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HEATING AND AIR CONDITIONING

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2. AND AIR CONDITIONING 24 15 DIAGNOSIS AND TESTING Continued JUNDERCHARGED ANYTHING IN THIS SHADED ARE 160 120 80 OVERCHARGED ANYTHING IN THIS SHADED AREA 2 60 40 4 50 P S I 100 P S I 150 P S I 200 P S I 250 P S I 300 P S I 350 P S I 400 P S I 450 P S I 500 P S I LIQUID LINE PRESSURE 80183484 VACUUM CONTROL SYSTEM Use an adjustable vacuum test set Special Tool 3707 and a suitable vacuum pump to test the heater A C vacuum control system With a finger placed over the end of the vacuum test hose probe Fig 15 adjust the bleed valve on the test set gauge to obtain a vacuum of exactly 27 kPa 8 in Hg Release and block the end of the probe several times to verify that the vacuum reading returns to the exact 27 kPa 8 in Hg setting Otherwise a false reading will be obtained during testing 19324 75 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 24 16 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING Continued PL 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 NO F
3. 17 24 2 HEATING AND AIR CONDITIONING GENERAL INFORMATION A C APPLICATION TABLE Total Refrigerant R134a 765 grams 27 oz 1 69 105 Capacity Total Oil Capacity ND 8 PAG oil 180 6 10 02 Nippondenso 10517 Freeze up Control Fin sensor 3 wire input to PCM evaporator mounted cycles clutch off below 34 F cycles back above 45 F Low psi Control opens lt 14 psi resets gt 38 psi expansion valve mounted High psi Control opens gt 470 psi resets lt 370 330 psi compressor mounted switch Control head manual type EO Mode Door eable SSCS door Clutch ay PCM 25 amps 12 70 Reads TPS RPM A C switch test fin sensor A C amp fan 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 spe
4. 2 Remove the evaporator lines foam seal and heater core tubes foam seal from the unit Fig 53 3 Remove the retaining clips and screws that hold the upper and lower housings together 4 Separate the two halves of the housing 5 Lift the heater core evaporator out of the case ASSEMBLY To reassemble reverse the above procedures ADJ USTMENTS MODE CONTROL CABLE 1 Engage cable to actuator arm lever on mode door and attach to housing Fig 47 2 Attach other end of cable to instrument panel control Fig 43 3 Turn the mode knob completely counterclock wise 4 While holding the knob in the counterclockwise position pull on the gray casing of the mode cable This will take up any free play in the cable and index the mode door to the mode knob 5 Then snap the cable hold down clip into posi tion TEMPERATURE CONTROL CABLE 1 Engage cable to actuator arm on temperature door and attach to housing Fig 47 2 Attach other end of cable to instrument panel control Fig 43 3 Turn the temperature knob completely counter clockwise PL USTMENTS Continued 4 While holding the knob in the counterclockwise position pull on the gray casing of the temperature cable This will take up any free play in the cable and index the temperature door to the temperature knob HEATING AND AIR CONDITIONING 24 35 5 Then snap the cable hold down clip into posi tion 6 Remount control
5. HEATER CORE TUBES 4 HEATER HOSE SUPPLY AND RETURN TUBES INSTALLATION For installation reverse the above procedures PL REMOVAL AND INSTALLATION Continued HIGH PRESSURE CUT OUT SWITCH WARNING THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOV ING THE HIGH PRESSURE CUT OUT SWITCH REMOVAL 1 Disconnect wiring connector at the switch Fig 39 2 Remove internal snap ring 3 Pull switch out of compressor INSTALLATION For installation reverse the above procedures Use a new O Ring Seal 80bcea29 Fig 39 High Pressure Cut Out Switch Location 1 DISCHARGE LINE 2 COMPRESSOR 3 HIGH PRESSURE CUT OUT SWITCH 4 SUCTION LINE HIGH PRESSURE RELIEF VALVE WARNING AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES NOSE AND THROAT USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R 134a SYSTEM IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE WORK AREA BEFORE RESUMING SER VICE HEATING AND AIR CONDITIONING 24 29 R 134a SERVICE EQUIPMENT OR VEHICLE A C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR MIXTURE OF AIR and R 134a CAN BE COMBUSTIBLE AT ELE VATED PRESSURES THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROP ERTY DAMAGE REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrige
6. set the control to maximum heat floor and high blower setting Using a test thermometer check the air temperature coming from the floor outlets refer to Temperature Reference chart TEMPERATURE REFERENCE CHART Minimum Outlet Ambient Temp Floor Temp Fahrenheit Fahrenheit 15 5 62 2 144 63 8 147 655 70 o If the floor outlet air temperature is insufficient refer to Group 7 Cooling Systems for specifications Both heater hoses should be HOT to the touch cool ant return hose should be slightly cooler than the supply hose If coolant return hose is much cooler than the supply hose locate and repair engine cool ant flow obstruction in heater system 24 14 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING Continued POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED COOLANT FLOW 1 Pinched or kinked heater hoses 2 Improper heater hose routing 3 Plugged heater hoses or supply and return ports at cooling system connections refer to Group 7 Cooling System 4 Plugged heater core 5 Air locked heater core 6 If coolant flow is verified and outlet tempera ture is insufficient a mechanical problem may exist POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT 1 Obstructed cowl air intake 2 Obstructed heater system outlets 3 Blend air door not functioning properly TEMPERATURE CONTROL If temperature cannot be adjusted with the TEMP lever on the control panel
7. 11 Blower Motor Electrical Diagnosis PL DIAGNOSIS AND TESTING Continued BLOWER MOTOR VIBRATION AND OR NOISE DIAGNOSIS The resistor block supplies the blower motor with varied voltage low and middle speeds or battery voltage high 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 Blower Motor Vibration Noise chart for diagnosis COMPRESSOR NOISE DIAGNOSIS Excessive noise while the A C is being used can be caused by loose mounts loose clutch or high operat ing pressure Verify compressor drive belt condition proper refrigerant charge and head pressure before compressor repair is performed If the A C drive belt slips at initial start up it does not necessarily mean the compressor has failed With the close tolerances of a compressor it is pos sible to experience a temporary lockup The longer the A C system is inactive the more likely the condi tion to occur This condition is the result of normal refrigerant movement within the A C system caused by temper ature changes The refrigerant movement may wash the oil out of the compressor EVAPORATOR PROBE TEST The work area and vehicle must be between 16 C 60 F and 32 C 90 F when testing the switch 1 Disconnect the three wire connector from the evaporator probe lead located behind the glove box Fig 12 2 Start
8. ing to remove the unit housing from the vehicle The evaporator probe is located in the unit housing and placed in the evaporator fins The probe prevents evaporator freeze up This is done by cycling the com pressor clutch OFF when evaporator temperature drops below freeze point It cycles ON when the evaporator temperature rises above freeze point The evaporator probe uses a thermistor probe in a capil lary tube The tube is inserted between the evapora tor fins in the heater A C unit housing HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system High pressures are pro duced in the system when it is operating Extreme care must be exercised to make sure that all connec tions are pressure tight Dirt and moisture can enter the system when it is opened for repair or replace ment of lines or components The refrigerant oil will absorb moisture readily out of the air This moisture will convert into acids within a closed system PL 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 h
9. 1 Connect the test vacuum probe to the vehicles Black supply hose Position the vacuum test gauge so it can be viewed from the passenger compartment 2 Place the Mode in the Panel position and the Circulation control in the Recirculation position 3 Remove the center instrument panel bezel 4 Remove the center vent duct 5 Remove and block the Supply Black vacuum line at the control The test gauge should return to the calibrated setting of 27 kPa 8 in Hg If not there is a leak in the Supply line 6 If there is no leak the Supply line reconnect it to the Control and remove the Actuator F eed Red line from the Control Block the vacuum connection on the Control from where the line was removed The test gauge should return to the calibrated setting of 27 kPa 8 in Hg If not there is a leak in the Con trol 7 If there is no leak the Supply line or the Control reconnect the Actuator Feed Red line to the control Remove and block the Actuator Feed Red line at the Actuator The actuator vacuum port is accessible behind and above the Glove Box The test PL DIAGNOSIS AND TESTING Continued gauge should return to the calibrated setting of 27 kPa 8 in If not there is a leak in the Actuator Feed line 8 If there is no leak in the Supply line Control or the Actuator Feed line the leak must be in the Actuator itself Connect the Vacuum hose from the Vacuum Test Gauge directly to the Ac
