Air Conditioner PDF

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 . . . . . . . . . . . . . . . . . . 17
EVACUATING 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
PL HEATING AND AIR CONDITIONING 24 - 1
GENERAL INFORMATION
A/C APPLICATION TABLE
Item Description Notes
Vehicle PL Neon
System expansion valve
Total Refrigerant
Capacity
R134a 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 34F, cycles back on
above 45F
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 @ 12V 0.5V @ 70F
Gap 0.014 - 0.026
DRB III
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-onl y and heater-A/C systems use a
combi nati on of, el ectri cal , cabl e, and vacuum con-
trol s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use, and suggested oper-
ati on of these control s.
The heater-onl y or heater-A/C control panel i s l ocated
to the ri ght of the i nstrument cl uster on the i nstrument
panel . The control panel contai ns rotary-type knobs.
There i s a bl ower motor speed swi tch, mode control
swi tch, temperature control , and ai rfl ow control .
The heater-onl y or heater-A/C control panel cannot
be repai red. I f faul ty or damaged, the enti re uni t
must be repl aced. The control knobs and the i l l umi -
nati on l amps are avai l abl e for servi ce repl acement.
HEATER AND AIR CONDITIONING
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y (Fi g. 1). The system combi nes
ai r condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es
i n a si ngl e uni t housi ng mounted under the i nstru-
ment panel . On heater-onl y systems, the evaporator
coi l i s omi tted from the housi ng and repl aced wi th an
ai r restri ctor pl ate.
Outsi de ai r enters the vehi cl e through the cowl top
openi ng at the base of the wi ndshi el d, and passes
through a pl enum chamber to the heater-A/C system
bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
24 - 2 HEATING AND AIR CONDITIONING PL
I t i s al so i mportant to keep the ai r i ntake openi ngs
cl ear of debri s because l eaf parti cl es and other debri s
that i s smal l enough to pass through the cowl pl e-
num screen can accumul ate wi thi n the heater-A/C
housi ng. The cl osed, warm, damp and dark envi ron-
ment created wi thi n the heater-A/C housi ng i s i deal
for the growth of certai n mol ds, mi l dews and other
fungi . Any accumul ati on of decayi ng pl ant matter
provi des an addi ti onal food source for fungal spores,
whi ch enter the housi ng wi th the fresh ai r. Excess
debri s, as wel l as objecti onabl e odors created by
decayi ng pl ant matter and growi ng fungi can be di s-
charged i nto the passenger compartment duri ng
heater-A/C system operati on.
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end-ai r
door control s the amount of uncondi ti oned ai r (or
cool ed ai r from the evaporator on model s wi th ai r
condi ti oni ng) that i s al l owed to fl ow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determi nes the di s-
charge ai r temperature by movi ng a cabl e, whi ch
operates the bl end-ai r door. Thi s al l ows an al most
i mmedi ate manual control of the output ai r tempera-
ture of the system.
The mode control knob on the heater-onl y or heat-
er-A/C control panel i s used to di rect the condi ti oned
ai r to the sel ected system outl ets. The mode control
swi tch uses a cabl e to control the mode door, whi l e
the reci rcul ati on ai r door i s operated by a vacuum
actuator motor.
On ai r condi ti oned vehi cl es, the outsi de ai r i ntake
can be shut off by sel ecti ng the reci rcul ati on mode
(Reci rc) wi th the mode control knob. Thi s wi l l oper-
ate a vacuum actuated reci rcul ati ng ai r door that
cl oses off the outsi de fresh ai r i ntake and reci rcul ates
the ai r that i s al ready i nsi de the vehi cl e.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s ai r condi ti oni ng system
uses an evaporator probe to mai ntai n mi ni mum
evaporator temperature and prevent evaporator
freezi ng, and cycl es the compressor cl utch.
INTRODUCTION
Both the heater and the heater/ai r condi ti oni ng
systems share many of the same functi oni ng compo-
nents. Thi s group wi l l deal wi th both systems
together when component functi on i s common, and
separatel y when they are not.
For proper operati on of the i nstrument panel con-
trol s, refer to the Owners Manual provi ded wi th the
vehi cl e.
To servi ce the heater core or evaporator, the uni t
housi ng must be removed from the vehi cl e (Fi g. 2).
Fig. 1 Common Blend-Air HVAC (Heating,
Ventilation, Air Conditioning) System - Typical
1 TEMPERATURE BLEND/AIR DOOR
2 EVAPORATOR CORE
3 BLOWER
4 PANEL DEFROST DOOR
5 HEAT DEFROST DOOR
6 HEATER CORE
7 RECIRCULATING AIR DOOR
Fig. 2 HVAC Unit Housing
1 AIR DISTRIBUTION
2 RECIRCULATION DOOR VACUUM ACTUATOR
3 AIR INLET
4 BLOWER MOTOR
5 EVAPORATOR PROBE CONNECTOR
6 CONTROL CABLES
7 VACUUM HARNESS
GENERAL INFORMATION (Continued)
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
SONAL INJURY CAN RESULT.
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
DESCRIPTION AND OPERATION
A/C REFRIGERANT LINES
DISCHARGE LINE
The di scharge l i ne i s the l i ne that goes from the
compressor to the condenser (Fi g. 3). I t has no ser-
vi ceabl e parts except the rubber O-ri ngs. I f the l i ne
i s found to be l eaki ng or i s damaged i t must be
repl aced as an assembl y.
LIQUID LINE
The l i qui d l i ne i s the l i ne that goes from the con-
denser to dri er (Fi g. 3). I t has no servi ceabl e parts
except the rubber O-ri ngs. I f the l i ne i s found to be
l eaki ng or i s damaged i t must be repl aced as an
assembl y.
SUCTION LINE
The sucti on l i ne i s the l arge l i ne that connects to
the expansi on val ve and goes to the compressor (Fi g.
3). I t al so has a smal l l i ne that goes to the fi l ter/
dri er. The sucti on l i ne uses a gasket on the expan-
si on val ve si de and rubber O-ri ngs on al l other
connecti ons.
There are no servi ceabl e parts on the sucti on l i ne
other than the rubber O-ri ngs and expansi on val ve
gasket. I f the l i ne i s found to be l eaki ng or i s dam-
aged i t must be repl aced as an assembl y.
Fig. 3 A/C Compressor Lines
1 CONDENSER LIQUID LINE
2 SUCTION LINE
3 COMPRESSOR MANIFOLD SCREWS
4 COMPRESSOR
5 DISCHARGE LINE
GENERAL INFORMATION (Continued)
A/C SERVICE PORT VALVE CORES
The A/C servi ce port val ve cores are servi ceabl e
i tems (Fi g. 4). The hi gh si de val ve i s l ocated on the
fi l ter-dri er, and the l ow si de val ve i s si tuated on the
sucti on l i ne, near the washer fl ui d reservoi r fi l l er.
BLOWER MOTOR RESISTOR
The bl ower motor resi stor i s l ocated i n the cowl , at
the base of the wi ndshi el d (Fi g. 5). There are two di f-
ferent resi stor bl ocks dependi ng on whether the vehi -
cl e i s equi pped wi th A/C or not. The bl ower motor
resi stors wi l l get hot when i n use (Fi g. 6). Do not
touch resi stor bl ock i f the bl ower motor has been
runni ng.
COMPRESSOR
The compressor used on thi s vehi cl e i s a Ni ppon-
denso 10S17. Thi s compressor uses an al umi num
swash pl ate, tefl on coated pi stons and al umi num
sl eevel ess cyl i nder wal l s.
NOISE
Excessi ve noi se that occurs when the ai r condi ti on-
i ng i s bei ng used may be caused by:
Loose bol ts
Mounti ng brackets
Loose compressor cl utch
Excessi ve hi gh refri gerant operati ng pressure
Veri fy the fol l owi ng before compressor repai r i s
performed:
(1) Compressor dri ve bel t condi ti on
(2) Proper refri gerant charge
(3) Thermal expansi on val ve (TXV) operati ng cor-
rectl y
(4) Head pressure i s normal
Fig. 4 A/C Service Port Valves
1 A/C SERVICE PORTS
2 FILTER/DRIER
Fig. 5 Blower Motor Resistor Block
1 RESISTOR BLOCK
2 ELECTRICAL CONNECTOR
Fig. 6 Blower Motor Resistors
1 RESISTOR BLOCK
2 RESISTORS
DESCRIPTION AND OPERATION (Continued)
COMPRESSOR FRONT SHAFT SEAL
The compressor front shaft seal i s not servi ceabl e.
I f a l eak i s detected at the shaft seal , the compressor
must be repl aced as a uni t.
CONDENSATION DRAIN TUBE
Condensati on that accumul ates i n the evaporator
housi ng i s drai ned from a tube through the dash and
on to the ground. Thi s tube must be kept open to
prevent condensate water from col l ecti ng i n the bot-
tom of the housi ng.
The tapered end of the drai n tube i s desi gned to
keep contami nants from enteri ng the heater A/C uni t
housi ng. I f the tube i s pi nched or bl ocked, condensate
cannot drai n, causi ng water to back up and spi l l i nto
the passenger compartment. I t i s normal to see con-
densate drai nage bel ow the vehi cl e. I f the tube i s
damaged, i t shoul d be repl aced.
ENGINE COOLING SYSTEM REQUIREMENTS
To mai ntai n ampl e temperature l evel s from the
heati ng-A/C system, the cool i ng system must be i n
proper worki ng order. Refer to Group 0, Lubri cati on
and Mai ntenance or Group 7, Cool i ng System of thi s
manual .
