service DODGE NEON 2000 Service Repair Manual

BODY COMPONENTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
GRILLE................................13
HOOD.................................13
FRONT DOOR...........................14
SPLASH SHIELD.........................16
DIAGNOSIS AND TESTING
WATER LEAKS..........................18
WIND NOISE............................19
SERVICE PROCEDURES
HEAT STAKING..........................19
PLASTIC BODY PANEL REPAIR..............19
REMOVAL AND INSTALLATION
GRILLE................................23
HOOD LATCH...........................24
HOOD LATCH STRIKER....................24
HOOD RELEASE CABLE...................25
HOOD.................................26
HOOD SILENCER........................26
HOOD HINGE...........................26
COWL COVER...........................27
FRONT WHEELHOUSE SPLASH SHIELD......28
FENDER...............................28
EXTERIOR BADGEING ATTACHED WITH
DOUBLE SIDED FOAM TAPE..............28
EXTERIOR BADGEING/TAPE STRIPES
ATTACHED WITH ADHESIVES.............28
FRONT/REAR DOOR WINDOW CRANK........29
FRONT DOOR TRIM......................30
FRONT DOOR WATER DAM................30
DOOR OUTER BELT WEATHERSTRIP.........30
FRONT/REAR DOOR INNER BELT
WEATHERSTRIP........................32
FRONT DOOR GLASS RUN WEATHERSTRIP . . . 32
FRONT DOOR OUTSIDE HANDLE............33
DOOR LOCK CYLINDER...................33
FRONT DOOR LATCH.....................33
FRONT DOOR LATCH STRIKER.............34
FRONT VERTICAL GUIDE BAR..............34
FRONT DOOR GLASS.....................36
FRONT DOOR CHECK STRAP..............36
FRONT DOOR...........................36
FRONT DOOR HINGE.....................38
FRONT/REAR DOOR APPLIQUE.............38
SIDE VIEW MIRROR......................39
SIDE VIEW MIRROR TRIM BEZEL............39
DOOR UPPER SECONDARY WEATHERSTRIP . . 39
SILL SECONDARY WEATHERSTRIP..........40
REAR DOOR TRIM.......................40REAR DOOR WATER DAM.................40
REAR DOOR OUTSIDE HANDLE.............40
REAR DOOR LATCH......................41
REAR DOOR LATCH STRIKER..............43
REAR DOOR GLASS......................43
REAR DOOR WINDOW REGULATOR.........43
REAR DOOR GLASS RUN WEATHERSTRIP....43
REAR DOOR CHECK STRAP................45
REAR DOOR............................45
REAR DOOR HINGE......................45
FUEL FILL DOOR.........................46
DECKLID LATCH.........................47
DECKLID...............................47
DECKLID LIFT SPRINGS...................47
DECKLID LOCK CYLINDER.................48
DECKLID LATCH STRIKER.................48
DECKLID OPENING WEATHERSTRIP.........49
TRUNK CARPET.........................49
DECKLID COVER.........................50
ROOF RAIL WEATHERSTRIP................50
ROOF RAIL WEATHERSTRIP RETAINER
CHANNEL.............................50
B-PILLAR WEATHERSTRIP CHANNEL.........51
A-PILLAR TRIM..........................51
DOOR SILL TRIM.........................51
SIDE COWL TRIM........................52
B-PILLAR TRIM..........................52
UPPER QUARTER TRIM...................53
LOWER QUARTER TRIM...................53
FLOOR CONSOLE........................54
FRONT SEAT BELT BUCKLE................54
FRONT SEAT BELT RETRACTOR............54
FRONT SHOULDER BELT ADJUSTER.........54
REAR SEAT BELT BUCKLE.................55
REAR SEAT BELT RETRACTOR.............55
CARPET...............................56
SUN VISOR.............................56
HEADLINER.............................57
INSIDE REAR VIEW MIRROR...............57
REAR SHELF TRIM PANEL.................57
BODY VENT.............................58
ADJUSTMENTS
FRONT DOOR LATCH ADJUSTMENT.........58
REAR DOOR LATCH ADJUSTMENT..........58
SPECIFICATIONS
BODY LUBRICATION......................59
SPECIAL TOOLS
BODY.................................59
23 - 12 BODYPL

WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will not
always seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
SERVICE PROCEDURES
HEAT STAKING
(1) Remove trim panel.
(2) Bend or move the trim panel components at
the heat staked joints. Observe the heat staked loca-
tions and/or component seams for looseness.(3) Heat stake the components.
(a) If the heat staked or component seam loca-
tion is loose, hold the two components tightly
together and using a soldering gun with a flat tip,
melt the material securing the components
together. Do not over heat the affected area, dam-
age to the exterior of the trim panel may occur.
(b) If the heat staked material is broken or miss-
ing, use a hot glue gun to apply new material to
the area to be repaired. The panels that are being
heat staked must be held together while the apply-
ing the glue. Once the new material is in place, it
may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
PLASTIC BODY PANEL REPAIR
DESCRIPTION OPERATION
Resin Transfer Molded (RTM) body panels are rein-
forced with a continuous fiberglass mesh. Epoxy
resin is injected into a gel-coated and fiberglass-lined
mold to form a body panel. Sheet molded compound
(SMC) body panels are constructed with fiberglass
strands usually 1 inch or shorter, epoxy resin formed
into sheet stock and pressed in mold flowing material
to form a sheet molded compound (SMC) body panel.
RTM and SMC body panels can be repaired with
epoxy adhesive after market products. Refer to
instructions provided by the manufacturer of prod-
ucts being used to repair RTM or SMC. Daimler-
Chrysler Corporation recommends that a trained
automotive body technician perform body panel
repair procedures (Fig. 1).
Fig. 1 Panel Repair
PLBODY 23 - 19
DIAGNOSIS AND TESTING (Continued)

SAFETY PRECAUTION AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING RTM AND SMC COMPONENTS.
PERSONAL INJURE CAN RESULT.
USE AN OSHA APPROVED BREATHING DEVICE
WHEN MIXING EPOXY, GRINDING RTM AND SMC,
AND SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
EPOXY RESIN, PETROLEUM, OR ALCOHOL BASED
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components and
electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds on
undamaged painted surfaces around repair areas.
Damage to finish can result.
PANEL SECTIONING
If it is required to section a large panel for an SMC
or RTM repair, it will be necessary to reinforce the
panel with epoxy structural adhesive (rigid repair
adhesive) (Fig. 2). To bond two plastic panels
together, a reinforcement must overlap both panels.
The panels must be ªV'dº at a 20 degree angle. The
area to be reinforced should be washed, then sanded.
Be sure to wipe off any excess soap and water when
finished. Lightly sand or abrade the plastic with an
abrasive pad or sandpaper. Blow off any dust with
compressed air or wipe with a clean dry rag.When bonding SMC or RTM panels, use a two-part
epoxy adhesive. Properly mix parts A and B, and
apply it to the panels being repaired. Be sure that
enough adhesive has been applied to allow squeeze
out and to fill the full bond line. Once the pieces
have been brought together, do not move them until
the adhesive is cured. The assembly can be held
together with clamps, rivets, etc. A faster cure can be
obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had
time to cure, rough sand the seam and apply the
final adhesive filler to the area being repaired.
Smooth the filler with a spatula, wooden tongue
depressor, or squeegee. For fine texturing, a small
amount of water can be applied to the filler surface
while smoothing. The cured filler can be sanded as
necessary and, as a final step, cleanup can be done
withy soapy water. Wipe the surface clean with a dry
cloth allowing time for the panel to dry before mov-
ing on with the repair.
PANEL REINFORCEMENT
Structural repair procedures for rigid panels such
as Sheet Molded compound (SMC) or Resin Transfer
Molded (RTM) with large cracks and holes will
require a reinforcement backing. Reinforcements can
be made with several applications of glass cloth sat-
urated with epoxy structural adhesive, semirigid or
flexible repair materials should be used for semirigid
or flexible part repairs (Fig. 3) and (Fig. 4). Open
meshed fiberglass dry wall tape can be used to form
a reinforcement. The dry wall tape allows the resin
to penetrate through and make a good bond between
the panel and the epoxy adhesive. Structurally, the
more dry wall tape used, the stronger the repair.
Another kind of repair that can be done to repair
large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
ªV'dº out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 5). It is recom-
mended that sharp edges be avoided because the
joint may show through after the panel is refinished.
²Panel repair for both flexible and rigid panels
are basically the same. The primary difference
between flexible panel repair and rigid panel repair
is in the adhesive materials used (Fig. 6).
²The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the
Fig. 2 Panel Sectioning
1 ± EXISTING PANEL
2 ± NEW PANEL
3 ± PANEL ADHESIVE
4 ± BONDING STRIP
23 - 20 BODYPL
SERVICE PROCEDURES (Continued)

