heating DODGE NEON 1999 Service Owner's Guide

(5) Remove the center vent duct.
(6) Remove and block the Supply (Black) vacuum
line at the control. The test gauge should return to
the calibrated setting of 27 kPa (8 in. Hg). If not,
there is a leak in the Supply line.
(7) If there is no leak in the Supply line, reconnect
it to the Control and remove the Actuator Feed (Red)
line from the Control. Block the vacuum connection
on the Control from where the line was removed. The
test gauge should return to the calibrated setting of27 kPa (8 in. Hg.). If not, there is a leak in the Con-
trol.
(8) If there is no leak in the Supply line or the
Control, reconnect the Actuator Feed (Red) line to the
control. Remove and block the Actuator Feed (Red)
line at the Actuator. The test gauge should return to
the calibrated setting of 27 kPa (8 in. Hg.). If not
there is a leak in the Actuator Feed line.
(9) If there is no leak in the Supply line, Control,
or the Actuator Feed line, the leak must be in the
Actuator itself. Connect the Vacuum hose from the
Vacuum Test Gauge directly to the Actuator to verify
the leak. The Actuator vacuum port is accessible
behind and above the Glove Box.
LOCATING PINCHED VACUUM LINES
The operation of the Circulation door can be
viewed by removing the blower motor and looking up
into the unit inlet. See Blower Motor Wheel and
Assembly removal and installation in this section for
service procedures.
(1) Connect the test vacuum probe to the vehicles
(Black) supply hose. Position the vacuum test gauge
so it can be viewed from the passenger compartment.
(2) Place the Mode in the Panel position and the
Circulation control in the Recirculation position.
(3) Remove the right instrument panel top cover.
Fig. 12 Charge Determination Chart
Fig. 13 Adjust Vacuum Test Bleed Valve
PLHEATING AND AIR CONDITIONING 24 - 13
DIAGNOSIS AND TESTING (Continued)

(4) Remove the right side upper instrument panel
bezel.
(5) Remove the center vent duct.
(6) Remove the Supply (Black) vacuum line at the
control. The test gauge should drop indicating free
flow through the Supply line. If not, there is a block-
age in the Supply line.
(7) If there is no blockage in the Supply line,
reconnect it to the Control. Remove the Actuator
Feed (Red) line from the Control. The test gauge
should drop indicating free flow through the Supply
line and Control. If not the vacuum switches on the
Control are not functioning.
(8) If there is no blockage in the Supply line or the
Control, reconnect the Actuator Feed (Red) line to the
control. Remove the Actuator Feed (Red) line at the
Actuator. The Actuator vacuum port is accessible
behind and above the Glove Box. The test guage
should drop indicating free flow through the supply
line, Control, and the Actuator Feed line. If not,
there is a blockage in the Actuator Feed line.
(9) If there is no blockage in the Supply line, Con-
trol, or the Actuator Feed line, the Actuator must
have failed. Connect the Vacuum hose from the Vac-
uum Test Gauge directly to the Actuator to verify the
Actuator has failed.
SERVICE PROCEDURES
CHARGING A/C SYSTEM
PARTIAL CHARGE
This vehicle does not have a sight glass. It is not
possible to determine the amount of (R-134a) chargein the system. Therefore it is necessary to completely
evacuate and recover the system, and then recharge
the system fully.
EVACUATION
Before adding refrigerant, all air must be evacu-
ated from the system.
²Connect a manifold gauge set to the A/C service
ports (Fig. 14).
²Use a vacuum pump or charging station and
evacuate system to 95 kPa (28 inches Hg) for 30 min-
utes.
²Go to Charging A/C System below.
CHARGING A/C SYSTEM
The procedure below should be used to fill the
refrigerant charge in the air conditioning system.
HEATERÐA/C VACUUM SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO FORCED AIR IN HEAT
POSITION1. Vacuum line pinched or
leaking.
2. Faulty heat defroster or
mode door.
3. Faulty selector switch.
4. Vacuum check valve.1. Locate and repair vacuum leak or pinched line.
2. Test actuators and door operation. Repair as
necassary.