The use of a bug screen i s not recommended. Any
obstructi ons forward of the condenser can reduce the
effecti veness of the ai r condi ti oni ng system.
EVAPORATOR PROBE
The evaporator probe can be repl aced wi thout hav-
i ng to remove the uni t housi ng from the vehi cl e.
The evaporator probe i s l ocated i n the uni t housi ng
and pl aced i n the evaporator fi ns. The probe prevents
evaporator freeze-up. Thi s i s done by cycl i ng the com-
pressor cl utch OFF when evaporator temperature
drops bel ow freeze poi nt. I t cycl es ON when the
evaporator temperature ri ses above freeze poi nt. The
evaporator probe uses a thermi stor probe i n a capi l -
l ary tube. The tube i s i nserted between the evapora-
tor fi ns i n the heater-A/C uni t housi ng.
HANDLING TUBING AND FITTINGS
Ki nks i n the refri gerant tubi ng or sharp bends i n
the refri gerant hose l i nes wi l l greatl y reduce the
capaci ty of the enti re system. Hi gh pressures are pro-
duced i n the system when i t i s operati ng. Extreme
care must be exerci sed to make sure that al l connec-
ti ons are pressure ti ght. Di rt and moi sture can enter
the system when i t i s opened for repai r or repl ace-
ment of l i nes or components. The refri gerant oi l wi l l
absorb moi sture readi l y out of the ai r. Thi s moi sture
wi l l convert i nto aci ds wi thi n a cl osed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HIGH PRESSURE CUT OUT SWITCH
The hi gh pressure cut out swi tch i s l ocated on the
rear of the compressor (Fi g. 7). I t turns off the com-
pressor i f the system pressure exceeds 3240 kPa (470
psi ).
LOW PRESSURE CUT OFF SWITCH
The Low Pressure Cut Off Swi tch (Fi g. 8) moni tors
the refri gerant gas pressure on the sucti on si de of
the system. The l ow pressure cut off swi tch i s l ocated
on the expansi on val ve. The l ow pressure cut off
swi tch turns off vol tage to the compressor cl utch coi l
when refri gerant gas pressure drops to l evel s that
coul d damage the compressor. The l ow pressure cut
out swi tch i s a seal ed factory cal i brated uni t. I t must
be repl aced i f defecti ve.
SIDE WINDOW DEMISTERS
The demi sters di rect ai r from the uni t housi ng
through the outl ets l ocated on the top corners of the
i nstrument panel . The demi sters operate when the
mode sel ector i s anywhere between fl oor and defrost
setti ngs. Some ai r may be noti ceabl e from the demi s-
ter outl ets when the mode sel ector i s i n the bi l evel to
fl oor posi ti ons.
SYSTEM AIRFLOW
The system pul l s outsi de (ambi ent) ai r through the
cowl openi ng at the base of the wi ndshi el d. Then i t
goes i nto the pl enum chamber above the uni t hous-
i ng. On ai r condi ti oned vehi cl es, the ai r passes
through the evaporator. Ai r fl ow can be di rected
ei ther through or around the heater core. Thi s i s
done by adjusti ng the bl end-ai r door wi th the TEMP
control on the i nstrument panel . The ai r fl ow can
then be di rected from the panel , fl oor and defrost
outl ets i n vari ous combi nati ons usi ng the mode sel ec-
tor. There are 17 di fferent mode sel ecti ons possi bl e.
Ai r fl ow vel oci ty can be adjusted wi th the bl ower
speed sel ector swi tch on the i nstrument panel .
On A/C equi pped vehi cl es the ambi ent ai r i ntake
can be control l ed by openi ng and cl osi ng the reci rcu-
l ati ng ai r door. When pl aced i n RECI RC, ai r that i s
i nsi de vehi cl e i s removed conti nuousl y and reci rcu-
l ated through uni t housi ng. Ambi ent ai r cannot be
control l ed on vehi cl es wi thout A/C. The system uses
outsi de ai r at al l ti mes.
The ai r condi ti oni ng compressor can be engaged by
turni ng the fan swi tch countercl ockwi se from the off
posi ti on. I t can al so be engaged by pl aci ng the mode
control i n the mi x to defrost posi ti ons. Thi s wi l l
remove heat and humi di ty from the ai r before i t i s
di rected through or around the heater core.
SYSTEM OIL LEVEL
I t i s i mportant to have the correct amount of oi l i n
the A/C system to ensure proper l ubri cati on of the
compressor. Too l i ttl e oi l wi l l resul t i n damage to the
compressor. Too much oi l wi l l reduce the cool i ng
capaci ty of the system and consequentl y resul t i n
hi gher di scharge ai r 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
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.
I t wi l l not be necessary to check oi l l evel i n the
compressor or to add oi l unl ess there has been an oi l
l oss. Oi l l oss at a l eak poi nt wi l l be evi dent by the
presence of a wet, shi ny surface around the l eak.
REFRIGERANT OIL LEVEL CHECK
When an ai r condi ti oni ng system i s fi rst assem-
bl ed, al l components (except the compressor) are
refri gerant oi l free. After the system has been
charged wi th R-134a refri gerant and operated, the oi l
i n the compressor i s di spersed through the l i nes and
components. The evaporator, condenser, and fi l ter-
dri er wi l l retai n a si gni fi cant amount of oi l , refer to
the Refri gerant Oi l Capaci ti es chart. When a compo-
nent i s repl aced, the speci fi ed amount of refri gerant
oi l must be added. When the compressor i s repl aced,
the amount of oi l that i s retai ned i n the rest of the
system must be drai ned from the repl acement com-
pressor. When a l i ne or component has ruptured and
oi l has escaped, the compressor shoul d be removed
and drai ned. The fi l ter-dri er must be repl aced al ong
wi th the ruptured part. The oi l capaci ty of the sys-
tem, mi nus the amount of oi l sti l l i n the remai ni ng
components, can be measured and poured i nto the
sucti on port of the compressor.
VACUUM CONTROL SYSTEM
The neon uses vacuum to operate onl y the reci rcu-
l ati on door (Fi g. 9). Al l other control s are cabl e.
When vacuum i s suppl i ed to the actuator, the door
moves to the Reci rcul ati on posi ti on (Fi g. 10). The
actuator i s spri ng l oaded so the door moves to the
Outsi de-ai r posi ti on when there i s no vacuum sup-
pl i ed. The operati on of the door can be vi ewed by
removi ng the bl ower motor and l ooki ng up i nto the
uni t i nl et.
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
Normal l y, vacuum i s suppl i ed to the actuator by
pl aci ng the Ci rcul ati on control knob i n the Reci rcul a-
ti on posi ti on. The Mode and the ci rcul ati on control
are mechani cal l y i nterl ocked so the ci rcul ati on con-
trol cannot be pl aced i n the RECI RC posi ti on i f the
mode control i s at or between the mi x and defrost
posi ti ons. Vacuum i s suppl i ed to the actuator onl y
when ci rcul ati on control i s at the RECI RC posi ti on.
I f the ci rcul ati on control i s between the outsi de ai r
posi ti on and RECI RC posi ti on the system wi l l be i n
outsi de ai r. I f the ci rcul ati on control i s i n the
RECI RC posi ti on and the mode control i s moved from
the fl oor to the defrost posi ti ons, the ci rcul ati on con-
trol wi l l move from the RECI RC posi ti on, to the out-
si de ai r posi ti on begi nni ng at the mi x posi ti on. Thi s
i s to prevent wi ndow foggi ng.
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST
The ai r condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passen-
ger compartment. The evaporator, l ocated i n the
heater A/C uni t, i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, moi sture i n the ai r condenses
to water, dehumi di fyi ng the ai r. Condensati on on the
evaporator fi ns reduces the evaporators abi l i ty to
absorb heat. Duri ng peri ods of hi gh heat and humi d-
i ty, an ai r condi ti oni ng system wi l l be l ess effecti ve.
Wi th the i nstrument control set to RECI RC, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, A/C performance l evel s ri se.
PERFORMANCE TEST PROCEDURE
Revi ew Safety Precauti ons and Warni ngs i n thi s
group before proceedi ng wi th thi s procedure. Ai r tem-
perature i n test room and on vehi cl e must be 21 C
(70F) mi ni mum for thi s test.
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 tachometer and mani fol d gauge set.
(2) Set control to A/C, RECI RC, and PANEL, tem-
perature l ever on ful l cool and bl ower on hi gh.
(3) Start engi ne and hol d at 1000 rpm wi th A/C
cl utch engaged.
(4) Engi ne shoul d be warmed up wi th doors and
wi ndows cl osed.
(5) I nsert a thermometer i n the l eft center A/C
outl et and operate the engi ne for fi ve mi nutes. The
A/C cl utch may cycl e dependi ng on ambi ent condi -
ti ons.
(6) Wi th the A/C cl utch engaged, compare the di s-
charge ai r temperature to the A/C Performance Tem-
peratures chart.
(7) I f the di scharge ai r temperature fai l s to meet
the speci fi cati ons i n the performance temperature
chart. Refer to the Refri gerant Servi ce Procedures for
further di agnosi s.
