. the low pressure vapor line just below the outlet of
Use the following general practices to maintain the rear evaporator. The capillary tube is held in
chemical stability in the refrigeration system: contact with the rear evaporator outlet tube by a metal
• Wipe away dirt and/or oil before you break a clip placed near the end of the tube.
refrigerant connection. This will reduce the
possibility of particulate contamination. Expansion (Orifice) Tube Description
• Cap, plug or tape both sides of an open The plastic expansion tube, with the mesh screen and
connection as soon as possible. This will minimize orifice is in the condenser outlet pipe in all the models,
the amount of dirt and moisture entering the except the models with rear air conditioning (RPO C69).
system. Models equipped with rear air conditioning use a
• Ensure that the following remain clean and dry: Y-shaped junction block in the tube between the
- The tools being used for the repair condenser and the front evaporator. The junction block
- The surrounding area of the repair is near the right side of the radiator support. The
expansion tube is between the junction block and the
- The hoses and connectors for the ACR4 front evaporator. Refer to Expansion (Orifice) Tube
machine or manifold gage set Replacement - Auxiliary or HVAC Component Views.
- The replacement parts
The orifice tube provides a restriction to the
• When adding polyalkylene glycol (PAG) lubricant, high-pressure liquid refrigerant in the liquid line,
ensure the transfer device and the container metering the flow of refrigerant to the evaporator as a
remain clean and dry to minimize moisture low-pressure liquid. The filter screens on both the
intrusion. inlet and outlet sides protect the expansion tube and
® Do not leave the A/C system open any longer orifice from contamination. Service the tube only
than necessary. as a replacement assembly.
When the engine is turned OFF with the air Accumulator Description
conditioning operating, the refrigerant in the system
flows from the high-pressure side of the expansion 1
tube orifice to the low-pressure side until the pressure
equalizes. This is detectable as a faint hissing
sound for 30-60 seconds. The hissing is normal
When system diagnostics indicate a restricted
expansion tube, replacement of the restricted
expansion tube may not be necessary. Metal chips,
flakes, or slivers found on the screen may be removed
with compressed air. Reuse the expansion tube
under the following conditions:
• The plastic frame is not broken.
• The expansion tube is not damaged or plugged.
• The screen material is not tom.
• The screen is not plugged with fine gritty material.
Evaporator Description
The evaporator cools and dehumidifies air before the 7
air enters the passenger compartment. The following
82105
events occur in the evaporator:
1. Low-pressure, low temperature liquid/vapor Legend
refrigerant enters the evaporator. (1 ) Refrigerant Vapor Inlet
2. The refrigerant flows through the evaporator’s (2 ) Inlet
tubing. (3) Baffle
3. The refrigerant evaporates. (4) Internal Tube
4. The refrigerant exits the evaporator as (5) Desiccant Bag
low-pressure, low temperature, mostly vapor (6 ) Filter
refrigerant.
(7) Oil Bleed Hole Location—In the Tube
5. As the refrigerant evaporates, the refrigerant
(8 ) Outlet
absorbs heat from the air flowing over the
evaporator.
As the process of heat loss from the air to the The sealed accumulator is connected to the evaporator
evaporator core is taking place, any moisture outlet pipe. The accumulator stores the refrigerant
(humidity) in the air condenses on the outside surface (vapor and liquid) and the oil from the evaporator. A
of the evaporator core and the moisture drains off desiccant at the accumulator bottom dries any
as water. moisture in the system. An oil bleed hole at the
accumulator outlet pipe end provides the oil return
Condenser Description path to the compressor. The accumulator is not
serviceable and should only be replaced when leaking
The condenser receives high pressure, high due to the following conditions:
temperature refrigerant vapor from the A/C compressor.
The condenser is made up of aluminum tubing and • Perforation
cooling fins which allow rapid heat transfer away from • A damaged sealing area
the high-pressure, high temperature refrigerant vapor.
The cooling fins cause the high pressure, high • Damaged fastener threads
temperature refrigerant vapor to condense into a • Outside air has entered the system for extended
high-pressure, medium temperature liquid. periods of time
Heater Core Description All the replacement compressors from the service
parts have 240 ml (8 fl oz) of oil in the crankcase.