3. Test selector switch and replace if necessary.
4. Test check valve and replace if necessary.
NO FORCED AIR IN PANEL
POSITION1. Vacuum line pinched or
leaking.
2. Faulty mode door.
3. Faulty selector switch.
4. Vacuum check valve.1. Locate and repair vacuum leak or pinched line.
2. Test actuator and door operation. Repair as
necessary.
3. Test selector switch and replace if necessary.
4. Test check valve and replace if necessary.
NO FORCED AIR IN
DEFROST POSITION1. Vacuum line pinched or
leaking.
2. Faulty heat, defroster, or
mode door.
3. Faulty selector switch.
4. Vacuum check valve.1. Locate and repair vacuum leak or pinched line.
2. Test actuators and door operation. Repair as
necessary.
3. Test selector switch and replace if necessary.
4. Test check valve and replace if necessary.
Fig. 14 A/C Service Ports
24 - 14 HEATING AND AIR CONDITIONINGPL
DIAGNOSIS AND TESTING (Continued)

This A/C system does not have or use a sight glass to
check or charge the system.
WARNING: REVIEW SAFETY PRECAUTIONS AND
WARNINGS IN THIS GROUP BEFORE CHARGING
THE REFRIGERANT SYSTEM.
AVOID BREATHING A/C REFRIGERANT AND
LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. MIXTURE
OF AIR and R-134a CAN BE COMBUSTIBLE AT ELE-
VATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION: Do not overcharge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for leaks and
evacuated, a refrigerant (R-134a) charge can be
injected into the system.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) If using a separate vacuum pump close all
valves before disconnecting pump. Connect manifold
gauge set to the A/C service ports (Fig. 14).
NOTE: The air conditioning system in this vehicle
holds 784 grams (28 oz. or 1.57 lbs.) of R-134a
refrigerant.
(2) Measure refrigerant (refer to capacities). Refer
to the instructions provided with the equipment
being used.
(3) Verify engine is shut off. Open the suction and
discharge valves. Open the charge valve to allow the
refrigerant to flow into the system. When the trans-
fer of refrigerant has stopped, close the suction and
discharge valve.
(4) If all of the charge did not transfer from the
dispensing device, put vehicle controls into the fol-
lowing mode:
²Automatic transaxle in park or manual tran-
saxle in neutral²Engine idling at 700 rpm
²A/C control set in 100 percent outside air
²Panel mode
²Blower motor ON high speed
²Vehicle windows closed
If the A/C compressor does not engage, test the
compressor clutch control circuit and correct any fail-
ure. Refer to Group 8W, Wiring Diagrams.
(5) Open the suction valve to allow the remaining
refrigerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Close all valves and test the A/C system perfor-
mance.
(7) Disconnect the charging station or manifold
gauge set. Install the service port caps.
EVACUATING REFRIGERANT SYSTEM
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
If a compressor designed to use R-134a refrigerant
is left open to the atmosphere for an extended period
of time. It is recommended that the refrigerant oil be
drained and replaced with new oil or a new compres-
sor be used. This will eliminate the possibility of con-
taminating the refrigerant system.
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be filled. Moisture and air mixed with the refrig-
erant will raise the compressor head pressure above
acceptable operating levels. This will reduce the per-
formance of the air conditioner and damage the com-
pressor. Moisture will boil at near room temperature
when exposed to vacuum. To evacuate the refrigerant
system:
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a suitable charging station, refrigerant
recovery machine, and a manifold gauge set with
vacuum pump (Fig. 15).
(2) Open the suction and discharge valves and
start the vacuum pump. The vacuum pump should
run a minimum of 45 minutes prior to charge to
eliminate all moisture in system. When the suction
gauge reads -88 kPa (- 26 in. Hg) vacuum or greater
for 45 minutes, close all valves and turn off vacuum
pump. If the system fails to reach specified vacuum,
PLHEATING AND AIR CONDITIONING 24 - 15
SERVICE PROCEDURES (Continued)

the refrigerant system likely has a leak that must be
corrected. If the refrigerant system maintains speci-
fied vacuum for at least 30 minutes, start the vac-
uum pump, open the suction and discharge valves.