A/C PERFORMANCE TEMPERATURES
Ambient Temperature 21C (70F) 26.5C (80F) 32C (90F) 37C (100F) 43C (110F)
Air Temperature at Left
Center Panel Outlet
1-8C
(34-46F)
3-9C
(37-49F)
4-10C
(39-50F)
6-11C
(43-52F)
7-18C
(45-65F)
Compressor Discharge
Pressure After the Filter
Drier
1034-1724 kPa
(150-250 PSI)
1517-2275 kPa
(220-330 PSI
1999-2620
kPa (290-380
PSI)
2068-2965
kPa (300-430
PSI)
2275-3421 kPa
(330-496 PSI)
Evaporator Suction
Pressure
103-207 kPa
(15-30 PSI)
117-221 kPa
(17-32 PSI)
138-241 kpa
(20-35 PSI)
172-269 kpa
(25-39 PSI)
207-345 kPa
(30-50 PSI)
BLOWER MOTOR ELECTRICAL DIAGNOSIS
Refer to the Bl ower Motor El ectri cal System Di ag-
nosi s chart (Fi g. 11) i n thi s secti on. Al so refer to
Group 8W, Wi ri ng Di agrams for more i nformati on.
Fig. 11 Blower Motor Electrical Diagnosis
DIAGNOSIS AND TESTING (Continued)
BLOWER MOTOR VIBRATION AND/OR NOISE
DIAGNOSIS
The resi stor bl ock suppl i es the bl ower motor wi th
vari ed vol tage (l ow and mi ddl e speeds) or battery
vol tage (hi gh speed).
CAUTION: Stay clear of the blower motor and resis-
tor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater-A/C
housing.
Refer to the Bl ower Motor Vi brati on/Noi se chart
for di agnosi s.
COMPRESSOR NOISE DIAGNOSIS
Excessi ve noi se whi l e the A/C i s bei ng used, can be
caused by l oose mounts, l oose cl utch, or hi gh operat-
i ng pressure. Veri fy compressor dri ve bel t condi ti on,
proper refri gerant charge and head pressure before
compressor repai r i s performed.
I f the A/C dri ve bel t sl i ps at i ni ti al start-up, i t does
not necessari l y mean the compressor has fai l ed.
Wi th the cl ose tol erances of a compressor i t i s pos-
si bl e to experi ence a temporary l ockup. The l onger
the A/C system i s i nacti ve, the more l i kel y the condi -
ti on to occur.
Thi s condi ti on i s the resul t of normal refri gerant
movement wi thi n the A/C system caused by temper-
ature changes. The refri gerant movement may wash
the oi l out of the compressor.
EVAPORATOR PROBE TEST
The work area and vehi cl e must be between 16 C
(60 F) and 32 C (90 F) when testi ng the swi tch.
(1) Di sconnect the three wi re connector from the
evaporator probe l ead l ocated behi nd the gl ove box
(Fi g. 12).
(2) Start engi ne and set A/C to l ow bl ower motor
speed, panel , ful l cool , and RECI RC.
(3) Usi ng a vol tmeter, check for battery vol tage
between Pi n 1 and 2. I f no vol tage i s detected, there
i s no power to the swi tch. Check wi ri ng and fuses.
Refer to Group 8W, Wi ri ng Di agrams for ci rcui t di ag-
nosi s.
(4) Usi ng a vol tmeter, check for battery vol tage
between Pi n 1 and Pi n 3. I f no vol tage i s detected,
there i s no vol tage from the Powertrai n Control Mod-
ul e. Refer to Group 8W, Wi ri ng Di agrams. I f vol tage
i s OK, connect a jumper wi re between Pi n 1 and Pi n
3. The compressor cl utch shoul d engage. I f the cl utch
engages, remove the jumper wi re i mmedi atel y and go
to Step 5. I f the compressor cl utch does not engage,
check the operati on of the cl utch and repai r as nec-
essary.
(5) I f compressor cl utch engages, connect the evap-
orator probe 3-way connector. The compressor cl utch
shoul d engage or cycl e dependi ng on evaporator tem-
perature. I f OK, go to Step 6. I f not OK, repl ace the
cl utch cycl i ng swi tch.
(6) The engi ne runni ng and the A/C set to:
Bl ower motor on l ow speed
Panel posi ti on
Ful l cool
RECI RC.
Cl ose al l doors and wi ndows. Pl ace a thermometer i n
the center di scharge vent.
(7) I f the cl utch does not begi n to cycl e off between
2 C to 7 C (35 F to 45 F), veri fy that the evapo-
rator probe i s ful l y i nstal l ed and not l oose i n evapo-
rator. I f i t i s not properl y i nstal l ed, i nstal l probe and
retest outl et temperature. I f the evaporator probe i s
properl y i nstal l ed, repl ace the cl utch cycl i ng swi tch.
EXPANSION VALVE
NOTE: Expansion valve tests should be performed
after compressor tests.
Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
Revi ew Safety Precauti ons and Warni ngs i n the
General I nformati on secti on of thi s Group. The work
area and vehi cl e must be 21 to 27C (70 to 85F)
when testi ng expansi on val ve. To test the expansi on
val ve:
(1) Connect a chargi ng stati on or mani fol d gauge
set to the refri gerant system servi ce ports.
(2) Di sconnect wi re connector at l ow pressure cut-
off swi tch (Fi g. 13). Usi ng a jumper wi re, jump ter-
mi nal s i nsi de wi re connector boot.
(3) Cl ose al l doors, wi ndows and vents to the pas-
senger compartment.
(4) Set Heater-A/C control to A/C, ful l heat, fl oor,
RECI RC. and hi gh bl ower.
(5) Start the engi ne and hol d the i dl e speed (1000
rpm). After the engi ne has reached runni ng temper-
ature, al l ow the passenger compartment to heat up.
Thi s wi l l create the need for maxi mum refri gerant
fl ow i nto the evaporator.
(6) I f the refri gerant charge i s suffi ci ent, di scharge
(hi gh pressure) gauge shoul d read 965 to 2620 kPa
(140 to 380 psi ). Sucti on (l ow pressure) gauge shoul d
read 103 to 2417 kPa (15 to 35 psi ). I f system cannot
achi eve proper pressure readi ngs, repl ace the expan-
si on val ve. I f pressure i s correct, proceed wi th test.
BLOWER MOTOR NOISE/VIBRATION DIAGNOSIS
WARNING: PROTECT SKIN AND EYES FROM CON-
TACTING CO2 PERSONAL INJURY CAN RESULT.
(7) I f sucti on si de l ow pressure i s wi thi n speci fi ed
range, freeze the expansi on val ve control head (Fi g.
13) for 30 seconds. Use a super col d substance (l i qui d
CO2). Do not spray refrigerant on the expansion
valve for this test. Sucti on si de l ow pressure shoul d
drop to 34.5 kPa (5 psi ) I f not, repl ace expansi on
val ve.
(8) Al l ow expansi on val ve to thaw. The l ow pres-
sure gauge readi ng shoul d stabi l i ze at 103 to 241
kPa (15 to 35 psi ). I f not, repl ace expansi on val ve.
(9) When expansi on val ve test i s compl ete, test
A/C overal l performance. Refer to the Heater and A/C
Performance Test i n thi s secti on. Remove al l test
equi pment before returni ng vehi cl e to use.
HEATER PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
Revi ew Safety Precauti ons and Warni ngs i n thi s
group before performi ng the fol l owi ng procedures.
Check the cool ant l evel , dri ve bel t tensi on, vacuum
l i ne connecti ons, radi ator ai r fl ow and fan operati on.
Start engi ne and al l ow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and
turn i t to the fi rst safety stop. Al l ow pressure to
escape through the overfl ow tube. When the system
stabi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engi ne cool ant i s provi ded to the heater system by
two 16 mm (5/8 i nch i nsi de di ameter) heater hoses.
Wi th engi ne i dl i ng at normal runni ng temperature,
set the control to maxi mum heat, fl oor, and hi gh
bl ower setti ng. Usi ng a test thermometer, check the
ai r temperature comi ng from the fl oor outl ets, refer
to Temperature Reference chart.
I f the fl oor outl et ai r temperature i s i nsuffi ci ent,
refer to Group 7, Cool i ng Systems for speci fi cati ons.
Both heater hoses shoul d be HOT to the touch (cool -
ant return hose shoul d be sl i ghtl y cool er than the
suppl y hose). I f cool ant return hose i s much cool er
than the suppl y hose, l ocate and repai r engi ne cool -
ant fl ow obstructi on i n heater system.
Fig. 12 Evaporator Probe Harness Connector
1 PIN #3
2 PIN #2
3 PIN #1
Fig. 13 Expansion Valve & Low Pressure Cut-Off
Switch - Typical
1 EXPANSION VALVE
2 LOW PRESSURE CUT OFF SWITCH
3 SUCTION LINE
4 CONTROL HEAD
TEMPERATURE REFERENCE CHART
Ambient Temp. Minimum
Floor
Outlet
Temp.
Celsius Fahrenheit Celsius Fahrenheit
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pi nched or ki nked heater hoses.
(2) I mproper heater hose routi ng.
(3) Pl ugged heater hoses or suppl y and return
ports at cool i ng system connecti ons, refer to Group 7,
Cool i ng System.
(4) Pl ugged heater core.
(5) Ai r l ocked heater core.
(6) I f cool ant fl ow i s veri fi ed and outl et tempera-
ture i s i nsuffi ci ent, a mechani cal probl em may exi st.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT
HEAT
(1) Obstructed cowl ai r i ntake.
(2) Obstructed heater system outl ets.
(3) Bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f temperature cannot be adjusted wi th the TEMP
l ever on the control panel , the fol l owi ng coul d requi re
servi ce:
(1) Bl end-ai r door bi ndi ng.