10. 21 Fig 20 Blower Motor Retaining Screws 1 BLOWER MOTOR 2 BLOWER MOTOR RETAINING SCREWS 3 BLOWER MOTOR WIRING WITHOUT AIR CONDITIONING REMOVAL 1 Disconnect blower motor wiring connector 2 Grasp the blower motor while pulling down tab Turn approximately 1 8 turn counterclockwise and remove blower motor assembly from unit hous ing Fig 21 INSTALLATION For installation reverse the above procedures Fig 21 Blower Motor Removal 1 BLOWER MODULE 2 BLOWER MOTOR 24 22 HEATING AND AIR CONDITIONING 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 windshield wipers 2 Remove cowl top screen 3 Disconnect the resistor block wiring connector Fig 22 80bcealc Fig 22 Blower Motor Resistor Block 1 RESISTOR BLOCK 2 ELECTRICAL CONNECTOR 4 Remove unsnap resistor block from vehicle INSTALLATION For installation reverse the above procedures BLOWER MOTOR WHEEL The blower motor whee is only serviced with the blower motor The wheel and the motor are balanced as an assembly If the blower motor wheel requires replacement the blower motor must also be replaced Refer to blower motor for replacement procedure COMPRESSOR CAUTION Add only new lubricant when system requires additional lu
11. 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 PL DESCRIPTION AND OPERATION A C REFRIGERANT LINES DISCHARGE LINE The discharge line is the line that goes from the compressor to the condenser Fig 3 It has no ser viceable parts except the rubber O rings If the line is found to be leaking or is damaged it must be replaced as an assembly 80bcea20 Fig 3 A C Compressor Lines 1 CONDENSER LIQUID LINE 2 SUCTION LINE 3 COMPRESSOR MANIFOLD SCREWS 4 COMPRESSOR 5 DISCHARGE LINE LIQUID LINE The liquid line is the line that goes from the con denser to drier Fig 3 It has no serviceable parts except the rubber O rings If the line is found to be leaking or is damaged it must be replaced as an assembly SUCTION LINE The suction line is the large line that connects to the expansion valve and goes to the compressor Fig 3 It also has a small line that goes to the filter drier The suction line uses a gasket on the expan sion valve side and rubber O rings on all other connections There are no serviceable parts on the suction line other than the rubber O rings and expansion valve gasket If the line is found to be leaking or is dam aged it must be replaced as an assembly PL DESCR
12. Position the test set gauge so that it can be viewed from the passenger compartment 2 Start with the Mode control in the Panel posi tion and the Circulation control in the Outsideair position 3 Move the Circulation control to the Recircula tion position the Circulation door should move into 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 1 Locate and repair vacuum leak or pinched line 2 Test actuator and door operation Repair as necessary 3 Test selector switch and replace if necessary 4 Test check valve and replace if necessary 1 Locate and repair vacuum leak or pinched line 2 Test actuators and door operation Repair as necessary 3 Test selector switch and replace if necessary 4 Test check valve and replace if necessary the Recirculation position After a short pause move the Mode control to the Defrost position the Circula tion door should move to the Outside air position The test gauge should return to the calibrated set ting of 27 kPa 8 in Hg after each selection is made If the gauge cannot achieve the calibrated set ting the vacuum circuit or a component has a leak 4 If the gauge achieves the calibrated setting but the door does not move there is either a pinched vac uum line or a failed actuator LOCATING VACUUM LEAKS
13. the following could require service 1 Blend air door binding 2 Faulty blend air door cable 3 Improper engine coolant temperature 4 Faulty Instrument Panel Control LOW PRESSURE CUT OFF SWITCH The work area must not be below 21 C 70 F to test the compressor clutch circuit 1 With gear selector in park or neutral and park brake set start engine and allow to idle 2 Raise hood and disconnect low pressure cut off switch connector boot 3 Using a suitable jumper wire jump across the terminals inside wire connector boot 4 If the compressor clutch does not engage the cycling clutch switch wiring relay or fuse can be defective Refer to Group 8W Wiring Diagrams 5 If clutch engages connect manifold gauge set Read low pressure gauge At pressure above 97 kPa 14 psi and above low pressure out off switch will complete the clutch circuit If the low pressure gauge reads below 140 kPa 20 psi the system is low on refrigerant charge or empty due to a leak Refer to Service Procedures System Leak Checking in this section 6 Install connector boot on switch and repeat Step 3 If the clutch does not engage replace the low pressure cut off switch PL SYSTEM CHARGE LEVEL TEST The procedure below should be used to check and or fill the refrigerant charge in the air condition ing system WARNING AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES NOSE AND TH
14. valves at the service port connector ends This will prevent refrigerant R 134a from being released into the atmosphere HEATING AND AIR CONDITIONING 24 19 9324 83 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 R 134a refrigerant requires a special type of com pressor oil When adding oil make sure to use the oil that is specified on the under hood label The use of R 134a will have a positive environmen tal impact due to it s zero ozone depletion and low global warming impact SERVICING REFRIGERANT OIL LEVEL CAUTION The refrigerant oil used in a R 134a A C system is unique Use only oils which were designed to work with R 134a refrigerant The oil designated for this vehicle is ND8 PAG polyalka lene glycol Recovery recycling equipment will measure the lubricant being removed This is the amount of cant to be added back to the system If a new com pressor is being installed drain lubricant from old compressor measure the amount drained and discard old lubricant Drain the lubricant from the new com pressor into a clean container Return the amount of lubricant measured from the old compressor plus the amount reclaimed from the system back into the new compressor 24 20 HEATING AND
15. 2 269 kpa 207 345 kPa Pressure 15 30 PSI 17 32 PSI 20 35 PSI 25 39 PSI 30 50 PSI BLOWER MOTOR ELECTRICAL DIAGNOSIS Refer to the Blower Motor Electrical System Diag nosis chart Fig 11 in this section Also refer to Group 8W Wiring Diagrams for more information 43 110 F 7 18 C 45 65 2275 3421 330 496 PSI Ambient Temperature 21 70 F Air Temperature at Left Center Panel Outlet Compressor Discharge 1 8 34 46 24 10 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING Continued BLOWER MOTOR DOES NOT BLOWER MOTOR INOPERATIVE OPERATE AT SELECTED SPEED INSPECT RESISTOR TEST FUSE CONTINUITY DEFECTIVE O K FUSE OPEN FUSE O K TEST CIRCUITS AND SWITCHES TEST BLOWER MOTOR FUSE REPAIR CIRCUIT OR REPLACE CONTROL MOTOR REPLACE RESISTOR SEE WIRING DIAGRAMS MOTOR SHORTED OR STALLED REPLACE MOTOR OF FUSE PL TEST VOLTAGE AT BOTH ENDS VOLTAGE PRESENT NO VOLTAGE CHECK FOR OPEN CIRCUIT FUSE BLOCK TO MOTOR TEST CONTINUITY FUSELINK TO IGN SWITCH TO FUSE BLOCK CHECK FOR BAD CONNECTION AT REPAIR REPAIR OPEN MOTOR CIRCUIT OR BAD CONNECTION TEST FOR REPAIR GROUND BODY GROUND CIRCUIT SEE AT MOTOR WIRING DIAGRAMS TEST BLOWER TEST MOTOR CHECK INST PANEL SWITCH CONTINUITY GROUND CONNECTION REPLACE CONTROL NO CONTINUITY REPLACE MOTOR 9524 4 Fig
16. 24 3 On air conditioned vehicles the outside air intake can be shut off by selecting the recirculation mode Recirc with the mode control knob This will oper ate a vacuum actuated recirculating air door that closes off the outside fresh air intake and recirculates the air that is already inside the vehicle The optional air conditioner for all models is designed for the use of non CFC R 134a refrigerant The air conditioning system has an evaporator to cool and dehumidify the incoming air prior to blending it with the heated air This air conditioning system uses an evaporator probe to maintain minimum evaporator temperature and prevent evaporator freezing and cycles the compressor clutch INTRODUCTION Both the heater and the heater air conditioning systems share many of the same functioning compo nents This group will deal with both systems together when component function is common and separately when they are not For proper operation of the instrument panel con trols refer to the Owner s Manual provided with the vehicle To service the heater core or evaporator the unit housing must be removed from the vehicle Fig 2 5 80bcea25 Fig 2 HVAC Unit Housing AIR DISTRIBUTION RECIRCULATION DOOR VACUUM ACTUATOR AIR INLET BLOWER MOTOR EVAPORATOR PROBE CONNECTOR CONTROL CABLES VACUUM HARNESS WD 24 4 HEATING AND AIR CONDITIONING GENERAL INFORMATION Continu