The heater core is the main component of the heater
system. The heater core is located inside of the When replacing the compressors, drain the o il from
heater and evaporator module. Engine coolant is the old compressor into an approved container.
pumped into the heater core from the engine whenever Note the amount drained. Drain the oil from the new
the engine is operating. The heater core fins transfers compressor. Then, fill the new compressor with new oil
the heat from the engine coolant to the air passing in the same amount that was drained from the old
over the heater core. The heater core has specific inlet compressor.
and outlet tubes. The placement of the heater hoses
should be noted prior to servicing the heater core High Pressure Relief Valve Description
or the heater hoses.
The compressor has a pressure relief valve as a safety
The temperature control is linked to the temperature
factor. Under certain conditions, the refrigerant on
valve by a flexible control cable. When you rotate
the discharge side may exceed the designed operating
temperature control counterclockwise to the full COLD
position, the temperature valve is held snugly pressure. Exceeding this pressure limit may cause
against the air entrance to the heater core. The refrigerant loss out of the pressure relief valve. In order
following actions occur: to prevent refrigerant loss or compressor damage,
the high pressure cutoff switch opens automatically at
® All of the airflow from the evaporator bypasses the
approximately 3036 kPa (440 psi). Opening the
heater core.
switch interrupts the current to the compressor clutch.
• No heat transfer occurs. Any condition that causes the opening of the switch
When you turn the temperature control away from the keeps the compressor from operating.
full COLD position, the temperature valve begins to
C a u t i o n : A v o i d b r e a t h i n g A / C Refrigerant-134a and
direct air to the heater core. This action allows
air to flow through the heater core. The farther the l u b r i c a n t v a p o r a n d m i s t E x p o s u r e m a y irritate
temperature control is rotated clockwise, the more the e y e s , n o s e , a n d t h r o a t T o r e m o v e R-134a from the
temperature valve directs air through the heater A / C s y s t e m , u s e s e r v i c e e q u i p m e n t c e r t i f i e d to
core. The air discharge is warmer when most of the m e e t t h e r e q u i r e m e n t s o f S A E J2210 (R-134a
airflow is heated in this manner. The air discharge re c y c lin g e q u i p m e n t ) . I f a c c i d e n t a l s y s t e m
is warmer because the heated and unheated air flows d i s c h a r g e o c c u r s , v e n t i l a t e t h e w o r k area before
join and mix together thoroughly beyond the r e s u m in g s e r v ic e . A d d itio n a l h e a lth a n d s a fe ty
heater core. i n f o r m a t i o n m a y b e o b t a i n e d f r o m t h e refrigerant
a n d lu b r ic a n t m a n u fa c tu r e r s .
When you rotate the temperature lever clockwise to
the full HOT position, the temperature valve blocks off Like the coolant in the engine cooling system, the
the passage that allows air to bypass the heater refrigerant is the substance in the air conditioning
core. This action causes passage of the airflow system that absorbs, carries, and then releases heat.
through the heater core. Although various substances are used as refrigerants
in other types of refrigeration systems, some
Compressor Description automotive air conditioning systems use a type called
Refrigerant-12 (R-12)
Compressor
This vehicle uses Refrigerant 134-a (R-134a). R-134a
The HT-6 compressor is belt-driven by the engine is a non-toxic, non-flammable, clear gas.
crankshaft through the compressor clutch pulley. The
compressor pulley rotates freely, without turning While the R-134a A/C system is very similar to an
the compressor shaft, until an electromagnetic clutch R-12 A/C system, the differences in the refrigerant,
coil is energized. When applied voltage energizes lubricants, and service equipment are important.
the clutch coil, a clutch plate and hub assembly move Refrigerant - 1 34a carries a charge of a special
rearward toward the compressor clutch pulley. The lubricant called polyalkaline glycol (PAG) refrigerant
magnetic force locks the clutch plate and the oil. GM PAG refrigerant oil has a slight blue tint. The oil
compressor clutch pulley together as one unit in order is hydroscopic (absorbs water from the atmosphere).
to drive the compressor shaft. Store the oil in closed containers.
Control Assembly Description Relays and Sensors Description
Blower Controls
The battery voltage is supplied at all times to the
