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Utilimaster Aeromaster 2019, Manual, Page: 3 / 34

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Utilimaster Aeromaster 2019 Manual Download Page 3

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03103436-A10030 Rev. B

AC System Overview

EVAPORATOR

COMPRESSOR

CONDENSER
BLOCK HOSE

RECEIVER/
  DRYER

CHARGING PORT

CONDENSER

COMPRESSOR
      HOSE

LOW PRESSURE
    SWITCH

EVAPORATOR
       HOSE

DRYER HOSE

TRANSDUCER
        PORT

 BINARY 
SWITCH

CONDENSER
BLOCK HOSE

RECEIVER/
  DRYER

COMPRESSOR
      HOSE

LOW PRESSURE
    SWITCH

TRANSDUCER
        PORT

 BINARY 
SWITCH

RESISTOR

THERMOSTAT

AC system overview (plenum omitted for clarity)

Summary of Contents for Aeromaster 2019

Page 1: ...rator Coil 31 Test System 34 Heater with Air Conditioning 2019 and Later Aeromaster NOTICE The information in this document is generic Details in illustrations and procedures may differ from those in your vehicle Because Utilimaster manufactures many different customized vehicle bodies this document cannot list and illustrate every possible option for every vehicle Nevertheless the most common bod...

Page 2: ...Put the transmission in Park if it is an automatic and set the parking brake before working on the vehicle Avoid contact with hot metal parts such as the radiator or exhaust system Do NOT smoke while working on the vehicle Always remove rings watches hanging jewelry and loose clothing before working on a vehicle Tie long hair securely behind your head Keep yourself and your clothing away from the ...

Page 3: ...EIVER DRYER CHARGING PORT CONDENSER COMPRESSOR HOSE LOW PRESSURE SWITCH EVAPORATOR HOSE DRYER HOSE TRANSDUCER PORT BINARY SWITCH CONDENSER BLOCK HOSE RECEIVER DRYER COMPRESSOR HOSE LOW PRESSURE SWITCH TRANSDUCER PORT BINARY SWITCH RESISTOR THERMOSTAT AC system overview plenum omitted for clarity ...

Page 4: ...sconnect the wire harness 2 Remove the 6 screws to the blower motor 3 Disconnect the vent hose Blower motor Installation 1 Connect the vent hose 2 Secure the blower motor with 5 screws Secure the wire harness and fasten wire harness clamp with 1 screw and flat washer ...

Page 5: ...ts or the HVAC controls 2 Unplug the fan switch from the HVAC controls Control head connections A fan switch B temp connector C mode connector D recirculation connector E max AC connector F backlight socket B C D E A F 3 Disconnect 4 wire harness connectors 4 Remove 2 backlight bulbs with 1 2 turn Installation 1 Secure the backlight bulbs into the control head with 1 2 turn ...

Page 6: ...ors match at the connectors 2 Connect the 4 wire harness connectors to the control head Ensure that the male and female wire colors match the adjoining harnesses 3 Plug in the fan switch connector 4 Attach the control head to the dash panel with 4 screws and nuts ...

Page 7: ...r and expansion valve be replaced whenever the system is opened for service 1 Evacuate the air conditioning system of all refrigerant 2 Remove horns air rams and any other obstructions and set aside 3 Disconnect air conditioning hoses from dryer 4 Remove binary switch 5 Remove 2 screws from dryer mounting bracket and set aside Discard dryer A Horn fasteners B dryer binary switch and C mounting scr...

Page 8: ...be replaced at the same time 1 Install binary switch 2 Lubricate 2 new O rings with mineral oil and attach to dryer 3 Secure dryer hoses 4 Torque nuts 5 Secure dryer with 2 screws 6 Charge air conditioning system with refrigerant 7 Start vehicle and check air conditioning performance Dryer location under the hood ...