damage part to its original strength and appearance
without exceeding the value of the replacement part.
²When plastic repairs are required, it is recom-
mended that the part be left on the vehicle when
every possible. That will save time, and the panel
will remain stationary during the repair. Misalign-
ment can cause stress in the repair areas and can
result in future failure.
VISUAL INSPECTION
Sheet Molded Compound (SMC) and Resin Trans-
fer Molded (RTM), because they are composites, reactdifferently to impact that sheet metal does. Compos-
ite materials can mask the severity of an accident.
Adhesive bond lines, interior structure of the doors,
and steel structure need to be inspected carefully to
get a true damage assessment. Close inspection may
require partial removal of interior trim or inner pan-
els.
Identify the type of repair:
Puncture or Crack ± Damage that has penetrated
completely through the panel. Damage is confined to
one general area; a panel section is not required.
However, a backer panel, open fiberglass tape, or
matted material must be bonded from behind (Fig.
7).
PANEL SURFACE PREPARATION
If a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achieve a successful repair. All spider
web cracks leading away from a damaged area must
be stopped or removed. To stop a running crack in a
SMC or RTM panel, drilla6mm(0.250 in.) hole at
the end of the crack farthest away from the damage.
If spider web cracks can not be stopped, the panel
would require replacement. The surfaces around the
damaged area should be stripped of paint and freed
Fig. 3 Softened Edges
1 ± SOFTENED EDGES
2 ± PANEL ADHESIVE
3 ± BONDING STRIP
Fig. 4 Panel Reinforcement
1 ± PANEL ADHESIVE
2 ± REINFORCEMENT
Fig. 5 Beveling AngleÐ20 Degrees
Fig. 6 Fiberglass Tape
Fig. 7 Damage Component
1 ± PUNCTURE
PLBODY 23 - 21
SERVICE PROCEDURES (Continued)