Then allow the system to evacuate an additional 10
minutes.
(3) Close all valves. Turn off and disconnect the
vacuum pump.
(4) The refrigerant system is prepared to be
charged with refrigerant.
R-134a REFRIGERANT
This vehicle uses a new type of refrigerant called
R-134a. It is a non-toxic, non-flammable, clear color-
less liquefied gas.
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause
compressor failure, refrigerant oil to sludge and/or
poor performance.Never add any other type of
refrigerant to a system designed to use R-134a
refrigerant. System failure will occur.
The high pressure service port is located on the
ffilter/drier. The low pressure service port is located
on the suction line near the strut tower.
When servicing a system, it is required that an air
conditioning charging recovery/recycling machine be
used (Fig. 16). Contact an automotive service equip-
ment supplier for proper equipment. Refer to the
operating instructions provided with the equipment
for proper operation.
A manifold gauge set (Fig. 17) must also be used in
conjunction with the charging and/or recovery/recy-
cling device. Only use gauges that have not been
used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back
flow valves at the service port connector ends. This
will prevent refrigerant R-134a from being released
into the atmosphere.R-134a refrigerant requires a special type of com-
pressor oil. When adding oil, make sure to use the oil
that is specified on the under hood label.
Due to the different characteristics of R-134a it
requires all new service procedures.
The use of R-134a will have a positive environmen-
tal impact due to it's zero ozone depletion and low
global warming impact.
Fig. 15 Refrigerant Recovery Machine HookupFig. 16 Refrigerant Recovery/Recycling Station
(Typical)
Fig. 17 Manifold Gauge Set- Typical
24 - 16 HEATING AND AIR CONDITIONINGPL
SERVICE PROCEDURES (Continued)

SERVICING REFRIGERANT OIL LEVEL
CAUTION: The refrigerant oil used in a R-134a A/C
system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil
designated for this vehicle is ND8 PAG (polyalka-
lene glycol).
Recovery/recycling equipment will measure the
lubricant being removed. This is the amount of lubri-
cant to be added back to the system. If a new com-
pressor is being installed, drain lubricant from old
compressor, measure the amount drained and discard
old lubricant. Drain the lubricant from the new com-
pressor into a clean container. Return the amount of
lubricant measured from the old compressor, plus the
amount reclaimed from the system back into the new
compressor.
(1) Discharge refrigerant system using recovery/re-
cycling equipment if charge is present.
(2) Disconnect refrigerant lines from A/C compres-
sor. Cap the open lines to prevent moisture from
entering system.
(3) Remove compressor from vehicle.
(4) From suction port on top of compressor, drain
lubricant from compressor.
(5) Add system capacity minus the capacity of
components that have not been replaced. Refer to the
Lubricant Capacity Chart. Add lubricant through the
suction port on compressor. This is not to exceed 200
ml (6.75 oz.) in total.
(6) Install compressor and connect refrigerant
lines. Then evacuate and charge refrigerant system.
SYSTEM LEAK CHECKING
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND
LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with
R-134a. This is accomplished by performing a system
Charge Level-Check or Fill. If while performing thistest A/C liquid line pressure is less than 345 kPa (50
psi) proceed to Empty Refrigerant System Leak Test.
If liquid line pressure is greater than 345 kPa (50
psi) proceed to low refrigerant level leak test. If the
refrigerant system is empty or low in refrigerant
charge, a leak at any line fitting or component seal is
likely. A review of the fittings, lines and components
for oily residue is an indication of the leak location.
To detect a leak in the refrigerant system, perform
one of the following procedures as indicated by the
symptoms.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approx. 28 in Hg.). Deter-
mine if the system holds a vacuum for 15 minutes. If
vacuum is held, a leak is probably not present. If sys-
tem will not maintain vacuum level, proceed with
this procedure.