(2) Faul ty bl end-ai r door cabl e.
(3) I mproper engi ne cool ant temperature.
(4) Faul ty I nstrument Panel Control .
The work area must not be bel ow 21C (70F) to
test the compressor cl utch ci rcui t.
(1) Wi th gear sel ector i n park or neutral and park
brake set, start engi ne and al l ow to i dl e.
(2) Rai se hood and di sconnect l ow pressure cut off
swi tch connector boot.
(3) Usi ng a sui tabl e jumper wi re, jump across the
termi nal s i nsi de wi re connector boot.
(4) I f the compressor cl utch does not engage, the
cycl i ng cl utch swi tch, wi ri ng, rel ay, or fuse can be
defecti ve. Refer to Group 8W, Wi ri ng Di agrams.
(5) I f cl utch engages, connect mani fol d gauge set.
Read l ow pressure gauge. At pressure above 97 kPa
(14 psi ) and above, l ow pressure out off swi tch wi l l
compl ete the cl utch ci rcui t. I f the l ow pressure gauge
reads bel ow 140 kPa (20 psi ), the system i s l ow on
refri gerant charge or empty due to a l eak. Refer to
Servi ce Procedures, System Leak Checki ng i n thi s
secti on.
(6) I nstal l connector boot on swi tch and repeat
Step 3. I f the cl utch does not engage, repl ace the l ow
pressure cut off swi tch.
SYSTEM CHARGE LEVEL TEST
The procedure bel ow shoul d be used to check
and/or fi l l the refri gerant charge i n the ai r condi ti on-
i ng system.
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.
NOTE: The maximum amount of R-134a refrigerant
that the air conditioning system holds is 765 grams
(27 oz. or 1.69 lbs.)
I t i s recommended to use the gauges or recl ai m/re-
cycl e equi pment.
(1) Use a mani fol d gauge and check the l i qui d l i ne
pressure.
(2) Attach a cl amp-on thermocoupl e (P. S. E.
66-324-0014 or 80PK-1A) or equi val ent to the l i qui d
l i ne near the fi l ter/dri er.
(3) The vehi cl e must be i n the fol l owi ng modes:
Automati c transaxl e i n park or manual tran-
saxl e i n neutral .
Engi ne at i dl e
A/C control s set to outsi de ai r
Panel mode
A/C ON ful l cool
Bl ower motor ON hi gh speed
Vehi cl e wi ndows cl osed
(4) Operate system for a coupl e of mi nutes to al l ow
the system to stabi l i ze.
(5) Observe fi l ter/dri er pressure and Li qui d l i ne
temperature. Usi ng the Charge Determi nati on Chart
(Fi g. 14) determi ne where the system i s currentl y
operati ng. I f the system i s not i n the proper range,
recl ai m al l the refri gerant and recharge per A/C
l abel .
VACUUM CONTROL SYSTEM
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 15), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
Fig. 14 Charge Determination Chart
Fig. 15 Adjust Vacuum Test Bleed Valve - Typical
1 VACUUM PUMP TOOL C-4289
2 VACUUM TEST SET C-3707
3 BLEED VALVE
4 PROBE
HEATER-A/C VACUUM SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO FORCED AIR IN
HEAT POSITION
1. 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 POSITION
leaking.
2. Faulty mode door.
2. Test actuator and door operation. Repair as
necessary.
NO FORCED AIR IN
DEFROST POSITION
leaking.
2. Faulty heat, defroster, or
mode door.
2. Test actuators and door operation. Repair as
necessary.
ONE-WAY CHECK VALVE
(1) Di sconnect the heater-A/C vacuum suppl y
(Bl ack) tube i n the engi ne compartment. Thi s tube
passes through an openi ng i n the dash panel .
(2) Remove the one-way vacuum check val ve. The
val ve i s l ocated on the (Bl ack) vacuum suppl y hose at
the brake power booster.
(3) Connect the test set vacuum suppl y hose to the
heater si de of the val ve. When connected to thi s si de
of the check val ve, no vacuum shoul d pass and the
test set gauge shoul d return to the 27 kPa (8 i n. Hg.)
setti ng. I f OK, go to step Step 4. I f not OK, repl ace
the faul ty val ve.
(4) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
HEATER-A/C CONTROLS
The operati on of the Ci rcul ati on door can be
vi ewed by removi ng the bl ower motor and l ooki ng up
i nto the uni t i nl et. See Bl ower Motor Wheel and
Assembl y removal and i nstal l ati on i n thi s secti on for
servi ce procedures.
(1) Connect the test set vacuum probe to the heat-
er-A/C vacuum suppl y (Bl ack) hose i n the engi ne
compartment. Posi ti on the test set gauge so that i t
can be vi ewed from the passenger compartment.
(2) Start wi th the Mode control i n the Panel posi -
ti on and the Ci rcul ati on control i n the Outsi de-ai r
posi ti on.
(3) Move the Ci rcul ati on control to the Reci rcul a-
ti on posi ti on (the Ci rcul ati on door shoul d move i nto
the Reci rcul ati on posi ti on). After a short pause move
the Mode control to the Defrost posi ti on (the Ci rcul a-
ti on door shoul d move to the Outsi de-ai r posi ti on).
The test gauge shoul d return to the cal i brated set-
ti ng of 27 kPa (8 i n. Hg.) after each sel ecti on i s
made. I f the gauge cannot achi eve the cal i brated set-
ti ng, the vacuum ci rcui t or a component has a l eak.
(4) I f the gauge achi eves the cal i brated setti ng but
the door does not move, there i s ei ther a pi nched vac-
uum l i ne or a fai l ed actuator.
LOCATING VACUUM LEAKS
(1) Connect the test vacuum probe to the vehi cl es
(Bl ack) suppl y hose. Posi ti on the vacuum test gauge
so i t can be vi ewed from the passenger compartment.
(2) Pl ace the Mode i n the Panel posi ti on and the
Ci rcul ati on control i n the Reci rcul ati on posi ti on.
(3) Remove the center i nstrument panel bezel .
(4) Remove the center vent duct.
(5) Remove and bl ock the Suppl y (Bl ack) vacuum
l i ne at the control . The test gauge shoul d return to
the cal i brated setti ng of 27 kPa (8 i n. Hg). I f not,
there i s a l eak i n the Suppl y l i ne.
(6) I f there i s no l eak i n the Suppl y l i ne, reconnect
i t to the Control and remove the Actuator Feed (Red)
l i ne from the Control . Bl ock the vacuum connecti on
on the Control from where the l i ne was removed. The
test gauge shoul d return to the cal i brated setti ng of
27 kPa (8 i n. Hg.). I f not, there i s a l eak i n the Con-
trol .
(7) I f there i s no l eak i n the Suppl y l i ne or the
Control , reconnect the Actuator Feed (Red) l i ne to the
control . Remove and bl ock the Actuator Feed (Red)
l i ne at the Actuator. The actuator vacuum port i s
accessi bl e behi nd and above the Gl ove Box. The test
gauge shoul d return to the cal i brated setti ng of 27
kPa (8 i n. Hg.). I f not there i s a l eak i n the Actuator
Feed l i ne.
(8) I f there i s no l eak i n the Suppl y l i ne, Control ,
or the Actuator Feed l i ne, the l eak must be i n the
Actuator i tsel f. Connect the Vacuum hose from the
Vacuum Test Gauge di rectl y to the Actuator to veri fy
the l eak.
LOCATING PINCHED VACUUM LINES
The operati on of the Ci rcul ati on door can be
vi ewed by removi ng the bl ower motor and l ooki ng up
i nto the uni t i nl et. See Bl ower Motor Wheel and
Assembl y removal and i nstal l ati on i n thi s secti on for
servi ce procedures.
(1) Connect the test vacuum probe to the vehi cl es
(Bl ack) suppl y hose. Posi ti on the vacuum test gauge
so i t can be vi ewed from the passenger compartment.
(2) Pl ace the Mode i n the Panel posi ti on and the
Ci rcul ati on control i n the Reci rcul ati on posi ti on.
(3) Remove the center i nstrument panel bezel .
(4) Remove the center vent duct.
(5) Remove the Suppl y (Bl ack) vacuum l i ne at the
control . The test gauge shoul d drop i ndi cati ng free
fl ow through the Suppl y l i ne. I f not, there i s a bl ock-
age i n the Suppl y l i ne.
(6) I f there i s no bl ockage i n the Suppl y l i ne,
reconnect i t to the Control . Remove the Actuator
Feed (Red) l i ne from the Control . The test gauge
shoul d drop i ndi cati ng free fl ow through the Suppl y
l i ne and Control . I f not the vacuum swi tches on the
Control are not functi oni ng.
(7) I f there i s no bl ockage i n the Suppl y l i ne or the
Control , reconnect the Actuator Feed (Red) l i ne to the
control . Remove the Actuator Feed (Red) l i ne at the
Actuator. The Actuator vacuum port i s accessi bl e
behi nd and above the Gl ove Box. The test gauge
shoul d drop i ndi cati ng free fl ow through the suppl y
l i ne, Control , and the Actuator Feed l i ne. I f not,
there i s a bl ockage i n the Actuator Feed l i ne.
(8) I f there i s no bl ockage i n the Suppl y l i ne, Con-
trol , or the Actuator Feed l i ne, the Actuator must
have fai l ed. Connect the Vacuum hose from the Vac-
uum Test Gauge di rectl y to the Actuator to veri fy the
Actuator has fai l ed.
