Chrysler Stratus Convertible. Manual — part 158
The RECIRC door actuator is located at the far
right of the A/C Heater housing near the right A-pil-
lar (Fig. 65).
REMOVAL
(1) Place the ignition key in the OFF position
before removing control module.
(2) Remove trim bezel (Fig. 66).
(3) Remove cluster hood bezel retaining screws in
the trim bezel opening (Fig. 67).
(4) Pry up the cluster hood bezel a few inches to
expose the cubby bin/cigar lighter bezel screws.
(5) Remove the cubby bin/cigar lighter bezel and
wiring.
(6) Remove the control module retaining screws.
(7) Drop the A/C control module into the cigar
lighter/cubby bin bezel opening (Fig. 68). Then dis-
connect the wiring on the rear of the control module.
(8) Release the recirculation cable retaining clip
from the top of the control module. Retain the clip for
future use. Then disconnect the recirculation control
cable.
(9) Remove right under panel silencer/duct.
(10) Disconnect cable flag at right of recirculation
housing (Fig. 69).
(11) Remove cable core end from recirculation
actuator lever.
INSTALLATION
For installation, reverse the above procedures. Ver-
ify that the cables are properly adjusted, free of
interference, and the module is seated properly.
Fig. 63 Mode Door Motor Location
1 – MODE DOOR MOTOR
Fig. 64 Mode Motor Connector
1 – CONNECTOR
2 – MODE MOTOR
Fig. 65 Recirculation Cable Location
1 – TEMPERATURE DOOR CABLE
2 – CONTROL MODULE
3 – A/C HOUSING
4 – RECIRCULATION DOOR CABLE
Fig. 66 Trim Bezel
1 – TRIM BEZEL
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HEATING AND AIR CONDITIONING
24 - 29
REMOVAL AND INSTALLATION (Continued)
CABLE ADJUSTMENT
The cables must be adjusted for proper function of
the control module. To adjust the cable, attach the
cable to the lever arm of the control module. Turn
the knob fully counterclockwise. Pull the cable jacket
away from the cable end until taut. Clip the cable
jacket to the control module. The knob should travel
a full 180° if the cable is properly adjusted.
SUCTION LINE
REMOVAL
(1) Remove refrigerant from the A/C system using
a refrigerant recovery machine.
(2) Remove suction line clip at right strut tower
(Fig. 70).
(3) Remove quick connect clip (Fig. 71). Disconnect
quick connect at expansion valve end using Special
Tool Kit 7193.
CAUTION: Cap all lines that are not being replaced
and cap the expansion valve tubes.
(4) Disconnect line at compressor end (Fig. 72).
(5) Remove suction line from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Tighten bolts to 22 N·m (200 in. lbs.).
Fig. 67 Control Module Screws
1 – CONTROL MODULE SCREWS
2 – CLUSTER HOOD SCREWS
Fig. 68 Control Module At Bezel Opening
1 – CONTROL MODULE
Fig. 69 Disconnect Recirculation Cable
1 – RECIRCULATION CABLE
Fig. 70 Suction Line Routing Clip
1 – A/C LINES CLIP
24 - 30
HEATING AND AIR CONDITIONING
JX
REMOVAL AND INSTALLATION (Continued)
TEMPERATURE DOOR CABLE
The blend-air (temperature) door is actuated by a
cable which mechanically positions the temperature
door.
The temperature door actuator is located at the
center of the A/C Heater housing at the center tun-
nel.
REMOVAL
(1) Place the ignition key in the OFF position
before removing control module.
(2) Remove trim bezel (Fig. 66).
(3) Remove cluster hood bezel retaining screws in
the trim bezel opening (Fig. 67).
(4) Pry up the cluster hood bezel a few inches to
expose the cubby bin/cigar lighter bezel screws.
(5) Remove the cubby bin/cigar lighter bezel and
wiring.
(6) Remove the control module retaining screws.
(7) Remove control module and disconnect the wire
connectors.
(8) Release the temperature control cable retaining
clip from the top of the control module. Retain the
clip for future use. Then disconnect the temperature
control cable.
(9) Disconnect cable at A/C housing (Fig. 73).
(10) Remove cable core end from temperature
actuator lever.
INSTALLATION
For installation, reverse the above procedures.
THERMAL LIMITER SWITCH
There is no serviceability of the thermal limiter
switch. If the thermal limiter switch fails, the com-
pressor must be replaced. To replace the compressor,
refer to Compressor Replacement in this section.
UNIT HOUSING
REMOVAL
The heater core may be removed without removing
the unit housing. Refer to heater core replacement in
this section.
(1) Disconnect battery negative remote cable. This
must be done to prevent accidental air bag deploy-
ment.