Page 9: ...two functions high pressure cut out and low pressure cut out Removal 1 Disconnect wire harness 2 Remove switch by turning counterclockwise and set aside Installation 1 Lubricate rubber seal inside switch with mineral oil 2 Secure switch by turning clockwise 3 Connect wire harness Binary switch on dryer ...

Page 10: ...Remove the keys from the ignition 2 If needed remove the front passenger s side splash guard and set aside Remove splash guard 3 Evacuate the air conditioning system of refrigerant 4 Remove the hose between the compressor and evaporator 5 Remove low pressure switch 6 Install low pressure switch to replacement hose 7 Torque switch 8 Install replacement air conditioning hose to evaporator Low pressu...

Page 11: ...sor fitting Hose fittings on compressor hoses removed for clarity TO EVAPORATOR TO CONDENSER COMPRESSOR FRONT 12 See dryer removal and installation Drier mounted under the hood 13 Torque hose fittings 14 Charge air conditioning system with refrigerant 15 Start vehicle and check air conditioning performance ...

Page 12: ...ose hose disconnected for clarity TRANSDUCER SWITCH HARNESS CONNECTOR CONDENSER BLOCK HOSE Removal 1 Disconnect the jumper harness from the AC condenser block hose 2 Use a combination wrench to remove transducer and discard Installation NOTICE The AC pressure transducer is chassis service part Refer to the chassis service information or your local dealer Use of an aftermarket transducer or high pr...

Page 13: ...ograph hose and wire configurations before removing them to ensure proper installation Reversing wires or hoses can damage AC components Depending on the model it may help to remove the dash cover to access the duct hoses and or the control head 1 Turn off the engine and remove the keys from the ignition 2 Move all heater controls to the OFF or COLD positions Typical dash cover fastener locations ...

Page 14: ...030 Rev B 4 Remove the 2 1 2 vent hoses Vent hoses are held in place with barbed catches 5 Disconnect the wire harness at the RH side of the plenum Plenum harness connector located between the plenum and evaporator assembly ...

Page 15: ...rom under the hood remove the 4 nuts and flat washers Plenum nuts under the windshield cowl 7 Pull the plenum away from cowl and place on a bench to service any of the internal components Plenum removed evaporator not shown for clarity ...

Page 16: ...v B Plenum Installation 1 Insert the plenum studs through the holes in the cowl Install 4 flat washers and nuts Torque the nuts to 25 29 lb ft 2 Connect the plenum harness to the evaporator assembly 3 Connect the 2 1 2 duct hoses ...

Page 17: ...oth the dash vents and or the defrost foot dump motors can be replaced 1 After the plenum is removed from the vehicle use a Phillips head screw driver to remove the 14 screws around the front metal panel and 2 screws from the face of the panel Front panel screws 2 Remove the wire harness clamp Wire harness clamp ...

Page 18: ...03436 A10030 Rev B 3 Remove 2 screws from the back facing panel and remove the blower adaptor Face panel screws and blower adaptor 4 Pull the plenum divider assembly out of the case Plenum divider assembly removed ...

Page 19: ...vo 6 Disconnect the wire harness and remove the 3 nuts spacers and screws holding the defrost foot dump servo 7 Remove the retaining washer from the actuator arm Defrost foot dump servo NOTICE When reassembling connect the wire harnesses BEFORE attaching the servo motors Use a socket to press the retaining washer in place Carefully install and align the wire grommets ...

Page 20: ...rvo Motor NOTICE The heater valve servo motor is mounted either on the cowl or mounted on top of the radiator bracket 1 Move all heater controls to the OFF or COLD positions 2 Place a catch pan under the vehicle for any coolant leakage 3 Remove any wire ties P clamps and protective convoluted tubing to allow access to the hose clamps and the heater valve ...

Page 21: ...onnect the wire harness 8 Install the replacement valve or servo motor 9 Connect the harness to the replacement motor 10 Attach the mounting bracket 11 Attach the hoses and secure the hose clamps to 39 43 in lbs 12 Release the clamps from the hoses 13 Clean up any coolant spill 14 Follow the chassis recommended practices for replacing any lost engine coolant 15 Start the engine and check the heate...