SERVICE PROCEDURES
CHARGING A/C SYSTEM
PARTIAL CHARGE
Thi s vehi cl e does not have a si ght gl ass. I t i s not
possi bl e to determi ne the amount of (R-134a) charge
i n the system. Therefore i t i s necessary to compl etel y
evacuate and recover the system, and then recharge
the system ful l y.
EVACUATION
Before addi ng refri gerant, al l ai r must be evacu-
ated from the system.
Connect a mani fol d gauge set to the A/C servi ce
ports (Fi g. 16).
Use a vacuum pump or chargi ng stati on and
evacuate system to 95 kPa (28 i nches Hg) for 30 mi n-
utes.
Go to Chargi ng A/C System bel ow.
CHARGING A/C SYSTEM
The procedure bel ow shoul d be used to fi l l the
refri gerant charge i n the ai r condi ti oni ng system.
Thi s A/C system does not have or use a si ght gl ass 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
VICE.
ERTY DAMAGE.
Fig. 16 A/C Service Ports
1 A/C SERVICE PORTS
2 FILTER/DRIER
CAUTION: Do not overcharge refrigerant system,
as excessive compressor head pressure can cause
noise and system failure.
After the system has been tested for l eaks and
evacuated, a refri gerant (R-134a) charge can be
i njected i nto the system.
(1) I f usi ng a separate vacuum pump cl ose al l
val ves before di sconnecti ng pump. Connect mani fol d
gauge set to the A/C servi ce ports (Fi g. 16).
NOTE: The air conditioning system in this vehicle
holds (27 oz. or 1.69 lbs.) of R-134a refrigerant.
(2) Measure refri gerant (refer to capaci ti es). Refer
to the i nstructi ons provi ded wi th the equi pment
bei ng used.
(3) Veri fy engi ne i s shut off. Open the sucti on and
di scharge val ves. Open the charge val ve to al l ow the
refri gerant to fl ow i nto the system. When the trans-
fer of refri gerant has stopped, cl ose the sucti on and
di scharge val ve.
(4) I f al l of the charge di d not transfer from the
di spensi ng devi ce, put vehi cl e control s i nto the fol -
l owi ng mode:
Automati c transaxl e i n park or manual tran-
saxl e i n neutral
Engi ne i dl i ng at 700 rpm
A/C control set i n 100 percent outsi de ai r
Panel mode
Bl ower motor ON hi gh speed
Vehi cl e wi ndows cl osed
I f the A/C compressor does not engage, test the
compressor cl utch control ci rcui t and correct any fai l -
ure. Refer to Group 8W, Wi ri ng Di agrams.
(5) Open the sucti on val ve to al l ow the remai ni ng
refri gerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH-PRESSURE) VALVE AT THIS TIME.
(6) Cl ose al l val ves and test the A/C system perfor-
mance.
(7) Di sconnect the chargi ng stati on or mani fol d
gauge set. I nstal l the servi ce 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.
I f a compressor desi gned to use R-134a refri gerant
i s l eft open to the atmosphere for an extended peri od
of ti me. I t i s recommended that the refri gerant oi l be
drai ned and repl aced wi th new oi l or a new compres-
sor be used. Thi s wi l l el i mi nate the possi bi l i ty of con-
tami nati ng the refri gerant system.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be fi l l ed. Moi sture and ai r mi xed wi th the refri g-
erant wi l l rai se the compressor head pressure above
acceptabl e operati ng l evel s. Thi s wi l l reduce the per-
formance of the ai r condi ti oner and damage the com-
pressor. Moi sture wi l l boi l at near room temperature
when exposed to vacuum. To evacuate the refri gerant
system:
(1) Connect a sui tabl e chargi ng stati on, refri gerant
recovery machi ne, and a mani fol d gauge set wi th
vacuum pump (Fi g. 17).
(2) Open the sucti on and di scharge val ves and
start the vacuum pump. The vacuum pump shoul d
run a mi ni mum of 45 mi nutes pri or to charge to
el i mi nate al l moi sture i n system. When the sucti on
gauge reads -88 kPa (- 26 i n. Hg) vacuum or greater
for 45 mi nutes, cl ose al l val ves and turn off vacuum
pump. I f the system fai l s to reach speci fi ed vacuum,
the refri gerant system l i kel y has a l eak that must be
corrected. I f the refri gerant system mai ntai ns speci -
fi ed vacuum for at l east 30 mi nutes, start the vac-
uum pump, open the sucti on and di scharge val ves.
Fig. 17 Refrigerant Recovery Machine Hookup -
Typical
1 LOW SIDE CONNECTOR
2 HIGH SIDE CONNECTOR
3 TO MANIFOLD SET
SERVICE PROCEDURES (Continued)
Then al l ow the system to evacuate an addi ti onal 10
mi nutes.
(3) Cl ose al l val ves. Turn off and di sconnect the
vacuum pump.
(4) The refri gerant system i s prepared to be
charged wi th refri gerant.
R-134a REFRIGERANT
Thi s vehi cl e uses a refri gerant cal l ed R-134a. I t i s
a non-toxi c, non-fl ammabl e, cl ear col orl ess l i quefi ed
gas.
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 i n a R-134a system coul d cause
compressor fai l ure, refri gerant oi l to sl udge 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 hi gh pressure servi ce port i s l ocated on the
ffi l ter/dri er. The l ow pressure servi ce port i s l ocated
on the sucti on l i ne near the strut tower.
When servi ci ng a system, i t i s requi red that an ai r
condi ti oni ng chargi ng recovery/recycl i ng machi ne be
used (Fi g. 18). Contact an automoti ve servi ce equi p-
ment suppl i er for proper equi pment. Refer to the
operati ng i nstructi ons provi ded wi th the equi pment
for proper operati on.
A mani fol d gauge set (Fi g. 19) must al so be used i n
conjuncti on wi th the chargi ng and/or recovery/recy-
cl i ng devi ce. Onl y use gauges that have not been
used for R-12. The servi ce hoses on the gauge set
shoul d have manual (turn wheel ) or automati c back
fl ow val ves at the servi ce port connector ends. Thi s
wi l l prevent refri gerant R-134a from bei ng rel eased
i nto the atmosphere.
R-134a refri gerant requi res a speci al type of com-
pressor oi l . When addi ng oi l , make sure to use the oi l
that i s speci fi ed on the under hood l abel .
The use of R-134a wi l l have a posi ti ve envi ronmen-
tal i mpact due to i ts zero ozone depl eti on and l ow
gl obal warmi ng i mpact.
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/recycl i ng equi pment wi l l measure the
l ubri cant bei ng removed. Thi s i s the amount of l ubri -
cant to be added back to the system. I f a new com-
pressor i s bei ng i nstal l ed, drai n l ubri cant from ol d
compressor, measure the amount drai ned and di scard
ol d l ubri cant. Drai n the l ubri cant from the new com-
pressor i nto a cl ean contai ner. Return the amount of
l ubri cant measured from the ol d compressor, pl us the
amount recl ai med from the system back i nto 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
(1) Di scharge refri gerant system usi ng recovery/re-
cycl i ng equi pment i f charge i s present.
(2) Di sconnect refri gerant l i nes from A/C compres-
sor. Cap the open l i nes to prevent moi sture from
enteri ng system.
(3) Remove compressor from vehi cl e.
(4) From sucti on port on top of compressor, drai n
l ubri cant from compressor.
(5) Add system capaci ty mi nus the capaci ty of
components that have not been repl aced. Refer to the
Lubri cant Capaci ty Chart. Add l ubri cant through the
sucti on port on compressor. Thi s i s not to exceed 180
ml (6.10 oz.) i n total .
(6) I nstal l compressor and connect refri gerant
l i nes. Then evacuate and charge refri gerant 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
VICE.
I f the A/C system i s not cool i ng properl y, determi ne
i f the refri gerant system i s ful l y charged wi th
R-134a. Thi s i s accompl i shed by performi ng a system
Charge Level -Check or Fi l l . I f whi l e performi ng thi s
test A/C l i qui d l i ne pressure i s l ess than 345 kPa (50
psi ) proceed to Empty Refri gerant System Leak Test.
I f l i qui d l i ne pressure i s greater than 345 kPa (50
psi ) proceed to l ow refri gerant l evel l eak test. I f the
refri gerant system i s empty or l ow i n refri gerant
charge, a l eak at any l i ne fi tti ng or component seal i s
l i kel y. A revi ew of the fi tti ngs, l i nes and components
for oi l y resi due i s an i ndi cati on of the l eak l ocati on.
To detect a l eak i n the refri gerant system, perform
one of the fol l owi ng procedures as i ndi cated by the
symptoms.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refri gerant system to the l owest
degree of vacuum possi bl e (approx. 28 i n Hg.). Deter-
mi ne i f the system hol ds a vacuum for 15 mi nutes. I f
vacuum i s hel d, a l eak i s probabl y not present. I f sys-
tem wi l l not mai ntai n vacuum l evel , proceed wi th
thi s procedure.
(2) Prepare a.284 Kg. (10 oz.) refri gerant charge to
be i njected i nto the system.
(3) Connect and di spense.284 Kg. (10 oz.) of refri g-
erant i nto the evacuated refri gerant system.
(4) Proceed to Step 2 of Low Refri gerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Determi ne i f there i s any (R-134a) refri gerant
i n the system.