No. 1 blower relay through the HTR A/C fuse and the
RED wire. When the control assembly is in the OFF
position, all the blower relays de-energize. In this state,
a voltage path through the relay contacts to the blower
motor does not exist. The blower motor does not run.
With the low blower speed selected, the current flows
through the No. 1 relay to the top of the resistor
board (A) and to both resistors.
With medium #1 blower speed selected, the current
flows through the No. 1 relay, to the No. 2 relay, to the
center of the resistor board (A), and one resistor to
the motor.
With medium #2 blower speed selected, the current
flow is the same as in medium #1. In addition, a
parallel current path goes through resistor (B) and the
No. 3 blower relay to the blower motor. This provides
a parallel path with a value less than one alone,
257929
but more voltage than for medium #1 blower speed. .
The air conditioning system on C/K models is With high blower speed selected, No. 1 and
electronically controlled. Three backlit, rotary knobs No. 2 blower relays are off. Relay No. 3 is on.
provide full control of the system. The rotary knobs Relay No. 3 provides a parallel battery feed circuit to
control the following items: the blower motor.
• The blower speed Compressor Pressure Switch
• The air temperature This system is equipped with a compressor pressure
• The mode of operation switch that is normally open. The switch activates
at 2758-2758 kPa (380-400 psi). The switch releases
Two push-to-latch buttons select recirculation mode at 1724 kPa (250 psi).
for maximum cooling and control over the air The switch drives the recirculation door to the closed
conditioning compressor. position in order to reduce the system load and
The blower speed rotary control has 4 fan speeds and decrease the system high-side pressure.
an OFF position. When the blower fan is turned off,
High Pressure Cutoff Switch
all the HVAC operations turn off also.
The system also has a high pressure cutoff switch.
The temperature rotary control has 180 degrees of This switch is normally closed. The switch opens
travel. A detent at the full cold-end of travel-engages at 2827-3103 kPa (410-450 psi) in order to interrupt
recirculation. Operating the system with the the voltage to the compressor coil. This stops the
temperature control placed in the detent results in compressor from cycling, and prevents the pressure
maximum cooling. Air inside the passenger relief valve from discharging refrigerant and oil.
compartment recirculates through the blower case.
Use of outside air is minimal. Manually select Pressure Cycling Switch
recirculation by pushing the RECIRC button. A switch that senses the low-side pressure as an
The mode rotary control has 3 major detents that indicator of evaporator temperature controls the
indicate mode positions: refrigeration cycle, the on and off operation of the
compressor. The pressure cycling switch is the freeze
® The vent protection device in the system. The switch senses
• The floor refrigerant pressure on the suction side of the system.
® The defrost The switch mounts on a standard service low-side
fitting. This switch also provides compressor
Placing the control anywhere in between the major cutoff during cold weather.
detents results in air output blending between the Additional compressor protection results from the
two modes. The recirculation mode is not available operating characteristics of the low-side pressure
anytime DEFROST is selected, or while air is cycling system. If a massive discharge occurs in the
being blended out of the defrost outlets. low side of the system, or the orifice tube becomes
Automatic recirculation occurs when the compressor plugged, low-side pressures may be insufficient
head pressures exceed 2275 kPa (350 psi) and in closing the contacts of the pressure switch. In the
disables after the head pressures reach 1724 kPa event of a low charge, insufficient cooling accompanied
(250 psi). When activated, automatic recirculation by rapid compressor clutch cycling is noticeable at
cannot be manually disabled by the MAX button. high outside or ambient air temperatures.
Do not remove the refrigerant charge in order to The auxiliary medium blower relay is energized when
replace the pressure cycling switch. The pressure the auxiliary heater control switch is in the MED
switch fitting has a service fitting. During the position. The current flows to the motor through 1
replacement of the pressure switch, install a new resistor and the motor operates at an intermediate
O-ring seal. Assemble the switch to 4.5 N-m (40 Ib in). speed. The auxiliary high blower relay is energized
when the auxiliary heater control switch is in the