17. 5 Remove snap ring retaining field coil onto com pressor housing Fig 28 Slide field coil off of com pressor housing 6 Examine frictional faces of the clutch pulley and front plate for wear The pulley and front plate should be replaced if there is excessive wear or scor ing If the friction surfaces are oily inspect the shaft nose area of the compressor for oil and remove the felt from the front cover If the compressor felt is sat urated with oil the shaft seal is leaking and will have to be replaced 7 Check bearing for roughness or excessive leak age of grease Replace bearing as required INSTALLATION 1 Align pin in back of field coil with hole in com pressor end housing and position field coil into place Make sure that lead wires are properly routed and fasten the coil wire bracket ground retaining screw NOTE A new snap ring must be used The bevel side of the snap ring must be outward 2 Install field coil retaining snap ring with Snap Ring Pliers Press snap ring to make sure it is prop erly seated in the groove PL 80 5575 Fig 28 Clutch Coil Snap Ring 1 SNAP RING PLIERS 2 CLUTCH COIL 3 COMPRESSOR 4 SNAP RING 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 Install pulley assembly to compressor If neces sary tap gent
18. AIR CONDITIONING SERVICE PROCEDURES Continued 1 Discharge refrigerant system using recovery re cycling equipment if charge is present 2 Disconnect refrigerant lines from A C compres sor Cap the open lines to prevent moisture from entering system 3 Remove compressor from vehicle 4 From suction port on top of compressor drain lubricant from compressor 5 Add system capacity minus the capacity of components that have not been replaced Refer to the Lubricant Capacity Chart Add lubricant through the suction port on compressor This is not to exceed 180 ml 6 10 oz in total 6 Install compressor and connect refrigerant lines Then evacuate and charge refrigerant system SYSTEM LEAK CHECKING WARNING R 134a SERVICE EQUIPMENT OR VEHI CLE A C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR MIXTURE OF AIR and R 134a CAN BE COM BUSTIBLE AT ELEVATED PRESSURES THESE TURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES NOSE AND THROAT USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R 134a SYSTEM IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE WORK AREA BEFORE RESUMING SER VICE If the A C system is not cooling properly determine if the refrigerant system is fully charged with R 134a This is accomplished by perfor
19. EDURE Review Safety Precautions and Warnings in this group before proceeding with this procedure Air tem perature in test room and on vehicle must be 21 C 70 F minimum for this 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 manifold gauge set 2 Set control to A C RECIRC and PANEL tem perature lever on full cool and blower on high 3 Start engine and hold at 1000 rpm with A C clutch engaged 4 Engine should be warmed up with doors and windows closed 5 Insert a thermometer in the left center A C outlet and operate the engine for five minutes The A C dutch may cycle depending on ambient condi tions 6 With the A C clutch engaged compare the dis charge air temperature to the A C Performance Tem peratures chart 7 If the discharge air temperature fails to meet the specifications in the performance temperature chart Refer to the Refrigerant Service Procedures for further diagnosis A C PERFORMANCE TEMPERATURES 26 5 C 80 F 3 9T 37 49 F 32 C 90 F 4 10 C 39 50 37 100 6 11 43 52 1034 1724 kPa 1517 2275 kPa 1999 2620 2068 2965 Pressure After the Filter 150 250 PSI 220 330 PSI kPa 290 380 kPa 300 430 Drier PSI PSI Evaporator Suction 103 207 kPa 117 221 kPa 138 241 kpa 17
20. IPTION AND OPERATION Continued A C SERVICE PORT VALVE CORES The A C service port valve cores are serviceable items Fig 4 The high side valve is located on the filter drier and the low side valve is situated on the suction line near the washer fluid reservoir filler HER ID ONLY WA FLU 80 4 Fig 4 A C Service Port Valves 1 A C SERVICE PORTS 2 FILTER DRIER BLOWER MOTOR RESISTOR The blower motor resistor is located in the cowl at the base of the windshield Fig 5 There are two dif ferent resistor blocks depending on whether the vehi cle is equipped with A C or not The blower motor resistors will get hot when in use Fig 6 Do not touch resistor block if the blower motor has been running COMPRESSOR The compressor used on this vehicle is a Nippon denso 10S17 This compressor uses an aluminum swash plate teflon coated pistons and aluminum sleeveless cylinder walls NOISE Excessive noise that occurs when the air condition ing is being used may be caused by e Loose bolts e Mounting brackets e Loose compressor clutch e Excessive high refrigerant operating pressure 24 5 HEATING AND AIR CONDITIONING 80bcealc Fig 5 Blower Motor Resistor Block 1 RESISTOR BLOCK 2 ELECTRICAL CONNECTOR 9424 5 Fig 6 Blower Motor Resistors 1 RESISTOR BLOCK 2 RESISTORS Verify the following before compressor repair is per
21. ORCED AIR IN PANEL POSITION 1 Vacuum line pinched or leaking 2 Faulty mode door 3 Faulty selector switch 4 Vacuum check valve NO FORCED AIR IN DEFROST POSITION 1 Vacuum line pinched or leaking 2 Faulty heat defroster or mode door 3 Faulty selector switch 4 Vacuum check valve ONE WAY CHECK VALVE 1 Disconnect the heater A C vacuum supply Black tube in the engine compartment This tube passes through an opening in the dash panel 2 Remove the one way vacuum check valve The valve is located on the Black vacuum supply hose at the brake power booster 3 Connect the test set vacuum supply hose to the heater side of the valve When connected to this side of the check valve no vacuum should pass and the test set gauge should return to the 27 kPa 8 in Hg setting If OK go to step Step 4 If not OK replace the faulty valve 4 Connect the test set vacuum supply hose to the engine vacuum side of the valve When connected to this side of the check valve vacuum should flow through the valve without restriction If not OK replace the faulty valve HEATER A C CONTROLS The operation of the Circulation door can be viewed by removing the blower motor and looking up into the unit inlet See Blower Motor Wheel and Assembly removal and installation in this section for service procedures 1 Connect the test set vacuum probe to the heat er A C vacuum supply Black hose in the engine compartment
22. OW PRESSURE CUT OFF SWITCH 6 EVAPORATOR 26 SIDE WINDOW DEMISTERS 7 EXPANSION 27 SYSTEM AIRFLOW 7 HEATER CORE ssie nites Steere 28 SYSTEM OIL LEVEL 7 HEATER HOSES iis 28 VACUUM CONTROL 5 8 HIGH PRESSURE CUT OUT SWITCH 29 DIAGNOSIS AND TESTING HIGH PRESSURE RELIEF VALVE 29 PERFORMANCE 5 9 LIQUID LINE 5455444 baw ed be 29 BLOWER MOTOR ELECTRICAL DIAGNOSIS 9 LOW PRESSURE CUT OFF SWITCH 29 BLOWER MOTOR VIBRATION AND OR MODE CONTROL CABLE 30 NOISE DIAGNOSIS 11 RECIRCULATION DOOR ACTUATOR 31 COMPRESSOR NOISE DIAGNOSIS 11 SUCTION LINE Guns 31 EVAPORATOR PROBE 5 11 TEMPERATURE CONTROL CABLE 32 EXPANSION VALVE 11 UNIT HOUSING 25525455456 a 32 HEATER PERFORMANCE TEST 13 DISASSEMBLY AND ASSEMBLY LOW PRESSURE CUT OFF SWITCH 14 5 34 SYSTEM CHARGE LEVEL 14 ADJUSTMENTS VACUUM CONTROL SYSTEM 15 MODE CONTROL CABLE 34 SERVICE PROCEDURES TEMPERATURE CONTROL CABLE 34 CHARGING A C SYSTEM
23. PL AND AIR CONDITIONING 24 1 HEATING AND AIR CONDITIONING TABLE OF CONTENTS page page GENERAL INFORMATION EVACUATING REFRIGERANT SYSTEM 18 A C APPLICATION 2 134 19 HEATER AND AIR CONDITIONING CONTROL 2 SERVICING REFRIGERANT OIL LEVEL 19 HEATER AND AIR CONDITIONING 2 SYSTEM LEAK 20 INTRODUCTION 6 3 REMOVAL AND INSTALLATION SAFETY PRECAUTIONS AND WARNINGS 4 FILTER DRIER 20 DESCRIPTION AND OPERATION SERVICE PORT VALVE CORES 21 REFRIGERANT LINES 4 BLOWER MOTOR AND WHEEL ASSEMBLY 21 BLOWER MOTOR RESISTOR 5 BLOWER MOTOR RESISTOR 22 COMPRESSOR 5 BLOWER MOTOR WHEEL 22 COMPRESSOR FRONT SHAFT SEAL 6 COMPRESSOR 22 CONDENSATION DRAIN TUBE 6 COMPRESSOR CLUTCH COIL ASSEMBLY 23 ENGINE COOLING SYSTEM REQUIREMENTS 6 CONDENSATION DRAIN TUBE 25 EVAPORATOR 6 CONDENSER 25 HANDLING TUBING AND FITTINGS 6 DISCHARGE 26 HIGH PRESSURE CUT OUT SWITCH 6 EVAPORATOR 26 L