(2) Posi ti on the vehi cl e i n a wi nd free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(3) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run for fi ve mi nutes wi th the system
set to the fol l owi ng:
Transaxl e i n Park
Engi ne I dl i ng at 700 rpm
A/C Control s Set i n 100 percent outsi de ai r
Bl ower swi tch i n the hi gh A/C posi ti on
A/C i n the ON posi ti on
Open al l wi ndows
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 vehi cl e and wai t 2 to 7 mi nutes.
Then use an El ectroni c Leak Detector that i s
desi gned to detect R-134a type refri gerant and search
for l eaks. Fi tti ngs, l i nes, or components that appear
to be oi l y usual l y i ndi cates a refri gerant l eak. To
i nspect the evaporator core for l eaks, i nsert the l eak
detector probe i nto the drai n tube openi ng or a heat
duct. A R-134a dye i s avai l abl e to ai d i n l eak detec-
ti on, use onl y Chrysl er approved refri gerant dye.
I f a thorough l eak check has been compl eted wi th-
out i ndi cati on of a l eak, proceed to System Charge
Level .
REMOVAL AND INSTALLATION
A/C FILTER/DRIER
The fi l ter/dri er i s mounted i n a rubber grommet on
the ri ght si de of the engi ne compartment. The refri g-
erant must be recovered from the A/C system before
repl aci ng the fi l ter/dri er assembl y.
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION.
REMOVAL
(1) Di sconnect l i qui d l i ne from fi l ter/dri er.
(2) Di sconnect l i qui d l i ne on sucti on l i ne assembl y
from fi l ter/dri er.
(3) Pul l fi l ter/dri er out of rubber grommet.
INSTALLATION
For i nstal l ati on, reverse the above procedures.
A/C SERVICE PORT VALVE CORES
REMOVAL
(1) Remove the val ve caps (Fi g. 4).
(2) Usi ng a R-134a refri gerant recovery machi ne,
Remove the refri gerant from A/C system.
(3) Usi ng a standard val ve core tool , remove the
val ve core. Be careful to prevent any dirt/debris
from entering the valve core opening or getting
on the replacement valve core.
INSTALLATION
(1) When assembl i ng the new val ve core i nto the
port, the core shoul d be oi l ed wi th cl ean ND8 PAG
compressor oi l .
CAUTION: A valve that is not fully seated can lead
to damage to the valve during evacuation and
charge. This can result in system refrigerant dis-
charge while uncoupling the charge adapters.
(2) I nstal l val ve core i nto port.
(3) Evacuate and charge the A/C system.
(4) I nstal l the val ve caps.
BLOWER MOTOR AND WHEEL ASSEMBLY
The bl ower motor i s l ocated on the bottom ri ght
si de of the uni t housi ng. The bl ower motor can be
removed from the vehi cl e wi thout havi ng to remove
the uni t housi ng assembl y.
WITH AIR CONDITIONING
REMOVAL
(1) Remove ri ght si de scuff pl ate.
(2) Pul l back carpet.
(3) Di sconnect bl ower motor wi ri ng connector.
(4) Remove bl ower motor retai ni ng screws, and
l ower bl ower motor assembl y from uni t housi ng (Fi g.
20).
INSTALLATION
WITHOUT AIR CONDITIONING
REMOVAL
(1) Di sconnect bl ower motor wi ri ng connector.
(2) Grasp the bl ower motor whi l e pul l i ng down
tab. Turn approxi matel y 1/8 turn countercl ockwi se
and remove bl ower motor assembl y from uni t hous-
i ng (Fi g. 21).
INSTALLATION
Fig. 20 Blower Motor Retaining Screws
1 BLOWER MOTOR
2 BLOWER MOTOR RETAINING SCREWS
3 BLOWER MOTOR WIRING
Fig. 21 Blower Motor Removal
1 BLOWER MODULE
2 BLOWER MOTOR
REMOVAL AND INSTALLATION (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 wi ndshi el d wi pers.
(2) Remove cowl top screen.
(3) Di sconnect the resi stor bl ock wi ri ng connector
(Fi g. 22).
(4) Remove/unsnap resi stor bl ock from vehi cl e.
INSTALLATION
BLOWER MOTOR WHEEL
The bl ower motor wheel i s onl y servi ced wi th the
bl ower motor. The wheel and the motor are bal anced
as an assembl y. I f the bl ower motor wheel requi res
repl acement, the bl ower motor must al so be repl aced.
Refer to bl ower motor for repl acement 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 unbol ted and reposi -
ti oned wi thout di schargi ng the refri gerant system.
Di schargi ng i s not necessary i f removi ng the com-
pressor cl utch/coi l assembl y, engi ne, cyl i nder head, or
al ternator.
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) Di sconnect battery negati ve cabl e.
(2) Loosen and remove dri ve bel ts, refer to Group
7, Engi ne Cool i ng.
remove the refri gerant from A/C system. I f the com-
pressor i s bei ng repl aced.
(4) Di sconnect compressor cl utch wi re l ead.
(5) Remove refri gerant l i nes from compressor, i f
necessary (Fi g. 23).
(6) I f system i s l eft open pl ace pl ug/cap over open
l i nes.
(7) Remove compressor attachi ng bol ts (Fi g. 24).
Fig. 22 Blower Motor Resistor Block
1 RESISTOR BLOCK
Fig. 23 A/C Compressor Lines
2 SUCTION LINE
3 COMPRESSOR MANIFOLD SCREWS
4 COMPRESSOR
5 DISCHARGE LINE
(8) Remove compressor. I f refri gerant l i nes were
not removed, l i ft compressor/cl utch assembl y and ti e
i t to a sui tabl e component.
INSTALLATION
Ti ghten the compressor mounti ng bol ts to 28
Nm (250 i n l bs).
Ti ghten the compressor l i nes to 12 Nm (108 i n
l bs).
COMPRESSOR CLUTCH/COIL ASSEMBLY
Compressor assembl y must be removed from
mounti ng. Al though, refri gerant di scharge i s not nec-
essary.
REMOVAL
(1) Remove the compressor shaft bol t (Fi g. 25). A
band type oi l fi l ter removal tool can be pl aced around
the cl utch pl ate to ai d i n bol t removal .
(2) Tap the cl utch pl ate wi th a pl asti c hammer and
remove cl utch pl ate and shi m(s) (Fi g. 26).
NOTE: Use care not to lose any of the shim(s).
CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Fig. 24 A/C Compressor Mounting Bolts
1 A/C COMPRESSOR
2 MOUNTING BOLTS
3 LOWER FRONT STRUT-TO-ENGINE BRACKET
Fig. 25 Compressor Shaft Bolt and Clutch Plate
1 COMPRESSOR SHAFT BOLT
2 COMPRESSOR CLUTCH PLATE
Fig. 26 Clutch Plate and Shim(s)
1 COMPRESSOR SHAFT
2 CLUTCH PLATE
3 CLUTCH PLATE SHIM
(3) Remove pul l ey retai ni ng snap ri ng wi th Snap
Ri ng Pl i ers, and sl i de pul l ey assembl y off of compres-
sor (Fi g. 27).
(4) Remove coi l wi re bracket/ground cl i p screw and
wi re harness.
(5) Remove snap ri ng retai ni ng fi el d coi l onto com-
pressor housi ng (Fi g. 28). Sl i de fi el d coi l off of com-
pressor housi ng.
(6) Exami ne fri cti onal faces of the cl utch pul l ey
and front pl ate for wear. The pul l ey and front pl ate
shoul d be repl aced i f there i s excessi ve wear or scor-
i ng. I f the fri cti on surfaces are oi l y, i nspect the shaft
nose area of the compressor for oi l and remove the
fel t from the front cover. I f the compressor fel t i s sat-
urated wi th oi l , the shaft seal i s l eaki ng and wi l l
have to be repl aced.
(7) Check beari ng for roughness or excessi ve l eak-
age of grease. Repl ace beari ng as requi red.
INSTALLATION
(1) Al i gn pi n i n back of fi el d coi l wi th hol e i n com-
pressor end housi ng, and posi ti on fi el d coi l i nto pl ace.
Make sure that l ead wi res are properl y routed, and
fasten the coi l wi re bracket/ground retai ni ng screw.
NOTE: A new snap ring must be used. The bevel
side of the snap ring must be outward.
(2) I nstal l fi el d coi l retai ni ng snap ri ng wi th Snap
Ri ng Pl i ers. Press snap ri ng to make sure i t i s prop-
erl y seated i n the groove.
CAUTION: If snap ring is not fully seated it will
vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Do not mar the pulley frictional surface.
(3) I nstal l pul l ey assembl y to compressor. I f neces-
sary, tap gentl y wi th a bl ock of wood on the fri cti on
surface (Fi g. 29).
(4) I nstal l pul l ey assembl y retai ni ng snap ri ng
(bevel si de outward) wi th Snap Ri ng Pl i ers. Press the
snap ri ng to make sure i t i s properl y seated i n the
groove.
(5) I f the ori gi nal front pl ate assembl y and pul l ey
assembl y are to be reused, the ol d shi m(s) can be
used. I f not, pl ace a tri al stack of shi ms, 2.54 mm
(0.10 i n.) thi ck, on the shaft agai nst the shoul der.
(6) I nstal l front pl ate assembl y onto shaft.
(7) I f i nstal l i ng a new front pl ate and/or pul l ey
assembl y, the gap between front pl ate and pul l ey face
must be checked. Use the fol l owi ng procedure:
(a) Attach a di al i ndi cator to front pl ate so that
movement of the pl ate can be measured.
