pressure DODGE NEON 2000 Service Repair Manual

gauge should return to the calibrated setting of 27
kPa (8 in. Hg.). If not there is a leak in the Actuator
Feed line.
(8) 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.
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 center instrument panel bezel.
(4) Remove the center vent duct.
(5) 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.
(6) 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.
(7) 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 gauge
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.
(8) 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) charge
in 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. 16).
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.
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.
Fig. 16 A/C Service Ports
1 ± A/C SERVICE PORTS
2 ± FILTER/DRIER
PLHEATING AND AIR CONDITIONING 24 - 17
DIAGNOSIS AND TESTING (Continued)

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)

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. 32).
(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.
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
²Heater Core
²Heating and Air Conditioning
DISASSEMBLE
(1) Separate the foam seals at the evaporator line
connection, and the dash panel air distribution out-
lets (Fig. 33).
(2) Disconnect fin sensing probe from harness.
(3) Remove upper to lower case retaining clip and
screws.
(4) Separate the case halves (Fig. 34).
(5) Lift the evaporator out of the module (Fig. 35).
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. 36).
(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.
(2) If previous probe was removed from top hole,
use a small plastic stick of approximately 1/8 inch
Fig. 31 Condenser Refrigerant Lines
1 ± LIQUID LINE
2 ± A/C LINE MOUNTING BOLTS
3 ± DISCHARGE LINE
4 ± CONDENSER
Fig. 32 Discharge Line
1 ± DISCHARGE LINE
2 ± A/C COMPRESSOR
3 ± HIGH PRESSURE CUT OUT SWITCH
4 ± SUCTION LINE
24 - 26 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Remove the wire connector from the low pres-
sure cut-off switch.
(2) Remove the center bolt of refrigerant line
plumbing sealing plate (Fig. 37).
(3) Carefully pull the refrigerant line-sealing plate
assembly from the expansion valve towards front of
vehicle. Do not scratch the expansion valve sealing
surfaces with pilot tubes.
(4) Cover the openings on A/C line-sealing plate
assembly to prevent contamination.
(5) Remove two screws securing the expansion
valve to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket on
the evaporator sealing plate.
(2) Carefully hold the expansion valve to the evap-
orator sealing plate so not to scratch the sealing sur-
face. Install two screws and tighten to 1163 N´m
(100630 in. lbs.).
(3) Remove and replace the aluminum gasket on
the refrigerant line- sealing plate assembly.
(4) Carefully hold the refrigerant line-sealing plate
assembly to the expansion valve. Install bolt and
tighten to 2363 N´m (200630 in. lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
HEATER CORE
Refer to HVAC Housing Disassembly and Assembly
in this section for heater core removal procedure.
HEATER HOSES
CAUTION: When removing hoses from heater core
inlet or outlet nipples DO NOT exert excess pres-
sure. The heater core may become damaged and
leak engine coolant.
NOTE: Review Cooling System Precautions before
proceeding with this operation.
REMOVAL
(1) Drain engine cooling system. Refer to Group 7,
Cooling System.
(2) Using spring tension clamp pliers, remove
clamps at end of heater hose to be removed (Fig. 38).
(3) Carefully rotate hose back and forth while pull-
ing away from connector nipple.INSTALLATION
For installation, reverse the above procedures.
Fig. 37 Expansion Valve - Typical
1 ± ALUMINUM N-GASKET
2 ± PLUMBING SEALING PLATE
3 ± LOW/DIFFERENTIAL PRESSURE CUT-OFF SWITCH
4 ± DASH PANEL
5 ± H-VALVE
6 ± EVAPORATOR SEALING PLATE
7 ± H-VALVE
Fig. 38 Heater Hoses and Clamps
1 ± COWL PANEL
2 ± HEATER HOSE AND CLAMPS
3 ± HEATER CORE TUBES
4 ± HEATER HOSE SUPPLY AND RETURN TUBES
24 - 28 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