24. ROAT 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 Ibs It is recommended to use the gauges or reclaim re cycle equipment 1 Use a manifold gauge and check the liquid line pressure 2 Attach a thermocouple 5 E 66 324 0014 or 80PK 1A or equivalent to the liquid line near the filter drier 3 The vehicle must be in the following modes e Automatic transaxle in park or manual tran saxle in neutral e Engine at idle e A C controls set to outside air e Panel mode e A C ON full cool e Blower motor ON high speed e Vehicle windows closed 4 Operate system for a couple of minutes to allow the system to stabilize 5 Observe filter drier pressure and Liquid line temperature Using the Charge Determination Chart Fig 14 determine where the system is currently operating If the system is not in the proper range reclaim all the refrigerant and recharge per A C label
25. TING 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 24 18 HEATING AND AIR CONDITIONING SERVICE PROCEDURES Continued CAUTION Do not overcharge refrigerant system as excessive compressor head pressure can cause noise and system failure After the system has been tested for leaks and evacuated a refrigerant R 134a charge can be injected into the system NOTE When connecting the service equipment coupling to the line fitting verify that the valve of the coupling is fully closed This will reduce the amount of effort required to make the connection 1 If using a separate vacuum pump close all valves before disconnecting pump Connect manifold gauge set to the A C service ports Fig 16 NOTE The air conditioning system in this vehicle holds 27 oz or 1 69 Ibs of R 134a refrigerant 2 Measure refrigerant refer to capacities Refer to the instructions provided with the equipment being used 3 Verify engine is shut off Open the suction and discharge valves Open the charge valve to allow the refrigerant to flow into the system When the
26. UTLET 8 CONDENSATE DRAIN TUBE 9 EXPANSION VALVE SCREWS 10 CONDENSER LIQUID LINE 11 COMPRESSOR SUCTION LINE INSTALLATION For installation reverse the above procedures TEMPERATURE CONTROL CABLE The Control Cable can be removed and installed without having to remove the instrument panel from the vehicle REMOVAL 1 Remove instrument panel center stack bezel Fig 41 2 Remove heater A C control head Fig 42 3 Remove center air duct 4 Disconnect cable at control panel Remove con trol from instrument panel 5 Disconnect cable at heater unit Fig 47 6 Remove cable from vehicle AY PS 2 lt 80 27 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 INSTALLATION For installation reverse the above procedures adjust cable and test See Temperature Control Cable Adjustment in this section UNIT HOUSING The instrument panel must be removed in order to remove the Unit Housing Refer to group 8E Instru ment Panel and Systems for detailed procedure WARNING THE R 134a REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM REMOVAL 1 Using a refrigerant recovery machine remove the refrigerant from the A C system if equipped 2 Remove instrument panel from veh
27. air distribution out lets Fig 33 2 Disconnect fin sensing probe from harness 3 Remove upper to lower case retaining clip and screws 4 Separate the case halves Fig 34 5 Lift the evaporator out of the module Fig 35 ASSEMBLE To reassemble reverse the above procedures EVAPORATOR PROBE The evaporator probe can be removed without removing the Unit Housing from the vehicle REMOVAL 1 Disconnect probe wiring connector from behind the glove box 2 Remove rubber blower module Fig 36 3 Note which of the three pilot holes the evapo rator probe is located in 4 Pull probe out of evaporator fins INSTALLATION 1 There are three pilot holes available for the probe The top hole is for service If top hole was not used by previous probe install probe in top hole 2 If previous probe was removed from top hole use a small plastic stick of approximately 1 8 inch grommet from evaporator PL REMOVAL AND INSTALLATION Continued 3 S T q 806 26 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 9424 50 Fig 34 Case Separation Typical 1 CASE HALVES 2 EVAPORATOR 3 BLOWER WHEEL diameter and make a new hole Make the hole 1 4 inch abov
28. alled without having to remove the instrument panel from the vehicle REMOVAL 1 Remove instrument panel center stack bezel Fig 41 2 Remove center air duct Fig 42 3 Remove heater A C control head and disconnect cable Fig 43 4 Disconnect cable at heater unit 5 Remove cable from vehicle INSTALLATION For installation reverse the above procedures adjust cable and test Refer to Mode Control Cable Adjustment at the end of this section PL gt SB R A ge S PERK ST Og 80bceal7 Fig 41 Instrument Panel Center Bezel amp 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 806 1 Fig 42 HVAC Center Air Duct amp Control Head 1 CENTER AIR DUCT 2 INSTRUMENT PANEL 3 HVAC CONTROL HEAD 4 ATTACHING SCREWS PL REMOVAL AND INSTALLATION Continued 80bceale Fig 43 HVAC Control Head Cables 1 HVAC CONTROL HEAD 2 ELECTRICAL CONNECTOR 3 CONTROL CABLES 4 VACUUM HARNESS HEATING AND AIR CONDITIONING 24 31 80 28 Fig 44 Recirculation Door Actuator Linkage 1 OUTSIDE AIR RECIRC DOOR HOUSING 2 VACUUM ACTUATOR LINKAGE 3 FOAM SEAL RECIRCULATION DOOR ACTUATOR The recirculation door actuator is a vacuum con trolled actuator used to control movement of th
29. bricant Do not use old reclaimed lubricant PL REMOVAL The A C compressor may be unbolted and reposi tioned without discharging the refrigerant system Discharging is not necessary if removing the com pressor clutch coil assembly engine cylinder head or alternator WARNING REFRIGERANT PRESSURES REMAIN HIGH EVEN THOUGH THE ENGINE MAY BE TURNED OFF DO NOT TWIST OR KINK THE REFRIGERANT LINES WHEN REMOVING A FULLY CHARGED COMPRESSOR SAFETY GLASSES MUST BE WORN 1 Disconnect battery negative cable 2 Loosen and remove drive belts refer to Group 7 Engine Cooling 3 Using a R 134a refrigerant recovery machine remove the refrigerant from A C system If the com pressor is being replaced 4 Disconnect compressor clutch wire lead 5 Remove refrigerant lines from compressor if necessary Fig 23 Ss lt lt 4 2 A 6 lt 2 487 52 80bcea20 Fig 23 A C Compressor Lines 1 CONDENSER LIQUID LINE 2 SUCTION LINE 3 COMPRESSOR MANIFOLD SCREWS 4 COMPRESSOR 5 DISCHARGE LINE 6 If system is left open place plug cap over open lines 7 Remove compressor attaching bolts Fig 24 PL REMOVAL AND INSTALLATION Continued 806 19 Fig 24 A C Compressor Mounting Bolts 1 COMPRESSOR 2 MOUNTING BOLTS 3 LOWER FRONT STRUT TO ENGINE BRACKET 8 Remove compressor If refrigerant lines were not rem
30. bris because leaf particles and other debris that is small enough to pass through the cowl ple num screen can accumulate within the heater A C housing The closed warm damp and dark environ ment created within the heater A C housing is ideal for the growth of certain molds mildews and other fungi Any accumulation of decaying plant matter provides an additional food source for fungal spores which enter the housing with the fresh air Excess debris well as objectionable odors created decaying plant matter and growing fungi can be dis charged into the passenger compartment during heater A C system operation The heater and optional air conditioner are blend air type systems In a blend air system a blend air door controls the amount of unconditioned air or cooled air from the evaporator on models with air conditioning that is allowed to flow through or around the heater core A temperature control knob on the heater A C control panel determines the dis charge air temperature by moving a cable which operates the blend air door This allows an almost immediate manual control of the output air tempera ture of the system The mode control knob on the heater only or heat er A C control panel is used to direct the conditioned air to the selected system outlets The mode control switch uses a cable to control the mode door while the recirculation air door is operated by a vacuum actuator motor HEATING AND AIR CONDITIONING
31. ce the expan sion valve If pressure is correct proceed with test 24 12 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING Continued PL BLOWER MOTOR NOISE VIBRATION DIAGNOSIS BLOWER MOTOR NOISE OR VIBRATION NOISE ENGINE ON CHECK BLOWER MOTOR IN ALL SPEED MODES NOISE PRESENT A C BUT A C AND POSSIBLE LEAVE ENGINE ON RADIATOR SHUT BLOWER FAN OR MOTOR OFF COMPRESSOR NOISE NOISE STILL PRESENT NOISE GONE PROBLEM NOT CHECK BLOWER IN BLOWER SCROLL AREA SYSTEM FAN RUBBING HOUSING FOREIGN MATERIAL IN FAN OR SCROLL REMOVE REPLACE FOREIGN MOTOR ADJUST MATERIAL TO CORRECT RE CHECK RE CHECK RE CHECK NOISE STILL NOISE PRESENT GONE REPLACE RE CHECK VIBRATION MOTOR MOUNTING MOUNTING OK LOOSE TIGHTEN RE CHECK VIBRATION STILL PRESENT REPLACE MOTOR WHEEL RE CHECK 9524 3 PL DIAGNOSIS AND TESTING Continued Fig 12 Evaporator Probe Harness Connector 80 7 366 1 PIN 3 2 PIN 2 3 PIN 1 Fig 13 Expansion Valve amp Low Pressure Cut Off Switch Typical 1 EXPANSION VALVE 2 LOW PRESSURE CUT OFF SWITCH 3 SUCTION LINE 4 CONTROL HEAD WARNING PROTECT SKIN AND EYES FROM CON TACTING CO2 PERSONAL INJURY CAN RESULT 7 If suction side low pressure is within specified range freeze the expansion valve
