Chrysler PT Cruiser. Manual — part 975

NOTE: For circuit descriptions and diagrams, refer
to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire
and connector repair procedures, further details on
wire harness routing and retention, as well as pin-
out and location views for the various wire harness
connectors, splices and grounds.

(1) Disconnect and isolate the negative battery

cable.

(2) Disconnect the wire harness connector from the

blower motor resistor (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/BLOWER

MOTOR

RESISTOR - REMOVAL).

(3) Using

an

ohmmeter,

check

for

continuity

between all of the blower motor resistor terminals. In
each case there should be continuity. If OK, repair
the wire harness circuits between the blower motor
switch and the blower motor resistor or blower motor
as required. If not OK, replace the faulty blower
motor resistor.

REMOVAL

WARNING: The blower motor resistor may get very
hot during normal operation. If the blower motor
was turned on prior to servicing the blower motor
resistor, wait five minutes to allow the blower motor
resistors to cool before performing diagnosis or
service. Failure to take this precaution can result in
possible personal injury.

CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the windshield wipers (Refer to 8 -

ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL).

(3) Remove the cowl top screen (Refer to 23 -

BODY/EXTERIOR/COWL

GRILLE

SCREEN

-

REMOVAL).

(4) Disconnect the wire harness connector from the

blower motor resistor (Fig. 16).

(5) Disengage the retaining clip and remove the

blower motor resistor from the engine compartment.

INSTALLATION

(1) Position the blower motor resistor into the

engine compartment.

(2) Install the blower motor resistor into the cowl

and engage the retaining clip.

(3) Connect the wire harness connector to the

blower motor resistor.

(4) Install the cowl top screen (Refer to 23 -

BODY/EXTERIOR/COWL

GRILLE

SCREEN

-

INSTALLATION).

(5) Install the windshield wipers (Refer to 8 -

ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
INSTALLATION).

(6) Reconnect the negative battery cable.

MODE DOOR CABLE

REMOVAL

NOTE: The mode control cable can be removed and
installed without having to remove the instrument
panel from the vehicle.

(1) Disconnect and isolate the negative battery

cable.

(2) Remove instrument panel center bezel (Refer to

23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - REMOVAL).

(3) Remove the center air duct (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
AIR OUTLETS - REMOVAL).

(4) Remove the A/C-heater control (Refer to 24 -

HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL).

(5) Reach through the center air duct opening in

the instrument panel to access and remove the screw
that secures the mode control cable housing to the
top of the HVAC housing (Fig. 17).

Fig. 16 Blower Motor Resistor - Typical

1 - BLOWER MOTOR RESISTOR
2 - ELECTRICAL CONNECTOR

24 - 22

CONTROLS

PT

BLOWER MOTOR RESISTOR (Continued)

(6) Disconnect the mode control cable end from the

mode-air door lever.

(7) Remove the mode control cable through the

A/C-heater control opening in the instrument panel.

INSTALLATION

(1) Position the mode control cable through the

A/C-heater control opening in the instrument panel.

(2) Reach through the center air duct opening in

the instrument panel to access and connect the mode
control cable to the mode-air door lever.

(3) Install the screw that secures the mode control

cable casing to the top of the HVAC housing. Tighten
the screw to 2 N·m (17 in. lbs.).

(4) Install and adjust the mode control cable. Refer

to the following Adjustment Procedure

(5) Install the A/C-heater control (Refer to 24 -

HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - INSTALLATION).

(6) Install the center air duct (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/AIR
OUTLETS - INSTALLATION).

(7) Install the instrument panel center bezel (Refer

to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).

(8) Reconnect the negative battery cable.

ADJUSTMENT PROCEDURE

(1) With the A/C-heater control removed from the

instrument panel and the mode control cable retain-
ing clip removed, turn the mode control completely
counterclockwise.

(2) While holding the mode control in the counter-

clockwise position, pull on the gray casing of the
mode control cable until all free play in the cable is
removed and the mode-air door is indexed to the
mode control.

(3) Install the cable retaining clip. Make sure that

the control cable is securely positioned by the retain-
ing clip.

RECIRCULATION DOOR
ACTUATOR

DESCRIPTION

NOTE: This vehicle uses vacuum to operate only
the recirculation door. All other controls are cable
operated.

Vehicles equipped with A/C have a vaccum oper-

ated recirculation door actuator. When vacuum is
supplied by the A/C-heater control to the recircula-
tion door actuator, the recirculation door moves to
the RECIRC position. The actuator is spring loaded
so the door moves to the Outside-air position when
there is no vacuum supplied. The operation of the
door can be viewed by removing the blower motor
and looking up into the HVAC housing.

OPERATION

Normally, vacuum is supplied to the actuator by

placing the recirculation control knob in the RECIRC
position. The mode and the recirculation controls are
mechanically interlocked so the recirculation control
cannot be placed in the RECIRC position if the mode
control is at/or between the mix and defrost posi-
tions. Vacuum is supplied to the actuator only when
recirculation control is at the RECIRC position. If the
recirculation control is between the Outside-air posi-
tion and RECIRC position the system will still be in
the Outside-air position. If the recirculation control is
in the RECIRC position and the mode control is
moved from the Floor to the Defrost positions, the
recirculation control will move from the RECIRC
position, to the Outside-air position beginning at the
Mix position. This is to help prevent window fogging.

The recirculation door actuator cannot be adjusted

or repaired and, if damaged or faulty, it must be
replaced.

REMOVAL

NOTE: The instrument panel must be removed from
the vehicle to gain access to the recirculation door
actuator.