ORm g/Flat Washer Description HI position. The current bypasses both resistors and
Install new approved service replacement air the motor operates at the highest speed.
conditioning O-ring(s) and flat washers whenever'a The auxiliary heater control switch provides an
joint or fitting is disassembled. illumination lamp in order to facilitate switch operations.
Some vehicles use flat sealing washers andO-ring(sj The lamp is powered by the instrument panel
to seal the refrigerant system. The flat washers are dimming system. .
used on block fittings of refrigerant components. The auxiliary blower motor is controlled by either of
The O-ring(s) is used to seal the refrigerant tubes. 2 auxiliary blower switches when the optional auxiliary
The O-ring fitting consists of: heating and air conditioning is provided. Both
• An aluminum alloy, externally threaded fitting switches are located in the overhead modules.
which is welded to an aluminum tube. 1 switch is located in the instrument panel. The other
® A free-spinning internally threaded nut. . switch is located in the center of the vehicle. The
auxiliary blower motor operates from the auxiliary
• An aluminum tube end which accommodates the
O-ring(s). blower switch. The auxiliary switch is located at the
front auxiliary HVAC control module and is in the
Verify that the flat washers or O-ring(s) have not been REAR position. Refer to HVAC Air Delivery Circuit
damaged prior to installation. Replace damaged parts. Description for a description of the control priorities for
Coat O-ring(s) and flat washers with the approved the ventilation modes.
refrigerant oil.
CKT 341 (BRN) supplies voltage to relay coil cavity 5
Failure to use the proper service replacement parts of each of the three auxiliary blower relays when
and procedures may result in a leak.
the ignition switch is in the RUN position. CKT 542
Service Gaps Seal ' . ■ (RED) supplies battery voltage to contact cavity 1
The primary seal for the service ports is the sealing of each of the 3 auxiliary blower relays when
cap. The cap contains a specially designed O-ring or the ignition switch is in the RUN position. No ground
gasket which provides a leak free seal. Should the path is provided for the relay coils when the auxiliary
cap be loose, missing, or the wrong usage, a loss of blower switch located at the front auxiliary HVAC
refrigerant could result. control module is in the OFF position. The relays
remain de-energized. The relay contacts remain open.
HVAC Blower Controls Circuit Description No voltage is supplied to the auxiliary blower motor.
A ground path is provided for the auxiliary low
Auxiliary Blower Controls blower relay through CKT 1925 (DK BLU) to the front
(Heater Without A/C) blower switch when the ignition switch is in the
CKT 341 (BRN) supplies battery voltage to relay coil RUN position, and the blower switch (located at the
cavity 5 of each of the 3 auxiliary blower relays front module) is in the LO position. A ground path
when the ignition switch is in the RUN position. is provided through CKT 150 (BLK) to ground G400.
CKT 542 (RED) supplies battery voltage to cavity 1 of The relay coil energizes. The relay contacts close. The
each of the 3 auxiliary blower relays when the relay coil applies battery voltage to the auxiliary
ignition switch is in the RUN position. The relay coils blower resistor through CKT 1176 (YEL). The current
are not grounded and the relays remain de-energized flows through the 2 resistors and to the auxiliary
when the auxiliary heater control switch is in the blower motor through CKT 1172 (YEL). The motor
OFF position. The auxiliary blower motor is supplied
operates at the slowest speed.
no voltage and the relay contacts remain open.
A ground path is provided for the auxiliary low blower;" The ground path is different when the auxiliary blower
relay coil through CKT 1926 (DK BLU) to the control switch at the front HVAC control module is in the
switch when the ignition switch is in the RUN position, REAR position. The ground path is different when the
and the auxiliary heater control switch is in the LO auxiliary blower switch at the auxiliary HVAC control
position. A ground path is then provided through module is in the' LO position. The ground path travels '
CKT 150 (BLK) to ground G200. The relay coil through CKT 1925 (DK BLU) to the auxiliary HVAC
energizes and the relay contacts close. CKT 1176 control module. CKT 77 (DK BLU) continues the
(YEL) applies battery voltage to the auxiliary blower ground path to the auxiliary and HVAC control logic
resistor. CKT 1172 (YEL) carries a current through module. CKT 77 (ORN) continues the ground path to
