wheel DODGE NEON 2000 Service Repair Manual

INNER BODY SIDE TO OUTER BODY SIDE AND WHEELHOUSE
PLBODY 23 - 93
SPECIFICATIONS (Continued)

OUTER BODY SIDE TO INNER WINDSHIELD OPENING
OUTER BODY SIDE PANEL TO INNER WHEELHOUSE AND LOWER DECK REAR CLOSURE
23 - 94 BODYPL
SPECIFICATIONS (Continued)

INNER QUARTER PANEL TO OUTER WHEELHOUSE AND REINFORCEMENT
23 - 96 BODYPL
SPECIFICATIONS (Continued)

QUARTER PANEL WHEELHOUSE TO UPPER QUARTER PANEL AND EXTENSION
PLBODY 23 - 97
SPECIFICATIONS (Continued)

REAR INNER WHEELHOUSE ASSEMBLY
23 - 98 BODYPL
SPECIFICATIONS (Continued)

REAR FLOOR PAN TO BODY SIDE SILL EXTENSION AND REAR WHEELHOUSE
23 - 100 BODYPL
SPECIFICATIONS (Continued)

OUTER BODY SIDE APERTURE TO CENTER PILLAR
INNER WHEELHOUSE TO OUTER WHEELHOUSE
PLBODY 23 - 109
SPECIFICATIONS (Continued)

INNER WHEELHOUSE TO WHEELHOUSE EXTENSION
PANEL SHELF TO TROUGH AND WHEELHOUSE
23 - 110 BODYPL
SPECIFICATIONS (Continued)

HEATING AND AIR CONDITIONING
TABLE OF CONTENTS
page page
GENERAL INFORMATION
A/C APPLICATION TABLE...................2
HEATER AND AIR CONDITIONING CONTROL...2
HEATER AND AIR CONDITIONING............2
INTRODUCTION..........................3
SAFETY PRECAUTIONS AND WARNINGS......4
DESCRIPTION AND OPERATION
A/C REFRIGERANT LINES..................4
BLOWER MOTOR RESISTOR................5
COMPRESSOR...........................5
COMPRESSOR FRONT SHAFT SEAL..........6
CONDENSATION DRAIN TUBE...............6
ENGINE COOLING SYSTEM REQUIREMENTS...6
EVAPORATOR PROBE......................6
HANDLING TUBING AND FITTINGS...........6
HIGH PRESSURE CUT OUT SWITCH..........6
LOW PRESSURE CUT OFF SWITCH..........6
SIDE WINDOW DEMISTERS................7
SYSTEM AIRFLOW........................7
SYSTEM OIL LEVEL.......................7
VACUUM CONTROL SYSTEM................8
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST..................9
BLOWER MOTOR ELECTRICAL DIAGNOSIS....9
BLOWER MOTOR VIBRATION AND/OR
NOISE DIAGNOSIS.....................11
COMPRESSOR NOISE DIAGNOSIS..........11
EVAPORATOR PROBE TEST................11
EXPANSION VALVE.......................11
HEATER PERFORMANCE TEST.............13
LOW PRESSURE CUT OFF SWITCH.........14
SYSTEM CHARGE LEVEL TEST.............14
VACUUM CONTROL SYSTEM...............15
SERVICE PROCEDURES
CHARGING A/C SYSTEM..................17EVACUATING REFRIGERANT SYSTEM........18
R-134a REFRIGERANT....................19
SERVICING REFRIGERANT OIL LEVEL.......19
SYSTEM LEAK CHECKING.................20
REMOVAL AND INSTALLATION
A/C FILTER/DRIER.......................20
A/C SERVICE PORT VALVE CORES..........21
BLOWER MOTOR AND WHEEL ASSEMBLY....21
BLOWER MOTOR RESISTOR...............22
BLOWER MOTOR WHEEL.................22
COMPRESSOR..........................22
COMPRESSOR CLUTCH/COIL ASSEMBLY.....23
CONDENSATION DRAIN TUBE..............25
CONDENSER............................25
DISCHARGE LINE........................26
EVAPORATOR...........................26
EVAPORATOR PROBE.....................26
EXPANSION VALVE.......................27
HEATER CORE..........................28
HEATER HOSES.........................28
HIGH PRESSURE CUT OUT SWITCH.........29
HIGH PRESSURE RELIEF VALVE............29
LIQUID LINE............................29
LOW PRESSURE CUT OFF SWITCH.........29
MODE CONTROL CABLE..................30
RECIRCULATION DOOR ACTUATOR.........31
SUCTION LINE..........................31
TEMPERATURE CONTROL CABLE...........32
UNIT HOUSING..........................32
DISASSEMBLY AND ASSEMBLY
HEATER-A/C HOUSING....................34
ADJUSTMENTS
MODE CONTROL CABLE..................34
TEMPERATURE CONTROL CABLE...........34
PLHEATING AND AIR CONDITIONING 24 - 1

HEATER-A/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.
ONE-WAY CHECK VALVE
(1) Disconnect the heater-A/C vacuum supply
(Black) tube in the engine compartment. This tube
passes through an opening in the dash panel.
(2) Remove the one-way vacuum check valve. The
valve is located on the (Black) vacuum supply hose at
the brake power booster.
(3) Connect the test set vacuum supply hose to the
heater side of the valve. When connected to this side
of the check valve, no vacuum should pass and the
test set gauge should return to the 27 kPa (8 in. Hg.)
setting. If OK, go to step Step 4. If not OK, replace
the faulty valve.
(4) Connect the test set vacuum supply hose to the
engine vacuum side of the valve. When connected to
this side of the check valve, vacuum should flow
through the valve without restriction. If not OK,
replace the faulty valve.
HEATER-A/C CONTROLS
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 set vacuum probe to the heat-
er-A/C vacuum supply (Black) hose in the engine
compartment. Position the test set gauge so that it
can be viewed from the passenger compartment.
(2) Start with the Mode control in the Panel posi-
tion and the Circulation control in the Outside-air
position.
(3) Move the Circulation control to the Recircula-
tion position (the Circulation door should move intothe Recirculation position). After a short pause move
the Mode control to the Defrost position (the Circula-
tion door should move to the Outside-air position).
The test gauge should return to the calibrated set-
ting of 27 kPa (8 in. Hg.) after each selection is
made. If the gauge cannot achieve the calibrated set-
ting, the vacuum circuit or a component has a leak.
(4) If the gauge achieves the calibrated setting but
the door does not move, there is either a pinched vac-
uum line or a failed actuator.
LOCATING VACUUM LEAKS
(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 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.
(6) 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 of
27 kPa (8 in. Hg.). If not, there is a leak in the Con-
trol.
(7) 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 actuator vacuum port is
accessible behind and above the Glove Box. The test
24 - 16 HEATING AND AIR CONDITIONINGPL
DIAGNOSIS AND TESTING (Continued)