Fig. 71 Quick Connect Clip
1 – SUCTION LINE
2 – SUCTION LINE CLIP
Fig. 72 Suction Line At Compressor
1 – SUCTION LINE
Fig. 73 Temperature Cable At A/C Housing
1 – TEMPERATURE CABLE
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HEATING AND AIR CONDITIONING
24 - 31
REMOVAL AND INSTALLATION (Continued)
WARNING: AVOID BREATHING A/C REFRIGERANT
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY
IRRITATE EYES, NOSE AND THROAT. USE ONLY
APPROVED SERVICE EQUIPMENT MEETING SAE
REQUIREMENTS TO DISCHARGE R-134a SYSTEM.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
R-134a SERVICE EQUIPMENT OR VEHICLE A/C
SYSTEM SHOULD NOT BE PRESSURE TESTED OR
LEAK TESTED WITH COMPRESSED AIR. SOME
MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO
BE COMBUSTIBLE AT ELEVATED PRESSURES.
THESE MIXTURES ARE POTENTIALLY DANGER-
OUS AND MAY RESULT IN FIRE OR EXPLOSION
CAUSING INJURY OR PROPERTY DAMAGE.
(2) Using an A/C recovery unit, remove all R-134a
refrigerant from the A/C system.
(3) Remove air cleaner hose and air distribution
duct from the engine.
(4) Drain the engine cooling system.
NOTE: If equipped with 2.5L engine, the upper
intake manifold has to be removed at this time to
access the heater hose connections at the bulk-
head. Refer to group 11, Exhaust System And Intake
Manifold for service information.
(5) Disconnect heater hoses at the dash panel.
Plug the heater core inlet and outlet tubes to prevent
antifreeze from spilling on the vehicle interior during
removal. If an appropriate plug cannot be found pull
back carpet and use caution when removing unit.
Keep the heater tubes elevated to prevent spillage of
coolant.
(6) Remove both A/C lines from expansion valve.
Use Special Tool Kit 7193 to disconnect quick connec-
tors on A/C lines. Refer to A/C line removal in this
section for complete procedure. After removing lines
cap the expansion valve openings and the A/C hose
openings. This will prevent any dirt or moisture from
entering the refrigerant system during servicing.
CAUTION: The lubricant used in this air condition-
ing system absorbs moisture readily (similar to
brake fluid). Do not leave any portion of the system
open for extended periods of time.
(7) Remove trim bezel (Fig. 66).
(8) Remove cluster hood bezel retaining screws in
the trim bezel opening (Fig. 67).
(9) Pry up the cluster hood bezel a few inches to
expose the cubby bin/cigar lighter bezel screws.
(10) Remove the cubby bin/cigar lighter bezel and
wiring.
(11) Remove the control module retaining screws.
(12) Drop the A/C control module into the cigar
lighter/cubby bin bezel opening (Fig. 68). Then dis-
connect the wiring on the rear of the control module.
(13) Release the cable clips from the top of the
control module. Retain the clips for future use. Then
disconnect the temperature control and recirculation
control cables.
(14) Remove the control module.
(15) Remove upper instrument panel bezel.
(16) Remove right and left instrument panel end
caps.
(17) Remove left lower knee bolster. Disconnect
mode door motor wiring.
(18) Remove right and left interior door post kick
panel.
(19) Remove front and rear halves of floor console.
(20) Remove the radio.
(21) Remove right side lower silencer/duct.
(22) Remove glove box assembly.
(23) Remove
right
side
vertical
support
strut
brace.
(24) Remove left side vertical support strut brace.
(25) Remove center lower distribution housing.
(26) Remove bolts securing Heater-A/C housing to
metal I/P frame.
(27) Remove upper instrument panel cowl trim
cover.
(28) Disconnect steering column from instrument
panel. Lower steering column.
(29) Remove instrument panel bolts at cowl fence.
(30) Remove bolts at lower A-posts.
(31) Remove instrument panel frame and wiring.
(32) Remove bolts securing Heater-A/C housing to
cowl.
INSTALLATION
For installation, reverse the above procedure. Ver-
ify that the cables are properly adjusted, free of
interference, and the control module is seated prop-
erly.
CABLE ADJUSTMENT
The cables must be adjusted for proper function of
the control module. To adjust the cable, attach the
cable to the lever arm of the control module. Turn
the knob fully counterclockwise. Pull the cable jacket
away from the cable end until taut. Clip the cable
jacket to the control module. The knob should travel
a full 180° if the cable is properly adjusted.
24 - 32
HEATING AND AIR CONDITIONING
JX
REMOVAL AND INSTALLATION (Continued)
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