Chrysler PT Cruiser. Manual — part 981
REMOVAL
WARNING: Review safety precautions and warnings
in this group before performing this procedure
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS).
Failure to follow the warnings and cautions could
result in possible personal injury or death.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
(3) Remove the battery support strut.
(4) Remove the nut that secures the A/C liquid line
from the A/C condenser.
(5) Disconnect the A/C liquid line from the A/C
condenser and remove and discard the O-ring seal.
(Fig. 7).
(6) Install plug in, or tape over the opened liquid
line fitting and the condenser outlet port.
(7) Remove the nut that secures the A/C discharge
line from the A/C condenser.
(8) Disconnect the A/C discharge line from the A/C
condenser and remove and discard the O-ring seal.
(9) Install plug in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(10) Remove upper radiator mounts (Refer to 7 -
COOLING/ENGINE/RADIATOR - REMOVAL)
(11) Remove the condenser retaining screws.
(12) Tilt the radiator back and carefully remove
the A/C condenser from the engine compartment.
INSTALLATION
NOTE: If the A/C condenser is being replaced, add
30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Tilt the radiator back and position the A/C con-
denser into the engine compartment.
(2) Install the screws that secure the A/C con-
denser to the radiator. Tighten the screws to 2 N·m
(17 in. lbs.).
(3) Install the upper radiator mounts (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION).
(4) Remove the tape or plug from the condenser
inlet port and the discharge line fitting.
(5) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.
(6) Connect the A/C discharge line to the A/C con-
denser.
(7) Install the nut that secures the A/C discharge
line to the A/C condenser. Tighten the nut to 5 N·m
(44 in. lbs.).
(8) Remove the tape or plug from the condenser
outlet port and the liquid line fitting.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
Use only the specified O-ring as it is made of a spe-
cial material for the R-134a system. Use only refrig-
erant oil of the type recommended for the compressor
in the vehicle.
(10) Connect the A/C liquid line to the A/C con-
denser.
(11) Install the nut that secures the A/C liquid line
to the A/C condenser. Tighten the nut to 5 N·m (44
in. lbs.).
(12) Install the battery support strut.
(13) Reconnect the negative battery cable.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
Fig. 7 A/C Condenser Refrigerant Lines - Typical
1 - A/C CONDENSER
2 - A/C LIQUID LINE
3 - A/C DISCHARGE LINE
4 - RADIATOR ASSEMBLY
24 - 46
PLUMBING
PT
A/C CONDENSER (Continued)
(15) Charge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
A/C DISCHARGE LINE
DESCRIPTION
The A/C discharge line is the refrigerant line that
goes from the A/C compressor to the A/C condenser
and includes the high side service port. The A/C dis-
charge line has no serviceable parts except for the
rubber O-rings and the service port valve core.
The A/C discharge line cannot be repaired and, if
leaking or damaged, it must be replaced.
REMOVAL
WARNING: Review safety precautions and warnings
in this group before performing this procedure
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS).
Failure to follow the warnings and cautions could
result in possible personal injury or death.
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
(3) Remove the bolt that secures the A/C discharge
line to the A/C compressor (Fig. 8).
(4) Disconnect the A/C discharge line from the A/C
compressor and remove and discard the O-ring seal.
(5) Install plug in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(6) Raise and support the vehicle.
(7) Remove the nut that secures the A/C discharge
line to the A/C condenser (Fig. 9).
(8) Disconnect the A/C discharge line from the A/C
condenser and remove and discard the O-ring seal.
(9) Install plug in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
INSTALLATION
NOTE: Replacement of the refrigerant line O-ring
seals is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals
could result in a refrigerant system leak.
(1) Position the A/C discharge line into the engine
compartment.
(2) Remove the tape or plugs from the discharge
line fitting and the condenser port..
Fig. 8 A/C Compressor Refrigerant Lines - Typical
1 - A/C DISCHARGE LINE
2 - BOLT
3 - A/C COMPRESSOR
4 - BOLT
5 - A/C SUCTION LINE
6 - SUCTION LINE RETAINING BRACKET
7 - ACCESSORY DRIVE BELT
Fig. 9 A/C Condenser Refrigerant Lines - Typical
1 - A/C CONDENSER
2 - A/C LIQUID LINE
3 - A/C DISCHARGE LINE
4 - RADIATOR ASSEMBLY
PT
PLUMBING
24 - 47
A/C CONDENSER (Continued)
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(4) Connect the A/C discharge line to the A/C con-
denser.