2 resistors and to the auxiliary blower motor. The the front auxiliary HVAC control module and
motor operates at the slowest speed. continues-to ground G400.
The auxiliary medium blower relay is energized when One switch is located in the instrument pane. The
the auxiliary blower switch is in the MED position. other switch is located in the center of the vehicle. The
The current flows to the motor through one resistor. auxiliary blower motor operates from the auxiliary
The motor operates at an intermediate speed. blower switch. The auxiliary switch is located at the
The auxiliary high blower relay is energized when the front auxiliary HVAC control module and is in the
auxiliary blower switch is in the HI position. The REAR position. Refer to HVAC Air Delivery Circuit
current bypasses both resistors. The motor operates Description for a description of the control priorities for
at the highest speed. the ventilation modes.
In order to facilitate switch operations, an illumination CKT 341 (BRN) supplies voltage to relay coil cavity 5
lamp is provided at each HVAC control module. of each of the three auxiliary blower relays when
The lamps are powered by the instrument panel the ignition switch is in the RUN position. CKT 542
dimming system. (RED) supplies battery voltage to contact cavity 1
The circuit operation for the optional auxiliary system of each of the 3 auxiliary blower relays when
is similar to that for the optional auxiliary HVAC the ignition switch is in the RUN position. No ground
option. path is provided for the relay coils when the auxiliary
blower switch located at the front auxiliary HVAC
Auxiliary Blower Controls control module is in the OFF position. The relays
(Heater Without A/C) remain de-energized. The relay contacts remain open.
CKT 341 (BRN) supplies battery voltage to relay coil No voltage is supplied to the auxiliary blower motor.
cavity 5 of each of the 3 auxiliary blower relays A ground path is provided for the auxiliary low
when the ignition switch is in the RUN position. blower relay through CKT 1925 (DK BLU) to the front
CKT 542 (RED) supplies battery voltage to cavity 1 of blower switch when the ignition switch is in the
each of the 3 auxiliary blower relays when the RUN position, and the blower switch (located at the
ignition switch is in the RUN position. The relay coils front module) is in the LO position. A ground path
are not grounded and the relays remain de-energized is provided through CKT 150 (BLK) to ground G400.
when the auxiliary heater control switch is in the The relay coil energizes. The relay contacts close. The
OFF position. The auxiliary blower motor is supplied relay coil applies battery voltage to the auxiliary
no voltage and the relay contacts remain open. blower resistor through CKT 1176 (YEL). The current
A ground path is provided for the auxiliary low blower flows through the 2 resistors and to the auxiliary
relay coil through CKT 1926 (DK BLU) to the control blower motor through CKT 1172 (YEL). The motor
switch when the ignition switch is in the RUN position, operates at the slowest speed.
and the auxiliary heater control switch is in the LO The ground path is different when the auxiliary blower
position. A ground path is then provided through switch at the front HVAC control module is in the
CKT 150 (BLK) to ground G200. The relay coil REAR position. The ground path is different when the
energizes and the relay contacts close. CKT 1176 auxiliary blower switch at the auxiliary HVAC control
(YEL) applies battery voltage to the auxiliary blower module is in the LO position. The ground path travels
resistor. CKT 1172 (YEL) carries a current through through CKT 1925 (DK BLU) to the auxiliary HVAC
2 resistors and to the auxiliary blower motor. The control module. CKT 77 (DK BLU) continues the
motor operates at the slowest speed. ground path to the auxiliary and HVAC control logic
The auxiliary medium blower relay is energized when module. CKT 77 (ORN) continues the ground path to
the auxiliary heater control switch is in the MED the front auxiliary HVAC control module and
position. The current flows to the motor through one continues to ground G400.
resistor and the motor operates at an intermediate The auxiliary medium blower relay is energized when
speed. The auxiliary high blower relay is energized the auxiliary blower switch is in the MED position.
when the auxiliary heater control switch is in the The current flows to the motor through one resistor.
HI position. The current bypasses both resistors and The motor operates at an intermediate speed.
the motor operates at the highest speed. The auxiliary high blower relay is energized when the
