oil pressure DODGE NEON 2000 Service Repair Manual

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. 16).
NOTE: The air conditioning system in this vehicle
holds (27 oz. or 1.69 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 neutral
²Engine 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. 17).
(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,
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.
Fig. 17 Refrigerant Recovery Machine Hookup -
Typical
1 ± LOW SIDE CONNECTOR
2 ± HIGH SIDE CONNECTOR
3 ± TO MANIFOLD SET
24 - 18 HEATING AND AIR CONDITIONINGPL
SERVICE PROCEDURES (Continued)

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 refrigerant called R-134a. It is
a non-toxic, non-flammable, clear colorless 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. 18). 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. 19) 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.
The use of R-134a will have a positive environmen-
tal impact due to it's zero ozone depletion and low
global warming impact.
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.
Fig. 18 Refrigerant Recovery/Recycling Station -
Typical
1 ± R-134 REFRIGERANT RECOVERY MACHINE
Fig. 19 Manifold Gauge Set - Typical
1 ± LOW PRESSURE GAUGE
2 ± HIGH PRESSURE GAUGE
3 ± VALVE
4 ± VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIP)
5 ± HIGH PRESSURE HOSE (RED W/BLACK STRIP)
6 ± LOW PRESSURE HOSE (BLUE W/BLACK STRIP)
7 ± VALVE
PLHEATING AND AIR CONDITIONING 24 - 19
SERVICE PROCEDURES (Continued)

(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 180
ml (6.10 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 this
test 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 refrig-
erant 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.
If a thorough leak check has been completed with-
out indication of a leak, proceed to System Charge
Level.
REMOVAL AND INSTALLATION
A/C FILTER/DRIER
The filter/drier is mounted in a rubber grommet on
the right side of the engine compartment. The refrig-
erant must be recovered from the A/C system before
replacing the filter/drier assembly.
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION.
24 - 20 HEATING AND AIR CONDITIONINGPL
SERVICE PROCEDURES (Continued)

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. 22).
(4) Remove/unsnap 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 (Fig. 23).
(6) If system is left open place plug/cap over open
lines.
(7) Remove compressor attaching bolts (Fig. 24).
Fig. 22 Blower Motor Resistor Block
1 ± RESISTOR BLOCK
2 ± ELECTRICAL CONNECTOR
Fig. 23 A/C Compressor Lines
1 ± CONDENSER LIQUID LINE
2 ± SUCTION LINE
3 ± COMPRESSOR MANIFOLD SCREWS
4 ± COMPRESSOR
5 ± DISCHARGE LINE
24 - 22 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

(8) Remove the heater core coolant supply hoses
from the heater core (Fig. 8).
(9) Working from inside the engine compartment,
remove the A/C-Heater housing retaining fasteners
from the bulkhead.
(10) Remove the A/C-Heater housing drain tube.
Remove the spring clip and pull the hose from the
housing nipple.
(11) Working from inside the vehicle, remove the
defroster duct from the A/C-Heater housing and body
attachment point.
(12) Remove the A/C-Heater housing retaining
bolts.
(13) Disconnect the electrical connectors from the
A/C-Heater housing.
(14) Remove the A/C-Heater housing from the
vehicle and place the assembly on a bench.
(15) Remove the heater core cover from the hous-
ing assembly.
(16) Remove the heater core coolant lines from the
heater core.
(17) Remove the screws necessary to disassemble
the A/C-Heater housing assembly (Fig. 9).
(18) Remove the heater core from the A/C-Heater
housing (Fig. 9).
Fig. 7 Expansion Valve Position & Orientation
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
Fig. 8 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 9 Heater - A/C Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
24 - 4 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install the heater core in the A/C-Heater hous-
ing.
(2) Reassemble the A/C-Heater housing.
(3) Install the housing in the vehicle and install
the retaining bolts. Torque the bolts to 20 N´m (177
in. lbs.).
(4) Connect the electrical connectors on the A/C-
Heater housing.
(5) Install the defroster duct on the A/C-Heater
housing and secure at the body attachment point.
(6) Install the A/C-Heater housing drain tube and
retaining clip.
(7) Install the A/C-Heater housing retaining fas-
teners. Torque the fasteners to 20 N´m (177 in. lbs.).
(8) Install the heater core coolant supply hoses on
the heater core (Fig. 11).
(9) Install the expansion valve, gasket and retain-
ing bolts. Torque the bolts to 11 N´m (97 in. lbs.).
(10) Connect the electrical connector on the bottom
of the expansion valve (Fig. 12).
CAUTION: Be certain the refrigerant line sealing
O-rings are well lubricated and free of tears.
(11) Install the refrigerant lines and retaining bolt
(Fig. 12). Torque the bolt to 23 N´m (203 in. lbs.).
Fig. 10 Heater - A/C Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
Fig. 11 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 12 Expansion Valve Position & Orientation
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
PLHEATING AND AIR CONDITIONING 24 - 5
REMOVAL AND INSTALLATION (Continued)