(2) Prepare a .284 Kg. (10 oz.) refrigerant charge
to be injected into the system.
(3) Connect and dispense .284 Kg. (10 oz.) of
refrigerant into the evacuated refrigerant system.
(4) Proceed to Step 2 of Low Refrigerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Determine if there is any (R-134a) refrigerant
in the system.
(2) Position the vehicle in a wind free work area.
This will aid in detecting small leaks.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run for five minutes with the system
set to the following:
²Transaxle in Park
²Engine Idling at 700 rpm
²A/C Controls Set in 100 percent outside air
²Blower switch in the high A/C position
²A/C in the ON position
²Open all windows
CAUTION: A leak detector designed for R-12 refrig-
erant (only) will not detect leaks in a R-134a refrig-
erant system.
(4) Shut off the vehicle and wait 2 to 7 minutes.
Then use an Electronic Leak Detector that is
designed to detect R-134a type refrigerant and search
for leaks. Fittings, lines, or components that appear
to be oily usually indicates a refrigerant leak. To
inspect the evaporator core for leaks, insert the leak
detector probe into the drain tube opening or a heat
duct. A R-134a dye is available to aid in leak detec-
tion, use only Chrysler approved refrigerant dye.
PLHEATING AND AIR CONDITIONING 24 - 17
SERVICE PROCEDURES (Continued)

If a thorough leak check has been completed with-
out indication of a leak, proceed to System Charge
Level.
REMOVAL AND INSTALLATION
A/C SERVICE PORT VALVE CORES
REMOVAL
(1) Remove the valve caps (Fig. 5) and (Fig. 6)
(2) Using a R-134a refrigerant recovery machine,
Remove the refrigerant from A/C system.
(3) Using a standard valve core tool, remove the
valve core.Be careful to prevent any dirt/debris
from entering the valve core opening or getting
on the replacement valve core.
INSTALLATION
(1) When assembling the new valve core into the
port, the core should be oiled with clean ND8 PAG
compressor oil.
CAUTION: A valve that is not fully seated can lead
to damage to the valve during evacuation and
charge. This can result in system refrigerant dis-
charge while uncoupling the charge adapters.
(2) Install valve core into port.
(3) Evacuate and charge the A/C system.
(4) Install the valve caps.
BLOWER MOTOR AND WHEEL ASSEMBLY
The blower motor is located on the bottom right
side of the unit housing. The blower motor can be
removed from the vehicle without having to remove
the unit housing assembly.
WITH AIR CONDITIONING
REMOVAL
(1) Remove right side scuff plate.
(2) Pull back carpet.
(3) Cut wheel housing silencer in line with blower
motor wiring.
(4) Disconnect blower motor wiring connector.
(5) RHD vehicle remove the motor cover.
(6) Remove three blower motor retaining screws
(Fig. 18).
(7) Lower blower motor assembly from unit hous-
ing.
INSTALLATION
For installation, reverse the above procedures.
Then tape silencer into position.
WITHOUT AIR CONDITIONING
REMOVAL
(1) Disconnect blower motor wiring connector.
(2) Grasp the blower motor while pulling down
tab. Turn approximately 1/8 turn counterclockwise
and remove blower motor assembly from unit hous-
ing (Fig. 19).
INSTALLATION
For installation, reverse the above procedures.
BLOWER MOTOR RESISTOR
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed.
REMOVAL
(1) Remove windshield wipers.
(2) Remove cowl top screen.
(3) Disconnect the resistor block wiring connector.
Fig. 18 Blower Motor Retaining Screws
Fig. 19 Blower Motor Removal
24 - 18 HEATING AND AIR CONDITIONINGPL
SERVICE PROCEDURES (Continued)

(4) Remove two resistor block retaining screws.
The screw threads attaching the resistor block are
not full length. It is necessary to gently pry out the
resistor block while turning the screws counterclock-
wise enabling the threads to engages.
(5) Remove resistor block from vehicle.
INSTALLATION
For installation, reverse the above procedures.