The auxiliary heater control switch provides an auxiliary blower switch is in the HI position. The
illumination lamp in order to facilitate switch operations. current bypasses both resistors. The motor operates
The lamp is powered by the instrument panel at the highest speed.
dimming system. To facilitate switch operations, an illumination lamp is
The auxiliary blower motor is controlled by either of provided at each HVAC control module. The lamps
two auxiliary blower switches when the optional are powered by the instrument panel dimming system.
auxiliary heating and air conditioning is provided. The circuit operation for the optional auxiliary system
Both switches are located in the overhead modules. is similar to that for the optional auxiliary HVAC option.
HVAC Compressor Controls Circuit The HVAC control module supplies voltage through
Description CKT 66 (LT GRN) when the ignition switch is in
the RUN position. The front blower switch is NOT in
The compressor for the air conditioning system is the OFF position. The A/C push-button switch is
driven by the engine by means of a belt drive and the depressed or the mode control dial on the module is
A/C compressor clutch. The clutch allows the the defrost detent. The A/C push-button switch is
compressor to be disengaged when air conditioning is a latching switch which allows a light emitting diode,
not required. or LED, on the switch to be illuminated when the
module enables compressor operations from
The battery supplies voltage to the following the switch. The mode control dial detent switch does
components: not light the LED, but does operate the compressor
• The HVAC control module (when the ignition during defrosting operations in order to dry the air and
switch is in the RUN position). prevent fogging.
• The A/C compressor clutch relay coil (when the The HVAC control module’s temperature control dial
ignition switch is in the RUN position). detent switch is used to control the water flow into the
heater core, in the Suburban/Utility vehicles with
• The normally open A/C compressor clutch relay gasoline engines only. With the ignition switch is in the
contact. RUN position, adjusting the dial to the coldest
In the HVAC control module, the battery supplies setting applies voltage on CKT 1596 (GRY/BLK) and
voltage to a detent contact on the temperature control energizes the water shut off valve’s actuator. The
dial for operation of the water valve on the actuator, ground at G105 through CKT 150 (BLK),
Suburban/Utility with the gasoline engine only. when energized, opens sending engine vacuum to the
water valve. The applied vacuum closes the valve
To drive the A/C compressor clutch, the A/C isolating the coolant flow to the heater core providing
compressor clutch must be energized. The relay maximum cooling.
contact on CKT 59 (DK GRN) supplies voltage to the
clutch coil. Diode D104 in the harness is HVAC Air Delivery Circuit Description
reverse-biased and prevents current flow bypassing
the clutch coil to ground. The collapsing magnetic field Front Ventilation Controls
of the clutch coil forward-biases the diode and Vehicles with heating and air conditioning and vehicles
dissipates the energy from the magnetic field when with heat only provide front air delivery and
the relay coil is de-energized. temperature controls. The heater only option’s heater
control module operates similarly to the HVAG
The A/C compressor clutch relay energizes when
control module except that the A/C pushbutton and
CKT 459 (GRN/WHT) provides a ground path provides
temperature dial MAX detent features are not provided
for the relay coil. The powertrain control module
for the control of the recirculation door. An auxiliary
(PCM for diesel vehicles only), or the vehicle control
cooling fan is provided for vehicles with air conditioning
module (VCM) provides the ground path through
and 7.4L gasoline engines. Refer to Engine Cooling
contacts-equivalents in the control module. The control
Fan Description - Electric in Engine Cooling.
modules may stop compressor operations. The
modules may enable compressor operations under The following are powered by CKT 141 (BRN) when
certain operating conditions. the ignition switch is in the RUN position.
* The front mode door motor
The VCM or the PCM enables A/C compressor clutch
operations when a voltage input is received from • The front temperature door motor
the HVAC control module on CKT 762 ° The recirculation door motor
(DK GRN/WHT). The 2 switch contacts between the Grounding for the door motors is passes through
HVAC control module and the VCM/PCM can CKT 150 (BLK) to ground G202. CKT 141 (BRN)
isolate the voltage. The A/C compressor high pressure powers the HVAC control module when the ignition