from was and oil. Scuff surfaces around repair area
with 360 grit wet/dry sand paper, or equivalent, to
assure adhesion of epoxy repair materials.
PATCHING PANELS
An RTM or SMC panel that has extensive punc-
ture type damage can be repaired by cutting out the
damaged material (Fig. 8). Use a suitable reciprocat-
ing saw or cut off wheel to remove the section of the
SMC or RTM panel that is damaged. The piece cut
out can be used as a template to shape the new
patch. It is not necessary to have access to the back
of the panel to install a patch. Bevel edges of cutout
at 20 degrees to expose a larger bonding area on the
outer side. This will allow for an increased reinforce-
ment areas.
PANEL PATCH FABRICATIONS
A patch can be fabricated from any rigid fiberglass
panel that has comparable contour with the repair
area. discard SMC or RTM panels. Lift gates and
fenders can be used to supply patch material. If
existing material is not available or compatible, a
patch can be constructed with epoxy and reinforce-
ment mesh (dry wall tape). Perform the following
operation if required:
(1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
patch required (Fig. 9).
(2) Tape waxed paper or plastic sheet with mesh to
a surface that has a compatible contour to the repair
area.
(3) Apply a liberal coat of epoxy adhesive over the
reinforcement mesh (Fig. 9). If necessary apply a sec-
ond or third coat of epoxy and mesh after firs coathas cured. The thickness of the patch should be the
same as the repair area.
(4) After patch has cured, peel waxed paper or
plastic from the back of the patch.
(5) If desired, a thin film coat of poesy can be
applied to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 8).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 8).
(7) Drill 3 mm (0.125 in.) holes in the support
squares 13 mm (0.5 in.) from the edge in the center
of one side.
(8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(9) Mix enough epoxy to cover one side of all sup-
port squares.
(10) Apply epoxy to the support squares on the
half with the hole pre-drilled in it.
(11) Using number 8 sheet metal screws, secure
support squares to back side of body panel with
epoxy sandwiched between the panel and squares
(Fig. 10).
Fig. 8 Damaged Panel Cutout and Patch
1 ± CUTOUT
2 ± DAMAGED BODY PANEL
3 ± 4MM (0.160 IN.) HOLES
4 ± PATCH CUT TO SIZE
Fig. 9 Fabricated Panel
1 ± STRUCTURAL ADHESIVE OR EPOXY RESIN
2 ± FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 ± WIDTH OF V-GROOVE
4 ± WAXED PAPER
23 - 22 BODYPL
SERVICE PROCEDURES (Continued)

(12) Position patch in cutout against support
squares and adjust patch until the gap is equal along
all sides (Fig. 11).
(13) Drill 3 mm (0.125 in.) holes in the support
squares through the pre-drilled holes in the patch.
(14) Apply a coat of epoxy to the exposed ends of
the support squares (Fig. 12).
(15) Install screws to hold the patch to support
squares (Fig. 13). Tighten screws until patch surface
is flush with panel surface.
(16) Allow epoxy to cure, and remove all screws.
(17) Using a 125 mm (5 in.) 24 grit disc grinder,
grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the
patch (Fig. 14). With compressed air, blow dust from
around patch.
(18) Apply adhesive backed nylon mesh (dry wall
tape) over gaps around patch (Fig. 15).
(19) Mix enough epoxy to cover the entire patch
area.
(20) Apply epoxy over the mesh around patch, and
smooth epoxy with a wide spreader to reduce finish
grinding. Use two to three layers of mesh and epoxy
to create a stronger repair (Fig. 16).
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can
be finished using the same methods as finishing
other types of body panels. If mesh material is
exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler.
Prime, block sand, and paint as required.
REMOVAL AND INSTALLATION
GRILLE
REMOVAL
(1) Release hood latch, open and support hood on
prop rod.
(2) Remove screws attaching grille to parking
lamps (Fig. 17).
(3) Remove screw attaching grille to radiator clo-
sure panel.
(4) Remove grille from vehicle.
INSTALLATION
(1) Place grille into position on vehicle.
Fig. 10 Secure Support Squares To Body Panel
1 ± SUPPORT SQUARES
2 ± SCREWS
3 ± DAMAGED BODY PANEL
Fig. 11 Position Patch In Cutout And Align
1 ± CUTOUT
2 ± SUPPORT SQUARES
Fig. 12 Apply Epoxy To Support Squares
1 ± APPLICATOR
2 ± SUPPORT SQUARES
3 ± EPOXY
PLBODY 23 - 23
SERVICE PROCEDURES (Continued)

SPECIFICATIONS
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other
underhood services, the hood latch release mecha-
nism and safety catch should be inspected, cleaned,
and lubricated. During the winter season, external
door lock cylinders should be lubricated to assure
proper operation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Decklid Hinges
MOPARTSPRAY WHITE LUBE OR EQUIVALENT
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Decklid Latch
MOPARTMULTIPURPOSE GREASE OR
EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Decklid Lock Cylinder
SPECIAL TOOLS
BODY
STICK, TRIM C 4755
PLBODY 23 - 59