BLOWER MOTOR WHEEL
The blower motor wheel is only serviced with the
blower motor. The wheel and the motor are balanced
as an assembly. If the blower motor wheel requires
replacement, the blower motor must also be replaced.
Refer to blower motor for replacement procedure.
COMPRESSOR
CAUTION: Add only new lubricant when system
requires additional lubricant. Do not use old
reclaimed lubricant.
REMOVAL
The A/C compressor may be unbolted and reposi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the com-
pressor clutch/coil assembly, engine, cylinder head, or
alternator.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE
TURNED OFF. DO NOT TWIST OR KINK THE
REFRIGERANT LINES WHEN REMOVING A FULLY
CHARGED COMPRESSOR. SAFETY GLASSES
MUST BE WORN.
(1) Disconnect battery negative cable.
(2) Loosen and remove drive belts, refer to Group
7, Engine Cooling.
(3) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system. If the com-
pressor is being replaced.
(4) Disconnect compressor clutch wire lead.
(5) Remove refrigerant lines from compressor, if
necessary.
(6) If system is left open place plug/cap over open
lines.
(7) Remove compressor attaching bolt.
(8) Remove compressor. If refrigerant lines were
not removed, lift compressor/clutch assembly and tie
it to a suitable component.
INSTALLATION
For installation, reverse the above procedures.
COMPRESSOR CLUTCH/COIL ASSEMBLY
Compressor assembly must be removed from mount-
ing. Although, refrigerant discharge is not necessary.
REMOVAL
(1) Remove the compressor shaft bolt (Fig. 20). A
band type oil filter removal tool can be placed around
the clutch plate to aid in bolt removal.
(2) Tap the clutch plate with a plastic hammer and
remove clutch plate and shim(s) (Fig. 21).
NOTE: Use care not to lose any of the shim(s).
CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Fig. 20 Compressor Shaft Bolt and Clutch Plate
Fig. 21 Clutch Plate and Shim(s)
PLHEATING AND AIR CONDITIONING 24 - 19
REMOVAL AND INSTALLATION (Continued)

(3) Remove pulley retaining snap ring with Snap
Ring Pliers, and slide pulley assembly off of compres-
sor (Fig. 22).
(4) Remove coil wire bracket/ground clip screw and
wire harness.
(5) Remove snap ring retaining field coil onto com-
pressor housing (Fig. 23). Slide field coil off of com-
pressor housing.(6) Examine frictional faces of the clutch pulley
and front plate for wear. The pulley and front plate
should be replaced if there is excessive wear or scor-
ing. If the friction surfaces are oily, inspect the shaft
nose area of the compressor for oil and remove the
felt from the front cover. If the compressor felt is sat-
urated with oil, the shaft seal is leaking and will
have to be replaced.
(7) Check bearing for roughness or excessive leak-
age of grease. Replace bearing as required.
INSTALLATION
(1) Align pin in back of field coil with hole in com-
pressor end housing, and position field coil into place.
Make sure that lead wires are properly routed, and
fasten the coil wire bracket/ground retaining screw.
NOTE: A new snap ring must be used. The bevel
side of the snap ring must be outward.
(2) Install field coil retaining snap ring with Snap
Ring Pliers. Press snap ring to make sure it is prop-
erly seated in the groove.
CAUTION: If snap ring is not fully seated it will
vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Do not mar the pulley frictional surface.
(3) Install pulley assembly to compressor. If neces-
sary, tap gently with a block of wood on the friction
surface (Fig. 24).
Fig. 22 Removing Pulley Snap Ring
Fig. 23 Clutch Coil Snap RingFig. 24 Installing Pulley Assembly
24 - 20 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

(4) Install pulley assembly retaining snap ring
(bevel side outward) with Snap Ring Pliers. Press the
snap ring to make sure it is properly seated in the
groove.
(5) If the original front plate assembly and pulley
assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 2.54 mm
(0.10 in.) thick, on the shaft against the shoulder.
(6) Install front plate assembly onto shaft.