32. chanically interlocked so the circulation con trol cannot be placed in the RECIRC position if the mode control is at or between the mix and defrost positions Vacuum is supplied to the actuator only when circulation control is at the RECIRC position If the circulation control is between the outside air position and RECIRC position the system will be in outside air If the circulation control is in the RECIRC position and the mode control is moved from the floor to the defrost positions the circulation con trol will move from the RECIRC position to the out side air position beginning at the mix position This is to prevent window fogging DIAGNOSIS AND TESTING A C PERFORMANCE TEST The air conditioning system is designed to remove heat and humidity from the air entering the passen ger compartment The evaporator located in the heater A C unit is cooled to temperatures near the freezing point warm damp air passes over the fins in the evaporator moisture in the air condenses to water dehumidifying the air Condensation on the evaporator fins reduces the evaporators ability to absorb heat During periods of high heat and humid ity an air conditioning system will be less effective With the instrument control set to RECIRC only air from the passenger compartment passes through the HEATING AND AIR CONDITIONING 24 9 evaporator As the passenger compartment air dehu midifies A C performance levels rise PERFORMANCE TEST PROC
33. control head Fig 13 for 30 seconds Use a super cold substance liquid 2 Do not spray refrigerant the expansion valve for this test Suction side low pressure should drop to 34 5 kPa 5 psi If not replace expansion valve HEATING AND AIR CONDITIONING 24 13 8 Allow expansion valve to thaw The low pres sure gauge reading should stabilize at 103 to 241 kPa 15 to 35 psi If not replace expansion valve 9 When expansion valve test is complete test A C overall performance Refer to the Heater and A C Performance Test in this section Remove all test equipment before returning vehicle to use HEATER PERFORMANCE TEST PRE DIAGNOSTIC PREPARATIONS Review Safety Precautions and Warnings in this group before performing the following procedures Check the coolant level drive belt tension vacuum line connections radiator air flow and fan operation Start engine and allow to warm up to normal tem perature WARNING DO NOT REMOVE RADIATOR CAP WHEN ENGINE IS HOT PERSONAL INJURY CAN RESULT If vehicle has been run recently wait 15 minutes before removing cap Place a rag over the cap and turn it to the first safety stop Allow pressure to escape through the overflow tube When the system stabilizes remove the cap completely MAXIMUM HEATER OUTPUT TEST AND ACTION Engine coolant is provided to the heater system by two 16 mm 5 8 inch inside diameter heater hoses With engine idling at normal running temperature
34. cted either through or around the heater core This is done by adjusting the blend air door with the TEMP control on the instrument panel The air flow can then be directed from the panel floor and defrost outlets in various combinations using the mode selec tor There are 17 different mode selections possible Air flow velocity can be adjusted with the blower speed selector switch on the instrument panel On A C equipped vehicles the ambient air intake can be controlled by opening and closing the recircu lating air door When placed in RECIRC air that is inside vehicle is removed continuously and recircu lated through unit housing Ambient air cannot be controlled on vehicles without A C The system uses outside air at all times The air conditioning compressor can be engaged by turning the fan switch counterclockwise from the off position It can also be engaged by placing the mode control in the mix to defrost positions This will remove heat and humidity from the air before it is directed through or around the heater core SYSTEM OIL LEVEL It is important to have the correct amount of oil in the A C system to ensure proper lubrication of the compressor Too little oil will result in damage to the compressor Too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures 24 8 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION Continued NOTE The oil used in the c
35. e or below the original hole in the evapora tor core HEATING AND AIR CONDITIONING 24 27 Fig 35 Evaporator Removal Typical 1 EVAPORATOR 2 BLOWER WHEEL 3 Insert new probe into hole between evaporator fins 4 Reinstall rubber probe access hole into evaporator grommet Fig 36 Evaporator Probe Location Typical 1 EVAPORATOR PROBE WIRING CONNECTOR 2 EVAPORATOR PROBE RUBBER GROMMET 3 EVAPORATOR BLOWER MODULE 9424 10 EXPANSION VALVE WARNING THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION 24 28 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued REMOVAL 1 Remove the wire connector from the low pres sure cut off switch 2 Remove the center bolt of refrigerant line plumbing sealing plate Fig 37 3 Carefully pull the refrigerant line sealing plate assembly from the expansion valve towards front of vehicle Do not scratch the expansion valve sealing surfaces with pilot tubes 4 Cover the openings on A C line sealing plate assembly to prevent contamination 5 Remove two screws securing the expansion valve to the evaporator sealing plate 6 Carefully remove valve INSTALLATION 1 Remove and replace the aluminum gasket on the evaporator sealing plate 2 Carefully hold the expansion valve to the evap orator sealing plate so not to scratch the sealing sur face Install two screws and tigh
36. e recirculation door in air conditioned equipped vehi cles The instrument panel must be removed from the vehicle to gain access to the recirculation door actua tor REMOVAL 1 Remove instrument panel from vehicle Refer to Group 8E Instrument Panel And Systems for removal procedures 2 Disconnect vacuum line from actuator 3 Disconnect actuator from recirculation door link Fig 44 4 Release tension on latch and slide recircula tion door actuator off housing INSTALLATION For installation reverse the above procedures SUCTION LINE WARNING THE REFRIGERANT MUST BE RECOV ERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS 4 RECIRC DOOR VACUUM ACTUATOR 5 DOOR LEVER 6 DOOR LEVER REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrigerant from A C system 2 Remove retaining bolt at expansion valve Fig 45 4 FWD 80bceaib Fig 45 Expansion Valve Center Bolt 1 EXPANSION VALVE 2 LOW PRESSURE CUTOFF SWITCH 3 LIQUID LINE 4 SUCTION LINE 24 32 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued 3 Remove line at expansion valve 4 Remove line at compressor Fig 46 80bcea24 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 O
37. e retaining screw Fig 51 80570e32 Fig 51 Housing Screws 1 RIGHT SIDE RETAINING SCREW 2 EVAPORATOR PROBE GROMMET 3 SCREW BOSSES 4 DASH PANEL STUD AND NUT 12 Remove remaining nut located on dash panel stud 13 Disconnect the wiring connectors 14 Remove assembly from the vehicle 24 34 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued INSTALLATION For installation reverse the above procedures DISASSEMBLY AND ASSEMBLY HEATER A C HOUSING Use this procedure if any or all of the following items require service e Heater core e Evaporator e HVAC housing The HVAC housing must be removed from the vehicle before beginning with this procedure Refer to Unit Housing in this section for removal procedure DISASSEMBLY 1 Separate the air distribution outlet foam seals at the case parting line Fig 52 80bcea25 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 PL 80 26 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
38. ed 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
39. ed Then allow the system to evacuate an additional 10 minutes 3 Close all valves Turn off and disconnect the vacuum pump 4 The refrigerant system is prepared to be charged with refrigerant R 134a REFRIGERANT This vehicle uses a refrigerant called R 134a It is a non toxic non flammable clear colorless liquefied gas R 134a refrigerant is not compatible with R 12 refrigerant in an air conditioning system Even a small amount of R 12 in a R 134a system could cause compressor failure refrigerant oil to sludge and or poor performance Never add any other type of refrigerant to a system designed to use R 134a refrigerant System failure will occur The high pressure service port is located on the ffilter drier The low pressure service port is located on the suction line near the strut tower When servicing a system it is required that an air conditioning charging recovery recycling machine be used Fig 18 Contact an automotive service equip ment supplier for proper equipment Refer to the operating instructions provided with the equipment for proper operation Fig 18 Refrigerant Recovery Recycling Station Typical 1 R 134 REFRIGERANT RECOVERY MACHINE A manifold gauge set Fig 19 must also be used in conjunction with the charging and or recovery recy cling device Only use gauges that have not been used for R 12 The service hoses on the gauge set should have manual turn wheel or automatic back flow
