oil capacity DODGE NEON 2000 Service User Guide

SIDE WINDOW DEMISTERS
The demisters direct air from the unit housing
through the outlets located on the top corners of the
instrument panel. The demisters operate when the
mode selector is anywhere between floor and defrost
settings. Some air may be noticeable from the demis-
ter outlets when the mode selector is in the bilevel to
floor positions.
SYSTEM AIRFLOW
The system pulls outside (ambient) air through the
cowl opening at the base of the windshield. Then it
goes into the plenum chamber above the unit hous-
ing. On air conditioned vehicles, the air passes
through the evaporator. Air flow can be directed
either through or around the heater core. This is
done by adjusting the blend-air door with the TEMP
control on the instrument panel. The air flow can
then be directed from the panel, floor and defrost
outlets in various combinations using the mode selec-
tor. There are 17 different mode selections possible.
Air flow velocity can be adjusted with the blower
speed selector switch on the instrument panel.
On A/C equipped vehicles the ambient air intake
can be controlled by opening and closing the recircu-
lating air door. When placed in RECIRC, air that is
inside vehicle is removed continuously and recircu-
lated through unit housing. Ambient air cannot be
controlled on vehicles without A/C. The system uses
outside air at all times.
The air conditioning compressor can be engaged by
turning the fan switch counterclockwise from the off
position. It can also be engaged by placing the mode
control in the mix to defrost positions. This will
remove heat and humidity from the air before it is
directed through or around the heater core.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
capacity of the system and consequently result in
higher discharge air temperatures.
Fig. 7 High Pressure Cut Out Switch Location
1 ± DISCHARGE LINE
2 ± A/C COMPRESSOR
3 ± HIGH PRESSURE CUT OUT SWITCH
4 ± SUCTION LINE
Fig. 8 Low Pressure Cut Off Switch
1 ± EXPANSION VALVE
2 ± LOW PRESSURE CUTOFF SWITCH
3 ± LIQUID LINE
4 ± SUCTION LINE
PLHEATING AND AIR CONDITIONING 24 - 7
DESCRIPTION AND OPERATION (Continued)

NOTE: The oil used in the compressor is ND8 PAG
R-134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial effort must be used to keep all R-134a system
components moisture-free. Moisture in the oil is
very difficult to remove and will cause a reliability
problem with the compressor.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with R-134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and
components. The evaporator, condenser, and filter-
drier will retain a significant amount of oil, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent is replaced, the specified amount of refrigerant
oil must be added. When the compressor is replaced,
the amount of oil that is retained in the rest of the
system must be drained from the replacement com-
pressor. When a line or component has ruptured and
oil has escaped, the compressor should be removed
and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the sys-
tem, minus the amount of oil still in the remaining
components, can be measured and poured into the
suction port of the compressor.
VACUUM CONTROL SYSTEM
The neon uses vacuum to operate only the recircu-
lation door (Fig. 9). All other controls are cable.
When vacuum is supplied to the actuator, the door
moves to the Recirculation position (Fig. 10). Theactuator is spring loaded so the door moves to the
Outside-air position when there is no vacuum sup-
plied. The operation of the door can be viewed by
removing the blower motor and looking up into the
unit inlet.
REFRIGERANT OIL CAPACITIES
Refrigerant Oil Capacities
Component ml oz
Total System 180ml 6.1 oz
Filter-Drier 30 ml 1.0 oz
Condenser 30 ml 1.0 oz
Evaporator 59 ml 2.0 oz
All Refrigerant Lines 44 ml 1.5 oz
Fig. 9 A/C Vacuum Line
1 ± BRAKE POWER BOOSTER
2 ± A/C VACUUM CHECK VALVE
3 ± VACUUM HARNESS
Fig. 10 Recirculation Air Door Vacuum Actuator
1 ± OUTSIDE AIR/RECIRC DOOR HOUSING
2 ± VACUUM ACTUATOR LINKAGE
3 ± FOAM SEAL
4 ± RECIRC DOOR VACUUM ACTUATOR
5 ± DOOR LEVER
6 ± DOOR LEVER
24 - 8 HEATING AND AIR CONDITIONINGPL
DESCRIPTION AND OPERATION (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)