Fig. 17 HVAC Housing Cables - Typical

1 - VACUUM HARNESS
2 - DOOR CAM
3 - HVAC UPPER HOUSING
4 - HVAC CONTROL CABLES
5 - MODE DOOR LEVERS
6 - DEFROSTER DUCT OUTLET

PT

CONTROLS

24 - 23

MODE DOOR CABLE (Continued)

(1) Disconnect and isolate the battery negative

cable.

(2) Remove instrument panel from vehicle (Refer

to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).

(3) Disconnect the vacuum line harness connector

from the recirculation door actuator.

(4) Release the latch that secures the recirculation

door actuator mount to the stanchion on the HVAC
housing, and disengage the recirculation door actua-
tor from the housing.

(5) Disconnect the recirculation door actuator link-

age from the recirculation door lever (Fig. 18).

(6) Remove the recirculation door actuator from

the HVAC housing.

INSTALLATION

(1) Position the recirculation door actuator to the

HVAC housing.

(2) Connect the recirculation door actuator linkage

to the recirculation door lever.

(3) Align the recirculation door actuator mount to

the stanchion on the HVAC housing, and press it
onto the stanchion firmly to engage the latch.

(4) Connect the vacuum harness connector to the

recirculation door actuator.

(5) Reinstall the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - INSTALLATION).

(6) Reconnect the battery negative cable.

TEMPERATURE CONTROL
CABLE

REMOVAL

NOTE:

The

temperature

control

cable

can

be

removed and installed without having to remove the
instrument panel from the vehicle.

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the instrument panel center bezel

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - REMOVAL).

(3) Remove the center air duct (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
AIR OUTLETS - REMOVAL).

(4) Remove the A/C-heater control (Refer to 24 -

HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL).

(5) Reach through the center air duct opening in

the instrument panel to access and remove the screw
that secures the temperature control cable housing to
the top of the HVAC housing (Fig. 19).

(6) Disconnect the temperature control cable from

the blend-air door lever.

(7) Remove the temperature control cable through

the A/C-heater control opening in the instrument
panel.

Fig. 18 Recirculation Door Actuator and Linkage -

Typical

1 - OUTSIDE AIR/RECIRC DOOR HOUSING
2 - VACUUM ACTUATOR LINKAGE
3 - FOAM SEAL
4 - RECIRC DOOR VACUUM ACTUATOR
5 - DOOR LEVER
6 - DOOR LEVER

Fig. 19 HVAC Housing Cables - Typical

1 - VACUUM HARNESS
2 - DOOR CAM
3 - HVAC UPPER HOUSING
4 - HVAC CONTROL CABLES
5 - MODE DOOR LEVERS
6 - DEFROSTER DUCT OUTLET

24 - 24

CONTROLS

PT

RECIRCULATION DOOR ACTUATOR (Continued)

INSTALLATION

(1) Position the temperature control cable through

the A/C-heater control opening in the instrument
panel.

(2) Reach through the center air duct opening in

the instrument panel to access and connect the tem-
perature control cable to the blend-air door lever.

(3) Install the screw that secures the temperature

control cable case to the top of the HVAC housing.
Tighten the screw to 2 N·m (17 in. lbs.).

(4) Install and adjust the temperature control

cable. Refer to the following Adjustment Procedure.

(5) Install the A/C-heater control (Refer to 24 -

HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - INSTALLATION).

(6) Install the center air duct (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/AIR
OUTLETS - INSTALLATION).

(7) Install the instrument panel center bezel (Refer

to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION).

(8) Reconnect the negative battery cable.

ADJUSTMENT PROCEDURE

(1) With the A/C-heater control removed from the

instrument panel and the temperature control cable
retaining clip removed, turn the temperature control
completely counterclockwise.

(2) While holding the temperature control in the

counterclockwise position, pull on the gray casing of
the temperature control cable until all free play in
the cable is removed and the blend-air door is
indexed to the temperature control.

(3) Install the cable retaining clip. Make sure that

the control cable is securely positioed by the retain-
ing clip.

VACUUM CHECK VALVE

DESCRIPTION

Vehicles equipped with A/C use vacuum to operate

the recirculation door. A vacuum check valve is con-
nected to the brake booster vacuum supply. The vac-
uum check valve is designed to allow vacuum to flow
in only one direction through the accessory vacuum
supply circuits and to stabilize the vacuum within
the HVAC recirculation circuit whenever the vehicle
is accelerating or engine vacuum varies due to oper-
ating conditions.

OPERATION

The use of a vacuum check valve helps to maintain

the system vacuum needed to retain the selected
heating-A/C mode settings. The check valve will pre-
vent the engine from bleeding down system vacuum

through the intake manifold during extended heavy
engine load (low engine vacuum) operation.

The vacuum check valve cannot be repaired and, if

faulty or damaged, it must be replaced.

REMOVAL

The vehicle uses vacuum to operate the recircula-

tion door. A vacuum check valve is connected to the
brake booster vacuum supply. The check valve is
used to stabilize the vacuum within the HVAC recir-
culation circuit whenever the vehicle is accelerating
or engine vacuum varies due to operating conditions.

(1) Disconnect the vacuum harness from the vac-

uum check valve (Fig. 20).

(2) Remove the vacuum check valve from the

brake booster vacuum check valve.

(3) Remove the vacuum check valve from the

engine compartment.

INSTALLATION

(1) Install the vacuum check valve onto the brake

booster vacuum check valve. Ensure correct vacuum
flow.

(2) Connect the vacuum harness to the vacuum

check valve.

Fig. 20 Vacuum Check Valve

1 - BRAKE POWER BOOSTER
2 - VACUUM CHECK VALVE
3 - VACUUM HARNESS

PT

CONTROLS

24 - 25

TEMPERATURE CONTROL CABLE (Continued)