Page 22: ... 3 Evacuate the air conditioning system of all refrigerant 4 On some models it may be necessary to remove the washer fluid bottle and bracket This can often be done without disconnecting the washer hose or draining the bottle Wire tie the hose out of the way 5 From under the hood disconnect the fresh air inlet duct hose and remove the air chamber Fresh air inlet duct 6 Place a catch pan under the ...

Page 23: ...hoses when clamping Position the clamp jaws on the hose so that leading edges of the clamp do NOT bite into the hose 9 Loosen the hose clamps and disconnect the hoses from the heater core 10 Once the system is evacuated disconnect the air conditioning hoses from the expansion valve located under the hood where the evaporator connections come through the cowl Heater and AC hose connections at evapo...

Page 24: ...ers 12 Remove the 4 nuts and washers that attach the evaporator to the cowl Evaporator fasteners The capillary tube is filled with gas and very fragile Use caution when removing 13 From inside the vehicle pull the evaporator assembly way from the cowl Do NOT yank or force the evaporator out when removing ...

Page 25: ...f 34 03103436 A10030 Rev B 14 Disconnect the 2 wires to the thermostat the blower motor harness the recirculation servo motor and plenum harnesses at the evaporator Evaporator harnesses and thermostat wires ...

Page 26: ...heater hoses and release the vice clamps 8 Charge the AC system 9 Install the fresh air intake plenum replacement part number 17901244 NOTICE Clean the air filter when servicing the evaporator Refer to the chassis manual for information on checking the coolant level and proper replacement requirements Loss of engine coolant should be minimal but it is IMPORTANT to check and refill as necessary 10 ...

Page 27: ...evaporator assembly from the vehicle and set on a bench 2 Remove the recirculation vent filter Recirculation vent filter 3 Disconnect the blower motor wire harness Do NOT remove the blower motor 4 Remove the 22 screws around the perimeter of the casing Casing screws ...

Page 28: ...5 Remove 1 fine thread screw from the plenum adaptor Fine thread plenum adaptor screw 6 Carefully pull the the thermostat probe out while pulling the casing apart 7 Cut the top of the heater core gasket Cut and peal back foam gasket ...

Page 29: ...of 34 03103436 A10030 Rev B 8 Remove the 2 screws behind the gasket Screws behind the foam gasket 9 From inside the casing scrape remove the sealant away from the pass through holes Sealant at pass through ...

Page 30: ...the front side of the casing 2 Install the foam gasket on the front side 3 Apply sealant around the pass through on the inside of the casing 4 Secure 22 screws around the perimeter of the casing 5 Secure 1 fine thread screw to the plenum adaptor 6 Firmly install the thermostat probe into the fins of the AC coil Insert thermostat probe ...

Page 31: ...0 Install the evaporator assembly into the vehicle Evaporator Coil Removal 1 Remove the heater core 2 Remove the sealant at the pass through and from the screw heads casing platform A B B C A sealant B screws C casing platform 3 Remove 4 screws from the casting platform Remove 2 screws below the casing platform near the servo motor Screws above the servo motor ...

Page 32: ... 03103436 A10030 Rev B 4 Remove 3 screws from the front of the casing Front casing screws 5 Remove 2 screws at the base of the evaporator 1 at the front and 1 at the rear Casing screws at base of the evaporator ...

Page 33: ...rd side where servo motor is and sliding it out Slide the casing platform out to the left Casing platform removed 7 Replace the evaporator coil Installation 1 Slide the platform into the casing base to the right 2 Secure 1 screw at the base of the AC evaporator at the front and 1 at the rear 3 Secure the front of the casing with 3 screws 4 Secure 4 screws at the pass through tubes 5 Install the he...

Page 34: ...purpose of helping you with the operation of the described equipment Shyft makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Shyft shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this ...

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