40. ed 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 PL GENERAL INFORMATION Continued 9324 3 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 It is also important to keep the air intake openings clear of de
41. engine and set A C to low blower motor speed panel full cool and RECIRC 3 Using a voltmeter check for battery voltage between Pin 1 and 2 If no voltage is detected there is no power to the switch Check wiring and fuses Refer to Group 8W Wiring Diagrams for circuit diag nosis 4 Using a voltmeter check for battery voltage between Pin 1 and Pin 3 If no voltage is detected there is no voltage from the Powertrain Control Mod ule Refer to Group 8W Wiring Diagrams If voltage is OK connect a jumper wire between Pin 1 and Pin 3 The compressor clutch should engage If the dutch engages remove the jumper wire immediately and go to Step 5 If the compressor clutch does not engage check the operation of the clutch and repair as nec essary HEATING AND AIR CONDITIONING 24 11 5 If compressor clutch engages connect the evap orator probe 3 way connector The compressor clutch should engage or cycle depending on evaporator tem perature If OK go to Step 6 If not OK replace the clutch cyding switch 6 The engine running and the A C set to e Blower motor on low speed Panel position e Full cool RECIRC Close all doors and windows Place a thermometer in the center discharge vent 7 If the clutch does not begin to cycle off between 2 to 7 35 F to 45 F verify that the evapo rator probe is fully installed and not loose in evapo rator If it is not properly installed install probe and rete
42. ere it must be evacuated before the system can be filled Moisture and air mixed with the refrig erant will raise the compressor head pressure above acceptable operating levels This will reduce the per formance of the air conditioner and damage the com pressor Moisture will boil at near room temperature when exposed to vacuum To evacuate the refrigerant system NOTE When connecting the service equipment coupling to the line fitting verify that the valve of the coupling is fully closed This will reduce the amount of effort required to make the connection 1 Connect a suitable charging station refrigerant recovery machine and a manifold gauge set with vacuum pump Fig 17 9 A gt 54 4 80a7e36f Fig 17 Refrigerant Recovery Machine Hookup Typical 1 LOW SIDE CONNECTOR 2 HIGH SIDE CONNECTOR 3 TO MANIFOLD SET 2 Open the suction and discharge valves and start the vacuum pump The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system When the suction gauge reads 88 kPa 26 in Hg vacuum or greater for 45 minutes close all valves and turn off vacuum pump If the system fails to reach specified vacuum the refrigerant system likely has a leak that must be corrected If the refrigerant system maintains speci fied vacuum for at least 30 minutes start the vac uum pump open the suction and discharge valves PL SERVICE PROCEDURES Continu
43. formed 1 Compressor drive belt condition 2 Proper refrigerant charge 3 Thermal expansion valve TXV operating cor rectly 4 Head pressure is normal 24 6 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION Continued COMPRESSOR FRONT SHAFT SEAL The compressor front shaft seal is not serviceable If a leak is detected at the shaft seal the compressor must be replaced as a unit CONDENSATION DRAIN TUBE Condensation that accumulates in the evaporator housing is drained from a tube through the dash and on to the ground This tube must be kept open to prevent condensate water from collecting in the bot tom of the housing The tapered end of the drain tube is designed to keep contaminants from entering the heater A C unit housing If the tube is pinched or blocked condensate cannot drain causing water to back up and spill into the passenger compartment It is normal to see con densate drainage below the vehicle If the tube is damaged it should be replaced ENGINE COOLING SYSTEM REQUIREMENTS To maintain ample temperature levels from the heating A C system the cooling system must be in proper working order Refer to Group 0 Lubrication and Maintenance or Group 7 Cooling System of this manual The use of a bug screen is not recommended Any obstructions forward of the condenser can reduce the effectiveness of the air conditioning system EVAPORATOR PROBE The evaporator probe can be replaced without hav
44. ghtening 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 clutch installation cycle the A C clutch 20 times 5 seconds on and 5 seconds off During this procedure set the system to the A C mode engine rpm at 1500 2000 and high blower speed This procedure burnishing will seat the opposing friction surfaces and provide a higher clutch torque capability CONDENSATION DRAIN TUBE REMOVAL 1 Raise vehicle 2 Locate rubber drain tube on right side of dash panel Fig 30 3 Squeeze clamp and remove drain tube P T g 3 9124 15 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 CONDENSER The condenser is located in front of the engine radiator It has no serviceable parts If damaged leaking the condenser assembly must be replaced WARNING THE REFRIGERANT MUST BE REMOVED FROM THE SYSTEM BEFORE REMOV ING THE CONDENSER REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrigerant from the A C system 2 Remove battery support strut 3 Remove refrigerant lines from condenser Fig 31 4 Remove upper radiator mounts 5 Remove condenser radiator mounting Screws 6 Tilt radiator back and remove condenser INSTALLATION For installatio
45. icle Refer to group Instrument Panel and Systems for detailed procedure 3 Drain cooling system and remove heater hoses at the dash panel Place plugs in the heater core out lets to prevent coolant spillage during unit housing removal 4 Unfasten coolant recovery container and set aside 5 Remove suction line at expansion valve Cap open refrigerant lines to prevent moisture and or dirt from entering PL REMOVAL AND INSTALLATION Continued 6 Remove expansion valve from evaporator and cap fittings 7 Remove rubber drain tube extension from con densation drain tube 8 Disconnect the vacuum harness at the power brake booster Fig 48 lt gt 72 80bcea22 Fig 48 HVAC Vacuum Harness 1 BRAKE POWER BOOSTER 2 A C VACUUM CHECK VALVE 3 VACUUM HARNESS 9 Unsnap and remove the defroster duct Fig Fig 49 HVAC Housing Defroster Duct 1 DEFROSTER DUCT 2 BODY 3 ELECTRICAL CONNECTOR 4 HVAC HOUSING 9 ths HEATING AND AIR CONDITIONING 24 33 10 Remove three retaining nuts located in the engine compartment on the dash panel Fig 50 7 Fig 50 Dash Panel Retaining Studs 1 BLOWER RESISTOR 2 EXPANSION VALVE 3 DRAIN TUBE 4 DASH PANEL 5 HEATER HOSES 6 RETAINING STUDS 11 Remove the right sid
46. ing the engine to run for five minutes with the system set to the following e Transaxle in Park e Engine Idling at 700 rpm e A C Controls Set in 100 percent outside air e Blower switch in the high A C position e A C in the ON position e Open all windows CAUTION A leak detector designed for R 12 refrig erant only will not detect leaks in a R 134a refrig erant system 4 Shut off the vehicle and wait 2 to 7 minutes Then use an Electronic Leak Detector that is designed to detect R 134a type refrigerant and search for leaks Fittings lines or components that appear to be oily usually indicates a refrigerant leak To inspect the evaporator core for leaks insert the leak detector probe into the drain tube opening or a heat duct A R 134a dye is available to aid in leak detec tion use only Chrysler approved refrigerant dye If a thorough leak check has been completed with out indication of a leak proceed to System Charge Level REMOVAL AND INSTALLATION A C FILTER DRIER The filter drier is mounted in a rubber grommet on the right side of the engine compartment The refrig erant must be recovered from the A C system before replacing the filter drier assembly WARNING THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PRO CEEDING WITH THIS OPERATION PL REMOVAL AND INSTALLATION Continued REMOVAL 1 Disconnect liquid line from filter drier 2 Disconnect liquid line on suction line assembly fr