SPECIFICATIONS
TABLE OF CONTENTS
page page
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS........60
BODY GAP AND FLUSH MEASUREMENTS.....61
BODY OPENING DIMENSION...............62BODY SEALING LOCATIONS................64
STRUCTURAL ADHESIVE LOCATIONS........74
TORQUE SPECIFICATIONS.................76
WELD LOCATIONS.......................77
SPECIFICATIONS
BODY LUBRICATION SPECIFICATIONS
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.
(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door Hinges ± Hinge Pin and Pivot Contact
Areas
²Hood Hinges ± Pivot Points
²Liftgate Hinges
²Decklid Hinges
MOPARTSPRAY WHITE CUBE OR EQUIVALENT
²Door Check Straps
²Liftgate Latches
²Liftgate Prop Pivots
²Ash Receiver
²Fuel Filler Door Remote Control Latch Mecha-
nism
²Parking Brake Mechanism
²Sliding Seat Tracks
²Decklid Latch
MOPARTMultipurpose GREASE OR EQUIVALENT
²All Other Hood Mechanisms
MOPARTLOCK CYLINDER LUBRICANT OR
EQUIVALENT
²Door Lock Cylinders
²Decklid Lock Cylinder
23 - 60 BODYPL

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

GENERAL INFORMATION
A/C APPLICATION TABLE
Item Description Notes
Vehicle PL Neon
System expansion valve
Total Refrigerant
CapacityR134a 765 grams / 27 oz / 1.69 lbs
Total Oil Capacity ND-8 PAG oil 180 ml / 6.10 oz
Compressor Nippondenso 10S17
Freeze-up Control Fin sensor-3 wire input to PCM, evaporator mounted, cycles
clutch off below 34É F, cycles back on
above 45É F
Low psi Control opens < 14 psi, resets > 38 psi expansion valve mounted
High psi Control opens > 470 psi, resets < 370 - 330 psi compressor mounted switch
Control head manual type
Mode Door cable
Blend Air Door cable
Fresh/Recirc door vacuum actuator
Blower Motor control head switched resistor block
Cooling Fan variable speed PCM controlled ISO solid state fan relay
Clutch
Control relay PCM
Draw 2.5 amps @ 12V60.5V @ 70É F
Gap 0.014º - 0.0269
DRB IIIT
Reads TPS, RPM, A/C switch test, fin sensor
A/C & fan relays
Actuators fan & clutch relays
HEATER AND AIR CONDITIONING CONTROL
Both the heater-only and heater-A/C systems use a
combination of, electrical, cable, and vacuum con-
trols. These controls provide the vehicle operator
with a number of setting options to help control the
climate and comfort within the vehicle. Refer to the
owner's manual in the vehicle glove box for more
information on the features, use, and suggested oper-
ation of these controls.
The heater-only or heater-A/C control panel is located
to the right of the instrument cluster on the instrument
panel. The control panel contains rotary-type knobs.
There is a blower motor speed switch, mode control
switch, temperature control, and airflow control.
The heater-only or heater-A/C control panel cannot
be repaired. If faulty or damaged, the entire unit
must be replaced. The control knobs and the illumi-
nation lamps are available for service replacement.
HEATER AND AIR CONDITIONING
All vehicles are equipped with a common heater-
A/C housing assembly (Fig. 1). The system combines
air conditioning, heating, and ventilating capabilities
in a single unit housing mounted under the instru-
ment panel. On heater-only systems, the evaporator
coil is omitted from the housing and replaced with an
air restrictor plate.
Outside air enters the vehicle through the cowl top
opening at the base of the windshield, and passes
through a plenum chamber to the heater-A/C system
blower housing. Air flow velocity can then be
adjusted with the blower motor speed selector switch
on the heater-A/C control panel. The air intake open-
ings must be kept free of snow, ice, leaves, and other
obstructions for the heater-A/C system to receive a
sufficient volume of outside air.
24 - 2 HEATING AND AIR CONDITIONINGPL