HIGH PRESSURE CUT OUT SWITCH
WARNING: THE REFRIGERANT MUST BE
REMOVED FROM THE SYSTEM BEFORE REMOV-
ING THE HIGH PRESSURE CUT OUT SWITCH.
REMOVAL
(1) Disconnect wiring connector at the switch (Fig.
39).
(2) Remove internal snap ring.
(3) Pull switch out of compressor.
INSTALLATION
For installation, reverse the above procedures. Use
a new O-Ring Seal.
HIGH PRESSURE RELIEF VALVE
WARNING: 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.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system.
(2) Rotate the high pressure relief valve counter-
clockwise and separate relief valve from the compres-
sor (Fig. 39).
INSTALLATION
For installation, reverse the above procedures
using a new O-Ring Seal. Evacuate and charge the
refrigerant system.
LIQUID LINE
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system.
(2) Disconnect liquid line at drier.
(3) Disconnect liquid line at condenser.
INSTALLATION
For installation, reverse the above procedures.
LOW PRESSURE CUT OFF SWITCH
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION. REFER TO
REFRIGERANT RECOVERY SECTION.
REMOVAL
(1) Disconnect the wire connector at the cut off
switch.
(2) Using a sender unit removal socket, remove the
switch from the expansion valve (Fig. 40).
Fig. 39 High Pressure Cut Out Switch Location
1 ± DISCHARGE LINE
2 ± A/C COMPRESSOR
3 ± HIGH PRESSURE CUT OUT SWITCH
4 ± SUCTION LINE
PLHEATING AND AIR CONDITIONING 24 - 29
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
NOTE: Verify the O-ring condition on the replace-
ment switch.
For installation, reverse the above procedures.
Evacuate and charge the system.
MODE CONTROL CABLE
The Mode Control Cable can be removed and
installed without having to remove the instrument
panel from the vehicle.
REMOVAL
(1) Remove instrument panel center stack bezel
(Fig. 41).
(2) Remove center air duct (Fig. 42).
(3) Remove heater-A/C control head and disconnect
cable (Fig. 43).
(4) Disconnect cable at heater unit.
(5) Remove cable from vehicle.
INSTALLATION
For installation, reverse the above procedures,
adjust cable and test. Refer to Mode Control Cable
Adjustment at the end of this section.
Fig. 40 Expansion Valve and Low Pressure Cut-Off
Switch
1 ± EXPANSION VALVE
2 ± LOW PRESSURE CUTOFF SWITCH
3 ± LIQUID LINE
4 ± SUCTION LINE
Fig. 41 Instrument Panel Center Bezel & Knobs
1 ± INSTRUMENT PANEL CENTER AIR DUCT
2 ± OUTSIDE AIR/RECIRC CONTROL KNOB
3 ± MODE CONTROL KNOB
4 ± BLOWER SPEED KNOB
5 ± TEMPERATURE CONTROL KNOB
Fig. 42 HVAC Center Air Duct & Control Head
1 ± CENTER AIR DUCT
2 ± INSTRUMENT PANEL
3 ± HVAC CONTROL HEAD
4 ± ATTACHING SCREWS
24 - 30 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

RECIRCULATION DOOR ACTUATOR
The recirculation door actuator is a vacuum con-
trolled actuator used to control movement of the
recirculation door in air conditioned equipped vehi-
cles.
The instrument panel must be removed from the
vehicle to gain access to the recirculation door actua-
tor.
REMOVAL
(1) Remove instrument panel from vehicle. Refer
to Group 8E, Instrument Panel And Systems for
removal procedures.
(2) Disconnect vacuum line from actuator.
(3) Disconnect actuator from recirculation door
link (Fig. 44).
(4) Release tension on latch, and slide recircula-
tion door actuator off housing.
INSTALLATION
For installation, reverse the above procedures.
SUCTION LINE
WARNING: THE REFRIGERANT MUST BE RECOV-
ERED BEFORE SERVICING ANY PART OF THE
REFRIGERANT SYSTEMS.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system.
(2) Remove retaining bolt at expansion valve (Fig.
45).
Fig. 43 HVAC Control Head Cables
1 ± HVAC CONTROL HEAD
2 ± ELECTRICAL CONNECTOR
3 ± CONTROL CABLES
4 ± VACUUM HARNESSFig. 44 Recirculation Door Actuator and Linkage
1 ± OUTSIDE AIR/RECIRC DOOR HOUSING
2 ± VACUUM ACTUATOR LINKAGE
3 ± FOAM SEAL
4 ± RECIRC DOOR VACUUM ACTUATOR
5 ± DOOR LEVER
6 ± DOOR LEVER
Fig. 45 Expansion Valve Center Bolt
1 ± EXPANSION VALVE
2 ± LOW PRESSURE CUTOFF SWITCH
3 ± LIQUID LINE
4 ± SUCTION LINE
PLHEATING AND AIR CONDITIONING 24 - 31
REMOVAL AND INSTALLATION (Continued)