47. itch Fig 8 monitors the refrigerant gas pressure on the suction side of the system The low pressure cut off switch is located on the expansion valve The low pressure cut off switch turns off voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor The low pressure cut out switch is a sealed factory calibrated unit It must be replaced if defective PL DESCRIPTION AND OPERATION Continued 80bcea29 Fig 7 High Pressure Cut Out Switch Location 1 DISCHARGE LINE 2 COMPRESSOR 3 HIGH PRESSURE CUT OUT SWITCH 4 SUCTION LINE 5 4 FWD 80bceatb Fig 8 Low Pressure Cut Off Switch 1 EXPANSION VALVE 2 LOW PRESSURE CUTOFF SWITCH 3 LIQUID LINE 4 SUCTION LINE 2 HEATING AND AIR CONDITIONING 24 7 SIDE WINDOW DEMISTERS The demisters direct air from the unit housing through the outlets located on the top corners of the instrument panel The demisters operate when the mode selector is anywhere between floor and defrost settings Some air may be noticeable from the demis ter outlets when the mode selector is in the bilevel to floor positions SYSTEM AIRFLOW The system pulls outside ambient air through the cowl opening at the base of the windshield Then it goes into the plenum chamber above the unit hous ing On air conditioned vehicles the air passes through the evaporator Air flow can be dire
48. ly with a block of wood on the friction surface Fig 29 4 Install pulley assembly retaining snap ring bevel side outward with Snap Ring Pliers Press the snap ring to make sure it is properly seated in the groove 5 If the original front plate assembly and pulley assembly are to be reused the old shim s can be used If not place a trial stack of shims 2 54 mm 0 10 in thick on the shaft against the shoulder 6 Install front plate assembly onto shaft 7 If installing a new front plate and or pulley assembly the gap between front plate and pulley face must be checked Use the following procedure a Attach a dial indicator to front plate so that movement of the plate can be measured b With the dial indicator zeroed on the front plate energize the clutch and record the amount of movement c The readings should be 0 35 to 0 65 mm 0 014 to 0 026 in If proper reading is not AND AIR CONDITIONING 24 25 REMOVAL AND INSTALLATION Continued INSTALLATION To install reverse the preceding operation Check the drain tube nipple on the heater A C housing for any obstructions 80 5575 Fig 29 Installing Pulley Assembly 1 PULLEY ASSEMBLY 2 WOOD BLOCK obtained add or subtract shims until desired read ing is obtained 8 Install compressor shaft bolt Tighten to 17 5 2 N m 155 20 in Ibs torque NOTE Shims may compress after ti
49. ming a system Charge Level Check or Fill If while performing this test A C liquid line pressure is less than 345 kPa 50 psi proceed to Empty Refrigerant System Leak Test If liquid line pressure is greater than 345 kPa 50 psi proceed to low refrigerant level leak test If the refrigerant system is empty or low in refrigerant charge a leak at any line fitting or component seal is likely A review of the fittings lines and components for oily residue is an indication of the leak location To detect a leak in the refrigerant system perform one of the following procedures as indicated by the symptoms EMPTY REFRIGERANT SYSTEM LEAK TEST 1 Evacuate the refrigerant system to the lowest degree of vacuum possible approx 28 in Hg Deter mine if the system holds a vacuum for 15 minutes If vacuum is held a leak is probably not present If sys PL tem will not maintain vacuum level proceed with this procedure 2 Prepare a 284 Kg 10 oz refrigerant charge to be injected into the system 3 Connect and dispense 284 Kg 10 oz of refrig erant into the evacuated refrigerant system 4 Proceed to Step 2 of Low Refrigerant Level Leak Test LOW REFRIGERANT LEVEL LEAK TEST 1 Determine if there is any R 134a refrigerant in the system 2 Position the vehicle in a wind free work area This will aid in detecting small leaks 3 Bring the refrigerant system up to operating temperature and pressure This is done by allow
50. n reverse the above procedures e Tighten the condenser refrigerant lines to 5 N m 45 in 105 24 26 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued 806 16 Fig 31 Condenser Refrigerant Lines 1 LIQUID LINE 2 A C LINE MOUNTING BOLTS 3 DISCHARGE LINE 4 CONDENSER DISCHARGE LINE WARNING THE REFRIGERANT SYSTEM MUST BE RECOVERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEM REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrigerant from A C system 2 From the top side of the vehicle remove line at compressor Fig 32 3 From the bottom side of the vehicle remove line at condenser INSTALLATION For installation reverse the above procedures EVAPORATOR This vehicle uses an aluminum plate and fin style evaporator It is located in the Evaporator Blower module The unit housing must be removed from the vehi cle before beginning with this procedure Refer to Unit Housing in this section for removal procedure Use this procedure if any or all of the following items require service e Evaporator e Air inlet duct e Heater Core e Heating and Air Conditioning PL 80bcea29 Fig 32 Discharge Line 1 DISCHARGE LINE 2 COMPRESSOR 3 HIGH PRESSURE CUT OUT SWITCH 4 SUCTION LINE DISASSEMBLE 1 Separate the foam seals at the evaporator line connection and the dash panel
51. oil has escaped the compressor should be removed and drained The filter drier must be replaced along with the ruptured part The oil capacity of the sys tem minus the amount of oil still in the remaining components can be measured and poured into the suction port of the compressor REFRIGERANT OIL CAPACITIES Refrigerant Oil Capacities Component Total System Filter Drier Condenser Evaporator All Refrigerant Lines VACUUM CONTROL SYSTEM The neon uses vacuum to operate only the recircu lation door Fig 9 All other controls are cable When vacuum is supplied to the actuator the door moves to the Recirculation position Fig 10 The PL actuator is spring loaded so the door moves to the Outsideair position when there is no vacuum sup plied The operation of the door can be viewed by removing the blower motor and looking up into the unit inlet 80bcea22 Fig 9 A C Vacuum Line 1 BRAKE POWER BOOSTER 2 VACUUM CHECK VALVE 3 VACUUM HARNESS 80bcea28 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 PL DESCRIPTION AND OPERATION Continued Normally vacuum is supplied to the actuator by placing the Circulation control knob in the Recircula tion position The Mode and the circulation control are me
52. om filter drier 3 Pull filter drier out of rubber grommet INSTALLATION For installation reverse the above procedures A C SERVICE PORT VALVE CORES REMOVAL 1 Remove the valve caps Fig 4 2 Using a R 134a refrigerant recovery machine Remove the refrigerant from A C system 3 Using a standard valve core tool remove the valve core Be careful to prevent any dirt debris from entering the valve core opening or getting on the replacement valve core INSTALLATION 1 When assembling the new valve core into the port the core should be oiled with clean ND8 amp PAG compressor oil 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 Install valve core into port 3 Evacuate and charge the A C system 4 Install the valve caps BLOWER MOTOR AND WHEEL ASSEMBLY The blower motor is located on the bottom right side of the unit housing The blower motor can be removed from the vehicle without having to remove the unit housing assembly WITH AIR CONDITIONING REMOVAL 1 Remove right side scuff plate 2 Pull back carpet 3 Disconnect blower motor wiring connector 4 Remove blower motor retaining screws and lower blower motor assembly from unit housing Fig 20 INSTALLATION For installation reverse the above procedures HEATING AND AIR CONDITIONING 24
53. ompressor is ND8 PAG R 134a refrigerant oil Only refrigerant oil of the same type should be used to service the system Do not use any other oil The oil container should be kept tightly capped until it is ready for use Tightly cap afterwards to prevent contamination from dirt and moisture Refrigerant oil will quickly absorb any moisture it comes in contact with Spe cial effort must be used to keep all R 134a system components moisture free Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss Oil loss at a leak point will be evident by the presence of a wet shiny surface around the leak REFRIGERANT OIL LEVEL CHECK When an air conditioning system is first assem bled all components except the compressor are refrigerant oil free After the system has been charged with R 134a refrigerant and operated the oil in the compressor is dispersed through the lines and components The evaporator condenser and filter drier will retain a significant amount of oil refer to the Refrigerant Oil Capacities chart When a compo nent is replaced the specified amount of refrigerant oil must be added When the compressor is replaced the amount of oil that is retained in the rest of the system must be drained from the replacement com pressor When a line or component has ruptured and
54. ose 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 high pressure cut out switch is located on the rear of the compressor Fig 7 It turns off the com pressor if the system pressure exceeds 3240 kPa 470 psi LOW PRESSURE CUT OFF SWITCH The Low Pressure Cut Off Sw