(5) Install the nut that secures the A/C discharge
line to the A/C condenser. Tighten the nut to 5 N·m
(44 in. lbs.).
(6) Lower the vehicle.
(7) Remove the tape or plugs from the discharge
line fitting and the compressor port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting. Use only the specified O-ring as it is made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(9) Connect the A/C discharge line to the A/C com-
pressor.
(10) Install the bolt that secures the A/C discharge
line to the A/C compressor. Tighten the bolt to 12
N·m (106 in. lbs.).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE).
(13) Recharge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING - STANDARD
PROCEDURE
-
REFRIGERANT
SYSTEM
CHARGE).
A/C EVAPORATOR
DESCRIPTION
The evaporator (Fig. 10) is located in the HVAC
housing, behind the instrument panel. The evapora-
tor is positioned in the housing so that all air that
enters the housing must pass over the fins of the
evaporator coils before it is distributed through the
system ducts and outlets. However, air passing over
the evaporator fins will only be conditioned when the
compressor is engaged and circulating refrigerant
through the evaporator tubes.
OPERATION
Refrigerant enters the evaporator from the variable
orifice valve as a low-temperature, low-pressure liq-
uid. As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas when
it leaves the evaporator.
The evaporator cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then
wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or
service. This is the only sure way to disable the air-
bag system. Failure to take the proper precautions
could result in an accidental airbag deployment and
possible personal injury or death.
WARNING: Review safety precautions and warnings
in this group before performing this procedure
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS).
Failure to follow the warnings and cautions could
result in possible personal injury or death.
(1) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC
HOUSING
-
DISASSEMBLY).
Fig. 10 Evaporator - LHD Shown, RHD Typical
1 - FOAM WRAP
2 - EVAPORATOR
3 - LOWER HVAC HOUSING
4 - BLOWER MOTOR AND WHEEL
24 - 48
PLUMBING
PT
A/C DISCHARGE LINE (Continued)
(3) Lift the A/C evaporator out of the lower half of
the HVAC housing (Fig. 11).
INSTALLATION
NOTE: If the evaporator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system.
(1) Install the evaporator coil into the bottom half
of the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
A/C VARIABLE ORIFICE TUBE
DESCRIPTION
A variable orifice valve (VOV) is factory installed
in the liquid line between the outlet of the condenser
and the inlet of the evaporator (Fig. 12). The VOV is
located in the end of the liquid line that is closest to
the condenser. The inlet end of the VOV has a nylon
mesh filter screen, which filters the refrigerant and
helps to reduce the potential for blockage of the
metering orifices by refrigerant system contaminants.
The outlet end of the tube has a nylon mesh diffuser
screen. The O-rings on the plastic body of the VOV
seal the tube to the inside of the liquid line and pre-
vent refrigerant from bypassing the metering orifices.
OPERATION
The variable orifice valve (VOV) is used to meter
the flow of liquid refrigerant into the evaporator coil.
The high-pressure liquid refrigerant from the con-
denser expands into a low-pressure liquid as it
passes through the metering orifices and diffuser
screen of the VOV. There are two parallel flow paths
integral to the VOV, a fixed port and a variable port.
As the temperature of the refrigerant increases, the
bimetal coil moves the variable port to the closed
position. High temperature results in more restric-
tion, and lower temperature results in less restric-
tion. This design improves A/C cooling at high loads
and or city traffic.
The VOV is not serviceable. It cannot be repaired,
and if faulty or plugged, it must be replaced as part
of the liquid line.
ACCUMULATOR
DESCRIPTION
The accumulator (Fig. 13) is mounted in the engine
compartment between the evaporator outlet and the
compressor
suction
port.
An
integral
mounting
bracket is used to secure the accumulator to the
frame rail with a bolt. A threaded fitting on the top
Fig. 11 A/C Evaporator - Typical
1 - A/C EVAPORATOR
2 - LOWER HVAC HOUSING
Fig. 12 Variable Orifice Valve
1 - FIXED AND VARIABLE ORIFICES
2 - O-RINGS
3 - FIXED PORT
4 - BIMETAL COIL
5 - INLET FILTER SCREEN
6 - VARIABLE PORT
7 - DIFFUSER SCREEN
PT
PLUMBING
24 - 49
A/C EVAPORATOR (Continued)
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