(b) Wi th the di al i ndi cator zeroed on the front
pl ate, energi ze the cl utch and record the amount of
movement.
(c) The readi ngs shoul d be 0.35 to 0.65 mm
(0.014 to 0.026 i n.). I f proper readi ng i s not
Fig. 27 Removing Pulley Snap Ring
1 SNAP RING
Fig. 28 Clutch Coil Snap Ring
1 SNAP RING PLIERS
2 CLUTCH COIL
3 COMPRESSOR
4 SNAP RING
obtai ned, add or subtract shi ms unti l desi red read-
i ng i s obtai ned.
(8) I nstal l compressor shaft bol t. Ti ghten to 17.5
2 Nm (155 20 i n. l bs.) torque.
NOTE: Shims may compress after tightening shaft
nut. Check air gap in four or more places to verify if
air gap is still correct. Spin pulley for final check.
CLUTCH BREAK-IN
After new cl utch i nstal l ati on, cycl e the A/C cl utch
20 ti mes (5 seconds on and 5 seconds off). Duri ng
thi s procedure, set the system to the A/C mode,
engi ne rpm at 1500 - 2000, and hi gh bl ower speed.
Thi s procedure (burni shi ng) wi l l seat the opposi ng
fri cti on surfaces and provi de a hi gher cl utch torque
capabi l i ty.
CONDENSATION DRAIN TUBE
REMOVAL
(1) Rai se vehi cl e.
(2) Locate rubber drai n tube on ri ght si de of dash
panel (Fi g. 30).
(3) Squeeze cl amp and remove drai n tube.
INSTALLATION
To i nstal l , reverse the precedi ng operati on. Check
the drai n tube ni ppl e on the heater-A/C housi ng for
any obstructi ons.
CONDENSER
The condenser i s l ocated i n front of the engi ne
radi ator. I t has no servi ceabl e parts. I f damaged or
l eaki ng, the condenser assembl y must be repl aced.
WARNING: THE REFRIGERANT MUST BE
REMOVED FROM THE SYSTEM BEFORE REMOV-
ING THE CONDENSER.
REMOVAL
remove the refri gerant from the A/C system.
(2) Remove battery support strut.
(3) Remove refri gerant l i nes from condenser (Fi g.
31).
(4) Remove upper radi ator mounts.
(5) Remove condenser to radi ator mounti ng
screws.
(6) Ti l t radi ator back and remove condenser.
INSTALLATION
Ti ghten the condenser refri gerant l i nes to 5 Nm
(45 i n l bs).
Fig. 29 Installing Pulley Assembly
1 PULLEY ASSEMBLY
2 WOOD BLOCK
Fig. 30 Condensate Water Drain Tube Typical
1 DASH PANEL (UNDER HOOD RIGHT SIDE)
2 CLAMP
3 CONDENSATE DRAIN TUBE
4 NIPPLE-A/C HEATER HOUSING
DISCHARGE LINE
WARNING: THE REFRIGERANT SYSTEM MUST BE
RECOVERED BEFORE SERVICING ANY PART OF
THE REFRIGERANT SYSTEM.
REMOVAL
remove the refri gerant from A/C system.
(2) From the top si de of the vehi cl e, remove l i ne at
compressor (Fi g. 32).
(3) From the bottom si de of the vehi cl e, remove
l i ne at condenser.
INSTALLATION
EVAPORATOR
Thi s vehi cl e uses an al umi num pl ate and fi n styl e
evaporator. I t i s l ocated i n the Evaporator/Bl ower
modul e.
The uni t housi ng must be removed from the vehi -
cl e before begi nni ng wi th thi s procedure. Refer to
Uni t Housi ng i n thi s secti on for removal procedure.
Use thi s procedure i f any or al l of the fol l owi ng
i tems requi re servi ce:
Evaporator
Ai r i nl et duct
Heater Core
Heati ng and Ai r Condi ti oni ng
DISASSEMBLE
(1) Separate the foam seal s at the evaporator l i ne
connecti on, and the dash panel ai r di stri buti on out-
l ets (Fi g. 33).
(2) Di sconnect fi n sensi ng probe from harness.
(3) Remove upper to l ower case retai ni ng cl i p and
screws.
(4) Separate the case hal ves (Fi g. 34).
(5) Li ft the evaporator out of the modul e (Fi g. 35).
ASSEMBLE
To reassembl e, reverse the above procedures.
EVAPORATOR PROBE
The evaporator probe can be removed wi thout
removi ng the Uni t Housi ng from the vehi cl e.
REMOVAL
(1) Di sconnect probe wi ri ng connector from behi nd
the gl ove box.
(2) Remove rubber grommet from evaporator/
bl ower modul e (Fi g. 36).
(3) Note whi ch of the three pi l ot hol es the evapo-
rator probe i s l ocated i n.
(4) Pul l probe out of evaporator fi ns.
INSTALLATION
(1) There are three pi l ot hol es avai l abl e for the
probe. The top hol e i s for servi ce. I f top hol e was not
used by previ ous probe, i nstal l probe i n top hol e.
(2) I f previ ous probe was removed from top hol e,
use a smal l pl asti c sti ck of approxi matel y 1/8 i nch
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
4 SUCTION LINE
di ameter, and make a new hol e. Make the hol e 1/4
i nch above, or bel ow the ori gi nal hol e i n the evapora-
tor core.
(3) I nsert new probe i nto hol e between evaporator
fi ns.
(4) Rei nstal l rubber grommet i nto evaporator
probe access hol e.
EXPANSION VALVE
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
Fig. 33 Lower HVAC Housing
1 EVAPORATOR AND CONNECTION
2 FOAM SEALS
3 HEATER CORE AND TUBES
4 HVAC HOUSING LOWER CASE
5 HOUSING MOUNTING STUDS
6 HOUSING DRAIN
7 WIRING
8 BLOWER MOTOR AND WHEEL
Fig. 34 Case Separation - Typical
1 CASE HALVES
2 EVAPORATOR
3 BLOWER WHEEL
Fig. 35 Evaporator Removal - Typical
1 EVAPORATOR
2 BLOWER WHEEL
Fig. 36 Evaporator Probe Location - Typical
1 EVAPORATOR PROBE WIRING CONNECTOR
2 EVAPORATOR PROBE RUBBER GROMMET
3 EVAPORATOR/BLOWER MODULE
REMOVAL
(1) Remove the wi re connector from the l ow pres-
sure cut-off swi tch.
(2) Remove the center bol t of refri gerant l i ne
pl umbi ng seal i ng pl ate (Fi g. 37).
(3) Careful l y pul l the refri gerant l i ne-seal i ng pl ate
assembl y from the expansi on val ve towards front of
vehi cl e. Do not scratch the expansi on val ve seal i ng
surfaces wi th pi l ot tubes.
(4) Cover the openi ngs on A/C l i ne-seal i ng pl ate
assembl y to prevent contami nati on.
(5) Remove two screws securi ng the expansi on
val ve to the evaporator seal i ng pl ate.
(6) Careful l y remove val ve.
INSTALLATION
(1) Remove and repl ace the al umi num gasket on
the evaporator seal i ng pl ate.
(2) Careful l y hol d the expansi on val ve to the evap-
orator seal i ng pl ate so not to scratch the seal i ng sur-
face. I nstal l two screws and ti ghten to 11 3 Nm
(100 30 i n. l bs.).
(3) Remove and repl ace the al umi num gasket on
the refri gerant l i ne- seal i ng pl ate assembl y.
(4) Careful l y hol d the refri gerant l i ne-seal i ng pl ate
assembl y to the expansi on val ve. I nstal l bol t and
ti ghten to 23 3 Nm (200 30 i n. l bs.).
(5) Connect wi res to l ow pressure cut-off swi tch.
(6) Evacuate and recharge system.
(7) After expansi on val ve i s i nstal l ed, system i s
charged, and l eaks have been checked, repeat A/C
performance check.
HEATER CORE
Refer to HVAC Housi ng Di sassembl y and Assembl y
i n thi s secti on 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) Drai n engi ne cool i ng system. Refer to Group 7,
Cool i ng System.
(2) Usi ng spri ng tensi on cl amp pl i ers, remove
cl amps at end of heater hose to be removed (Fi g. 38).
(3) Careful l y rotate hose back and forth whi l e pul l -
i ng away from connector ni ppl e.
INSTALLATION
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
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) Di sconnect wi ri ng connector at the swi tch (Fi g.
39).
(2) Remove i nternal snap ri ng.
(3) Pul l swi tch out of compressor.
INSTALLATION
For i nstal l ati on, reverse the above procedures. Use
a new O-Ri ng Seal .
HIGH PRESSURE RELIEF VALVE
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
VICE.
ERTY DAMAGE.
REMOVAL
(2) Rotate the hi gh pressure rel i ef val ve counter-
cl ockwi se and separate rel i ef val ve from the compres-
sor (Fi g. 39).
INSTALLATION
For i nstal l ati on, reverse the above procedures
usi ng a new O-Ri ng Seal . Evacuate and charge the
refri gerant system.
LIQUID LINE
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(2) Di sconnect l i qui d l i ne at dri er.
(3) Di sconnect l i qui d l i ne at condenser.
INSTALLATION
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION. REFER TO
REFRIGERANT RECOVERY SECTION.
REMOVAL
(1) Di sconnect the wi re connector at the cut off
swi tch.
(2) Usi ng a sender uni t removal socket, remove the
swi tch from the expansi on val ve (Fi g. 40).