55. oved lift compressor clutch assembly and tie it to a suitable component INSTALLATION For installation reverse the above procedures e Tighten the compressor mounting bolts to 28 N m 250 in Ibs e Tighten the compressor lines to 12 N m 108 in 105 COMPRESSOR CLUTCH COIL ASSEMBLY Compressor assembly must be removed from mounting Although refrigerant discharge is not nec REMOVAL 1 Remove the compressor shaft bolt Fig 25 A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal 2 Tap the clutch plate with a plastic hammer and remove clutch plate and shim s Fig 26 NOTE Use care not to lose any of the shim s 24 23 HEATING AND AIR CONDITIONING 80a9974f Fig 25 Compressor Shaft Bolt and Clutch Plate 1 COMPRESSOR SHAFT BOLT 2 COMPRESSOR CLUTCH PLATE 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 26 Clutch Plate and Shim s 1 COMPRESSOR SHAFT 2 CLUTCH PLATE 3 CLUTCH PLATE SHIM 24 24 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued 3 Remove pulley retaining snap ring with Snap Ring Pliers and slide pulley assembly off of compres sor Fig 27 D Fig 27 Removing Pulley Snap Ring 1 SNAP RING 4 Remove coil wire bracket ground clip screw and wire harness
56. rant from A C system 2 Rotate the high pressure relief valve counter clockwise and separate relief valve from the compres sor Fig 39 INSTALLATION For installation reverse the above procedures using a new O Ring Seal Evacuate and charge the refrigerant system LIQUID LINE WARNING THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrigerant from A C system 2 Disconnect liquid line at drier 3 Disconnect liquid line at condenser INSTALLATION For installation reverse the above procedures LOW PRESSURE CUT OFF SWITCH WARNING THE REFRIGERATION SYSTEM MUST BE COMPLETELY RECOVERED BEFORE PRO CEEDING WITH THIS OPERATION REFER TO REFRIGERANT RECOVERY SECTION REMOVAL 1 Disconnect the wire connector at the cut off switch 2 Using a sender unit removal socket remove the switch from the expansion valve Fig 40 24 30 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION Continued INSTALLATION NOTE Verify the O ring condition on the replace ment switch For installation reverse the above procedures Evacuate and charge the system FWD 80bceatb Fig 40 Expansion Valve and Low Pressure Cut Off Switch 1 EXPANSION VALVE 2 LOW PRESSURE CUTOFF SWITCH 3 LIQUID LINE 4 SUCTION LINE MODE CONTROL CABLE The Mode Control Cable can be removed and inst
57. st outlet temperature If the evaporator probe is properly installed replace the clutch cycling switch 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 Review Safety Precautions and Warnings in the General Information section of this Group The work area and vehicle must be 21 to 27 C 70 to 85 F when testing expansion valve To test the expansion valve 1 Connect a charging station or manifold gauge set to the refrigerant system service ports 2 Disconnect wire connector at low pressure cut off switch Fig 13 Using a jumper wire jump ter minals inside wire connector boot 3 Close all doors windows and vents to the pas senger compartment 4 Set Heater A C control to A C full heat floor RECIRC and high blower 5 Start the engine and hold the idle speed 1000 rpm After the engine has reached running temper ature allow the passenger compartment to heat up This will create the need for maximum refrigerant flow into the evaporator 6 If the refrigerant charge is sufficient discharge high pressure gauge should read 965 to 2620 kPa 140 to 380 psi Suction low pressure gauge should read 103 to 2417 kPa 15 to 35 psi If system cannot achieve proper pressure readings repla
58. ten to 11 3 Nem 100 30 in Ibs 3 Remove and replace the aluminum gasket on the refrigerant line sealing plate assembly 4 Carefully hold the refrigerant line sealing plate assembly to the expansion valve Install bolt and tighten to 23 3 N m 200 30 in Ibs 5 Connect wires to low pressure cut off switch 6 Evacuate and recharge system 7 After expansion valve is installed system is charged and leaks have been checked repeat A C performance check HEATER CORE Refer to HVAC Housing Disassembly and Assembly in this section for heater core removal procedure HEATER HOSES CAUTION When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pres sure The heater core may become damaged and leak engine coolant NOTE Review Cooling System Precautions before proceeding with this operation REMOVAL 1 Drain engine cooling system Refer to Group 7 Cooling System 2 Using spring tension clamp pliers remove clamps at end of heater hose to be removed Fig 38 3 Carefully rotate hose back and forth while pull ing away from connector nipple PL 9024 40 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 80 2 Fig 38 Heater Hoses and Clamps 1 COWL PANEL 2 HEATER HOSE AND CLAMPS 3
59. trans fer of refrigerant has stopped close the suction and discharge valve 4 If all of the charge did not transfer from the dispensing device put vehicle controls into the fol lowing mode e Automatic transaxle in park or manual tran saxle in neutral e Engine idling at 700 rpm A C control set in 100 percent outside air Panel mode Blower motor ON high speed Vehicle windows closed If the A C compressor does not engage test the compressor clutch control circuit and correct any fail ure Refer to Group 8W Wiring Diagrams 5 Open the suction valve to allow the remaining refrigerant to transfer to the system WARNING TAKE CARE NOT TO OPEN THE DIS CHARGE HIGH PRESSURE VALVE AT THIS TIME 6 Close all valves and test the A C system perfor mance 7 Disconnect the charging station or manifold gauge set Install the service port caps EVACUATING REFRIGERANT SYSTEM NOTE Special effort must be used to prevent mois ture from entering the A C system oil Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor PL If a compressor designed to use R 134a refrigerant is left open to the atmosphere for an extended period of time It is recommended that the refrigerant oil be drained and replaced with new oil or a new compres sor be used This will eliminate the possibility of con taminating the refrigerant system If the refrigerant system has been open to the atmosph
60. tuator Feed line 8 If there is no blockage in the Supply line Con trol or the Actuator Feed line the Actuator must have failed Connect the Vacuum hose from the Vac uum Test Gauge directly to the Actuator to verify the Actuator has failed SERVICE PROCEDURES CHARGING A C SYSTEM PARTIAL CHARGE This vehicle does not have a sight glass It is not possible to determine the amount of R 134a charge in the system Therefore it is necessary to completely evacuate and recover the system and then recharge the system fully HEATING AND AIR CONDITIONING 24 17 EVACUATION Before adding refrigerant all air must be evacu ated from the system e Connect a manifold gauge set to the A C service ports Fig 16 e Use a vacuum pump or charging station and evacuate system to 95 kPa 28 inches Hg for 30 min utes e Go to Charging A C System below gt gt f WA FLU 80 4 Fig 16 A C Service Ports 1 A C SERVICE PORTS 2 FILTER DRIER CHARGING A C SYSTEM The procedure below should be used to fill the refrigerant charge in the air conditioning system This A C system does not have or use a sight glass to check or charge the system WARNING REVIEW SAFETY PRECAUTIONS AND WARNINGS IN THIS GROUP BEFORE CHARGING THE REFRIGERANT SYSTEM AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES NOSE AND THROAT USE ONLY APPROVED SERVICE EQUIPMENT MEE
61. tuator to verify the leak LOCATING PINCHED VACUUM LINES The operation of the Circulation door can be viewed by removing the blower motor and looking up into the unit inlet See Blower Motor Wheel and Assembly removal and installation in this section for service procedures 1 Connect the test vacuum probe to the vehicles Black supply hose Position the vacuum test gauge so it can be viewed from the passenger compartment 2 Place the Mode in the Panel position and the Circulation control in the Recirculation position 3 Remove the center instrument pane bezel 4 Remove the center vent duct 5 Remove the Supply Black vacuum line at the control The test gauge should drop indicating free flow through the Supply line If not there is a block age in the Supply line 6 If there is no blockage in the Supply line reconnect it to the Control Remove the Actuator Feed Red line from the Control The test gauge should drop indicating free flow through the Supply line and Control If not the vacuum switches on the Control are not functioning 7 If there is no blockage in the Supply line the Control reconnect the Actuator F eed Red line to the control Remove the Actuator Feed Red line at the Actuator The Actuator vacuum port is accessible behind and above the Glove Box The test gauge should drop indicating free flow through the supply line Control and the Actuator Feed line If not there is a blockage in the Ac

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