cutout switch monitors the compressor high side switch is in the RUN position. Grounding passes
pressure. The switch contacts open in order to stop through CKT 150 (BLK) to ground G200 for the IP.
the compressor. This reduces the pressure when The HVAC control module ventilation controls for the
the pressure exceeds the limit. The switch does not front mode door and the recirculation door are
operate unless conditions are unusual. The A/C disabled when the module front blower switch is in the
compressor cycling switch compressor monitors low OFF position. The ventilation controls are enabled
side pressure in order to provide freeze protection. The when the front blower switch is in the HI, M2, M1, or
switch contacts open when the low side pressure LO positions. The front temperature door is not
reaches the limit. The contacts close when the dependent on the front blower operations. The front
pressure recovers. The switch operates normally in temperature door can be controlled only when
order to cycle the compressor while operating. the switch is in the RUN position.
The mode doors and the temperature doors are Rear Auxiliary Ventilation Controls
positioned in proportion to the variable voltage signal The rear auxiliary air delivery and the temperature
received from the HVAC control module. The controls provided with the combined rear auxiliary
temperature dial at the HVAC control module adjusts heater and air conditioner option, the C36 + C69, work
a rheostat which provides a voltage signal independently of the ventilation controls used for the
proportional to the dial position. CKT 733 (LT BLU) front of the vehicle. The front system provides a
carries the voltage to the front temperature door motor. recirculation door and the door controls. The rear
The front temperature door motor responds to the auxiliary system does not have the recirculation door
voltage signal. The mode dial at the HVAC control and the door controls. The rear auxiliary mode
module adjusts a rheostat. The mode dial provides a door and the rear auxiliary temperature door are
voltage signal proportional to the dial position. exclusively controlled from either of the 2 auxiliary
CKT 454 (WHT) carries voltage to the front mode door HVAC control modules. The front auxiliary HVAC
motor. The front mode door motor responds to the control module blower switch is located above the IP.
voltage signal. The front auxiliary HVAC control module blower
has a permissive position called REAR. The REAR
The recirculation door is a 2-position door. The position enables control from the rear auxiliary HVAC
recirculation door is in the recirculation position only control module. Relay contacts in the auxiliary
when input CKT 1614 (DK GRN) is grounded through HVAC control logic module change state in order to
the HVAC control module. The recirculation door is enable control input from the ventilation controls when
grounded when the auxiliary cooling fan A/C pressure in the REAR position with the ignition switch in the
switch operates the auxiliary cooling fan for air RUN position. The ventilation controls are located at
conditioned vehicles with 7.4L gasoline engines. Refer the- rear auxiliary HVAC control module. The logic
to Auxiliary Cooling Fan Circuit Description in module relay is de-energized when the front auxiliary
Engine Cooling. HVAC control module blower switch is NOT in the
The recirculation door is normally in the outside air REAR position. The logic module relay controls inputs
position but moves to the inside air position when the from the front auxiliary HVAC control module that
control the doors.
input wire is grounded. The LED on the HVAC
control module is illuminated when the recirculation Each control module produces a variable voltage
door is grounded through the HVAC control module. signal to the door motor. Each door motor is powered
from CKT 341 (BRN) when the ignition switch is in
the RUN position. Door grounding passes through
CKT 150 (BLK) to ground G400. The variable voltage
signal operates the door motor to a position
consistent with the signals voltage. The voltage
corresponds to the control dial selection on the
selected control module.
Special Too ls and Equipment
Illustration Tool Number/ Description Illustration Tool Number/ Description
J21213-A J 39400-A
Four Jack-Dual Range H-10 Leak Detector
Temperature Tester
3545 82132
IIf 1
£1 ' J 39500-B
J 26549-D
Orifice Tube Remover and ft Refrigerant Recovery,
Extractor Recycling and
(■S i Recharging (ACR4)
BJ
3546 82133
J26549-E J 39037
Orifice Tube Remover and Charge Valve (Socket)
Installer
82125 3549
J 38042
Dual O-Ring Separator
261768