Fig. 39 High Pressure Cut Out Switch Location
1 DISCHARGE LINE
2 A/C COMPRESSOR
4 SUCTION LINE
INSTALLATION
NOTE: Verify the O-ring condition on the replace-
ment switch.
Evacuate and charge the system.
MODE CONTROL CABLE
The Mode Control Cabl e can be removed and
i nstal l ed wi thout havi ng to remove the i nstrument
panel from the vehi cl e.
REMOVAL
(1) Remove i nstrument panel center stack bezel
(Fi g. 41).
(2) Remove center ai r duct (Fi g. 42).
(3) Remove heater-A/C control head and di sconnect
cabl e (Fi g. 43).
(4) Di sconnect cabl e at heater uni t.
(5) Remove cabl e from vehi cl e.
INSTALLATION
For i nstal l ati on, reverse the above procedures,
adjust cabl e and test. Refer to Mode Control Cabl e
Adjustment at the end of thi s secti on.
Fig. 40 Expansion Valve and Low Pressure Cut-Off
Switch
1 EXPANSION VALVE
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
RECIRCULATION DOOR ACTUATOR
The reci rcul ati on door actuator i s a vacuum con-
trol l ed actuator used to control movement of the
reci rcul ati on door i n ai r condi ti oned equi pped vehi -
cl es.
The i nstrument panel must be removed from the
vehi cl e to gai n access to the reci rcul ati on door actua-
tor.
REMOVAL
(1) Remove i nstrument panel from vehi cl e. Refer
to Group 8E, I nstrument Panel And Systems for
removal procedures.
(2) Di sconnect vacuum l i ne from actuator.
(3) Di sconnect actuator from reci rcul ati on door
l i nk (Fi g. 44).
(4) Rel ease tensi on on l atch, and sl i de reci rcul a-
ti on door actuator off housi ng.
INSTALLATION
SUCTION LINE
WARNING: THE REFRIGERANT MUST BE RECOV-
ERED BEFORE SERVICING ANY PART OF THE
REFRIGERANT SYSTEMS.
REMOVAL
(2) Remove retai ni ng bol t at expansi on val ve (Fi g.
45).
Fig. 43 HVAC Control Head Cables
1 HVAC CONTROL HEAD
3 CONTROL CABLES
4 VACUUM HARNESS
Fig. 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
3 LIQUID LINE
4 SUCTION LINE
(3) Remove l i ne at expansi on val ve.
(4) Remove l i ne at compressor (Fi g. 46).
INSTALLATION
TEMPERATURE CONTROL CABLE
The Control Cabl e can be removed and i nstal l ed
wi thout havi ng to remove the i nstrument panel from
the vehi cl e.
REMOVAL
(1) Remove i nstrument panel center stack bezel
(Fi g. 41).
(2) Remove heater-A/C control head (Fi g. 42).
(3) Remove center ai r duct.
(4) Di sconnect cabl e at control panel . Remove con-
trol from i nstrument panel .
(5) Di sconnect cabl e at heater uni t (Fi g. 47).
(6) Remove cabl e from vehi cl e.
INSTALLATION
For i nstal l ati on, reverse the above procedures,
adjust cabl e and test. See Temperature Control Cabl e
Adjustment i n thi s secti on.
UNIT HOUSING
The i nstrument panel must be removed i n order to
remove the Uni t Housi ng. Refer to group 8E I nstru-
ment Panel and Systems for detai l ed procedure.
WARNING: THE R-134a REFRIGERANT SYSTEM
MUST BE RECOVERED BEFORE SERVICING ANY
PART OF THE REFRIGERANT SYSTEM.
REMOVAL
(1) Usi ng a refri gerant recovery machi ne, remove
the refri gerant from the A/C system, i f equi pped.
(2) Remove i nstrument panel from vehi cl e. Refer
to group 8E I nstrument Panel and Systems for
detai l ed procedure.
(3) Drai n cool i ng system and remove heater hoses
at the dash panel . Pl ace pl ugs i n the heater core out-
l ets to prevent cool ant spi l l age duri ng uni t housi ng
removal .
(4) Unfasten cool ant recovery contai ner and set
asi de.
(5) Remove sucti on l i ne at expansi on val ve. Cap
open refri gerant l i nes to prevent moi sture and/or di rt
from enteri ng.
Fig. 46 A/C Compressor Suction Line
1 FILTER DRIER
2 SERVICE PORTS
3 FILTER DRIER MOUNTING GROMMET
4 EVAPORATOR LINE BLOCK
5 EXPANSION VALVE
6 LOW PRESSURE CUT OUT SWITCH CONNECTOR
7 HVAC HOUSING DRAIN OUTLET
8 CONDENSATE DRAIN TUBE
9 EXPANSION VALVE SCREWS
11 COMPRESSOR SUCTION LINE
Fig. 47 HVAC Housing Cables
1 VACUUM HARNESS
2 DOOR CAM
3 HVAC UPPER HOUSING
4 HVAC CONTROL HEADS CABLES
5 MODE DOOR LEVERS
6 DEFROSTER DUCT OUTLET
(6) Remove expansi on val ve from evaporator, and
cap fi tti ngs.
(7) Remove rubber drai n tube extensi on from con-
densati on drai n tube.
(8) Di sconnect the vacuum harness at the power
brake booster (Fi g. 48).
(9) Unsnap and remove the defroster duct (Fi g.
49).
(10) Remove three retai ni ng nuts l ocated i n the
engi ne compartment, on the dash panel (Fi g. 50).
(11) Remove the ri ght si de retai ni ng screw (Fi g.
51).
(12) Remove remai ni ng nut l ocated on dash panel
stud.
(13) Di sconnect the wi ri ng connectors.
(14) Remove assembl y from the vehi cl e.
Fig. 48 HVAC Vacuum Harness
1 BRAKE POWER BOOSTER
2 A/C VACUUM CHECK VALVE
3 VACUUM HARNESS
Fig. 49 HVAC Housing Defroster Duct
1 DEFROSTER DUCT
2 BODY
4 HVAC HOUSING
Fig. 50 Dash Panel Retaining Studs
1 BLOWER RESISTOR
2 EXPANSION VALVE
3 DRAIN TUBE
4 DASH PANEL
5 HEATER HOSES
6 RETAINING STUDS
Fig. 51 Housing Screws
1 RIGHT SIDE RETAINING SCREW
2 EVAPORATOR PROBE GROMMET
3 SCREW BOSSES
4 DASH PANEL STUD AND NUT
INSTALLATION
DISASSEMBLY AND ASSEMBLY
HEATER-A/C HOUSING
Use thi s procedure i f any or al l of the fol l owi ng
i tems requi re servi ce:
Heater core
Evaporator
HVAC housi ng
The HVAC housi ng must be removed from the
vehi cl e before begi nni ng wi th thi s procedure. Refer to
Uni t Housi ng i n thi s secti on for removal procedure.
DISASSEMBLY
(1) Separate the ai r di stri buti on outl et foam seal s
at the case parti ng l i ne (Fi g. 52).
(2) Remove the evaporator l i nes foam seal , and
heater core tubes foam seal from the uni t (Fi g. 53).
(3) Remove the retai ni ng cl i ps and screws that
hol d the upper and l ower housi ngs together.
(4) Separate the two hal ves of the housi ng.
(5) Li ft the heater core/evaporator out of the case.
ASSEMBLY
To reassembl e, reverse the above procedures.
ADJ USTMENTS
MODE CONTROL CABLE
(1) Engage cabl e to actuator arm l ever on mode
door and attach to housi ng (Fi g. 47).
(2) Attach other end of cabl e to i nstrument panel
control (Fi g. 43).
(3) Turn the mode knob compl etel y countercl ock-
wi se.
(4) Whi l e hol di ng the knob i n the countercl ockwi se
posi ti on, pul l on the gray casi ng of the mode cabl e.
Thi s wi l l take up any free pl ay i n the cabl e and i ndex
the mode door to the mode knob.
(5) Then snap the cabl e hol d down cl i p i nto posi -
ti on.
TEMPERATURE CONTROL CABLE
(1) Engage cabl e to actuator arm on temperature
door and attach to housi ng (Fi g. 47).
(2) Attach other end of cabl e to i nstrument panel
control (Fi g. 43).
(3) Turn the temperature knob compl etel y counter-
cl ockwi se.
Fig. 52 HVAC Housing Air Distribution Foam Seals
1 AIR DISTRIBUTION
2 RECIRCULATION DOOR VACUUM ACTUATOR
3 AIR INLET
4 BLOWER MOTOR
5 EVAPORATOR PROBE CONNECTOR
6 CONTROL CABLES
7 VACUUM HARNESS
Fig. 53 HVAC Housing Evaporator Connection and
Heater Core Tube Seals
1 EVAPORATOR AND CONNECTION
2 FOAM SEALS
3 HEATER CORE AND TUBES
4 HVAC HOUSING LOWER CASE
5 HOUSING MOUNTING STUDS
6 HOUSING DRAIN
7 WIRING
8 BLOWER MOTOR AND WHEEL
(4) Whi l e hol di ng the knob i n the countercl ockwi se
posi ti on, pul l on the gray casi ng of the temperature
cabl e. Thi s wi l l take up any free pl ay i n the cabl e
and i ndex the temperature door to the temperature
knob.
(5) Then snap the cabl e hol d down cl i p i nto posi -
ti on.
(6) Remount control .
ADJ USTMENTS (Continued)

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