(7) If installing a new front plate and/or pulley
assembly, the gap between front plate and pulley face
must be checked. Use the following procedure:
(a) Attach a dial indicator to front plate so that
movement of the plate can be measured.
(b) With the dial indicator zeroed on the front
plate, energize the clutch and record the amount of
movement.
(c) The readings should be 0.35 to 0.65 mm
(0.014 to 0.026 in.). If proper reading is not
obtained, add or subtract shims until desired read-
ing is obtained.
(8) Install compressor shaft bolt. Tighten to 17.5
62 N´m (155620 in. lbs.) torque.
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After new clutch installation, cycle the A/C clutch
20 times (5 seconds on and 5 seconds off). During
this procedure, set the system to the A/C mode,
engine rpm at 1500 - 2000, and high blower speed.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher clutch torque
capability.
CONDENSATION DRAIN TUBE
REMOVAL
(1) Raise vehicle.
(2) Locate rubber drain tube on right side of dash
panel (Fig. 25).
(3) Squeeze clamp and remove drain tube.
INSTALLATION
To install, reverse the preceding operation. Check
the drain tube nipple on the heater-A/C housing for
any obstructions.
CONDENSER
The condenser is located in front of the engine
radiator. It has no serviceable parts. If damaged or
leaking, the condenser assembly must be replaced.WARNING: THE REFRIGERANT MUST BE
REMOVED FROM THE SYSTEM BEFORE REMOV-
ING THE CONDENSER.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from the A/C system.
(2) Remove battery support strut.
(3) Remove refrigerant lines from condenser.
(4) Remove upper radiator mounts.
(5) Remove condenser to radiator mounting
screws.
(6) Tilt radiator back and remove condenser.
INSTALLATION
For installation, reverse the above procedures.
DISCHARGE LINE
WARNING: THE REFRIGERANT SYSTEM MUST BE
RECOVERED BEFORE SERVICING ANY PART OF
THE REFRIGERANT SYSTEM.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system.
(2) From the top side of the vehicle, remove line at
compressor (Fig. 26).
(3) From the bottom side of the vehicle, remove
line at condenser.
INSTALLATION
For installation, reverse the above procedures.
EVAPORATOR
This vehicle uses an aluminum plate and fin style
evaporator. It is located in the Evaporator/Blower
module.
Fig. 25 Condensate Water Drain Tube ± Typical
PLHEATING AND AIR CONDITIONING 24 - 21
REMOVAL AND INSTALLATION (Continued)

The unit housing must be removed from the vehi-
cle before beginning with this procedure. Refer to
Unit Housing in this section for removal procedure.
Use this procedure if any or all of the following
items require service:
²Evaporator
²Air inlet duct
²Recirculation door
²Evaporator/Blower module case
DISASSEMBLE
The RHD vehicle Unit Housing does not separate,
and is only one unit.
(1) Remove the clips and screws that hold the Unit
Housing to the Evaporator/Blower Module. Then sep-
arate the two units.
(2) Remove the evaporator to dash panel foam seal
(Fig. 27).
(3) Disconnect fin sensing switch from harness.
(4) Remove upper to lower case retaining clips and
screws.
(5) Separate the case halves (Fig. 28).
(6) Lift the evaporator out of the module (Fig. 29).
ASSEMBLE
To reassemble, reverse the above procedures.
EVAPORATOR PROBE
The evaporator probe can be removed without
removing the Unit Housing from the vehicle.
REMOVAL
(1) Disconnect probe wiring connector from behind
the glove box.
(2) Remove rubber grommet from evaporator/
blower module (Fig. 30).
(3) Note which of the three pilot holes the evapo-
rator probe is located in.
(4) Pull probe out of evaporator fins.
INSTALLATION
(1) There are three pilot holes available for the
probe. The top hole is for service. If top hole was not
used by previous probe, install probe in top hole.
Fig. 27 Foam Seal Removal
Fig. 28 Case Separation
Fig. 29 Evaporator Removal
Fig. 26 Discharge Line
24 - 22 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)