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Chevrolet Suburban Service Manual

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Section 1

GM SPO Group Numbers

Heater Blower Controls Schematic Icons

Power <4- Underhood Power

On the right side B pillar, near the door

Engine harness approx. 6.5 cm (2.5 in)

S185 At Diode D104 — —

IP harness, approx. 8 cm (3 in) from the

IP harness, approx. 16 cm (6 in) from the

HVAC harness, approx. 8 cm (3 in) from

IP harness, approx. 24 cm (9.5 in) from the

( 1) Dash (4) IP Harness

( 1) Blower Resistor (7) Temperature Door Motor

Auxiliary Blower Motor m m

Connector Part 12034003

Connector Part 02977940 281199

Connector Part • 12034003 • 12064752

Auxiliary Heater Control Switch

Connector Part • 12004267 Connector Part • 12064877

Blower Motor Relay, High DK BLU 101 Blower Resistor Output

w n HVAC Control Module Connector C2

Air Delivery Improper If the cause of the condition is not discovered,

Blower Motor Inoperative at Any Speed - Auxiliary

Blower Motor Inoperative at High Speed Only

Blower Motor High Speed Inoperative - Auxiliary

Blower Motor Inoperative at Low Speed Only

Blower Motor Low Speed Inoperative - Auxiliary

Blower Motor Inoperative Med-2

Blower Motor Operates at High Speed Only - Auxiliary

1. Remove the auxiliary HVAC control module front

1. Connect all disconnect components test to this point.

Locate and repair the open the circuit(s) between cavity 2 of

Blower Motor Always On

1. Remove the high blower motor relay.

Connect a J 3 9 2 0 0 (continuity) between pins C1 and A2 of

1. Disconnect the HVAC control module connector C2.

Blower Motor Operates Continuously - Auxiliary

1. Adjust the heater controls to the following modes:

1. Inspect the following areas of the vehicle for cold

1. Remove the floor air outlet. Refer to A ir O u tle t

1. Inspect the following parts:

1. Turn the temperature rotary knob to full HOT.

Did you find and correct the condition? System OK Go to Step 14

4. Disconnect the temperature and mode cables

Blower Switch Replacement

Blower Motor and Fan Replacement

Air Outlet Replacement - Floor

Air Outlet Replacement - Rear Floor

3. Remove the instrument panel storage

Air Outlet Duct Replacement - Left Lap

7. Push the inlet hose (5) into the connector (1).

Heater Hoses Replacement

Heater Hoses Replacement

3. Connect the inlet hose (1) to the heater core.

Hot Water Bypass Valve Replacement

Heater Core Replacement

13. On the engine side of the cowl, remove the

7. On the interior side of the cowl, install the screw.

Control Switch Replacement - Auxiliary

Control Switch Replacement - Auxiliary

Heater Hoses Replacement - Auxiliary

8. Disconnect the heater inlet hose (1) from the tee

Notice: Refer to Fastener Notice in Cautions and

Heater Hoses Replacement - Auxiliary