Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 200
AA BODY PROCEDURE
WARNING: IF EQUIPPED WITH A/C, THE REFRIG-
ERATION SYSTEM MUST BE COMPLETELY EMPTY
BEFORE PROCEEDING WITH THIS OPERATION.
Refer to Group 8E and Group 23 for component re-
moval and installation when performing this opera-
tion.
(1) Perform steps 1 through 7 of Blower Motor re-
moval and installation.
(2) Remove relay panel above glove compartment
opening.
(3) Disconnect the A/C vacuum line connector and
radio noise capacitor connectors.
(4) Remove left windshield pillar trim cover.
(5) Remove left lower side cowl trim cover.
(6) Remove hood release handle mechanism attach-
ing screws.
(7) Remove steering column trim covers.
(8) Disconnect parking brake release mechanism
connecting rod. Gain access through fuse panel open-
ing.
(9) Remove lower left instrument panel silencer.
(10) Remove lower left instrument panel reinforce-
ment.
(11) Remove instrument panel center (radio) bezel.
(12) Remove forward floor console.
(13) Remove the radio.
(14) Remove the heater-A/C control.
(15) Remove cigar lighter.
(16) Remove
message
center/trip
computer,
if
equipped.
(17) Disconnect side window demister tubes from
top of heat A/C unit.
(18) Remove steering column upper attaching bolts
and allow the steering wheel to rest on the driver
seat cushion.
(19) Remove upper instrument panel (defroster
outlet) cover.
(20) Remove upper instrument panel attaching
screws from below the windshield opening.
(21) Loosen (do not remove) the left lower cowl in-
strument panel attaching screw.
(22) Remove the right lower cowl instrument panel
attaching screw.
CAUTION: Protect the passenger seat cover from
soiling or damage using a suitable cover.
(23) Carefully pull the right side of the instrument
panel away from the vehicle. Allow the instrument
panel to rest on the passenger seat cushion.
CAUTION: Before proceeding with the next opera-
tion, review the Safety Precautions and Warnings at
the front of this Group.
(24) From the engine compartment, drain the cool-
ing system and disconnect the heater hoses from the
heater core nipples. Plug the nipples to avoid spilling
coolant inside the vehicle.
(25) Disconnect the refrigerant lines from the ex-
pansion-valve at the dash panel on the right side of
the vehicle. Seal the refrigerant lines to prevent con-
tamination.
(26) Remove the expansion valve from the evapo-
rator plate. Seal the valve to avoid contamination.
(27) Remove the condensate drain tube.
(28) Remove heater-A/C unit to dash panel attach-
ing nuts.
(29) From inside the vehicle, pull rearward on the
heater-A/C unit to clear the dash panel silencer and
remove the unit from the vehicle.
To install, reverse the preceding operation. Refill
cooling system and test for leaks. Evacuate and
charge the refrigerant system and test overall perfor-
mance.
AG, AJ BODY PROCEDURE
WARNING: IF EQUIPPED WITH A/C, THE REFRIG-
ERATION SYSTEM MUST BE COMPLETELY EMPTY
BEFORE PROCEEDING WITH THIS OPERATION.
(1) Disconnect the battery negative cable.
(2) Drain the coolant from cooling system. Refer to
Group 7, Cooling System.
(3) Remove the air conditioner expansion valve (if
equipped).
(4) Disconnect the heater hoses from heater core.
Then plug or cap the tubes on heater core. This will
prevent spilling coolant into the interior of vehicle
during unit removal.
(5) Remove the condensate drain tube.
(6) Disconnect the A/C-heater vacuum supply line
from vacuum supply nipple (in the engine compart-
ment).
(7) Remove the four A/C-heater assembly-to-dash
panel attaching nuts.
(8) Remove the passenger side front seat. Refer to
Group 23, Body.
(9) Remove the kick panel/sill cover at right door
opening.
(10) Remove the body computer (Fig. 6) located at
the lower right section of the right front door pillar.
(11) Remove the glove box assembly. Refer to
Group 8E, Instrument Panel.
(12) Remove the carpeted panels from both sides of
the console.
(13) Un-clip the radio antenna cable from the
metal support (Fig. 6) located behind and below the
glove box opening.
(14) Instrument panel removal is not necessary to
remove the A/C-heater assembly from the vehicle.
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HEATING AND AIR CONDITIONING
Ä
Although, part of the lower instrument panel must
be cut. The cut line is marked: CUT HERE FOR
A/C HTR REMOVAL.
This cut line is stamped (indented) into the right-
outer side of the instrument panel padding (outboard
of the glove box opening). Using a hacksaw blade,
cut the instrument panel padding along the indented
line from point A to point B (Fig. 7). CUT THE
PLASTIC ONLY. Do not cut the metal support be-
hind the instrument panel padding.
(15) Remove the metal support behind and below
the glove box opening, and the previously cut piece of
the instrument panel that is riveted to it.
(16) Remove the radio choke, security alarm mod-
ule and the lamp outage module from above the
glove box opening (if equipped).
(17) Remove the plastic cover under the steering
column.
(18) Remove the metal support under the steering
column.
(19) AJ Body only: Remove the under-panel si-
lencer pad from under the glove box opening.
(20) Remove the lower heat distribution duct (3
screws).
(21) Remove the air distribution duct through the
opening at the left side of instrument panel.
(22) Reach through glove box opening and discon-
nect the demister hoses from the top of the A/C-heat-
er assembly.
(23) Disconnect the temperature control cable from
the bottom of the A/C-heater assembly and position
out of the way.
(24) Disconnect wiring at the blower motor and
fin-sensing cycling clutch switch electrical connectors.
(25) Un-plug the antenna cable from the radio.
(26) Remove the metal (A/C-heater-to-instrument
panel) hanger strap from the upper part of the A/C-
heater assembly.
(27) Roll back the floor carpeting from under the
A/C-heater assembly far enough to avoid restricting
unit removal.
(28) Remove the A/C-heater assembly through the
opening on the right side of the console, and remove
unit from vehicle.
The instrument panel (to the left side of the glove box
opening) must be slightly folded back to remove the
unit from the vehicle. If wrinkles appear in the instru-
ment panel after the unit has been installed, they may
be removed using a heat gun. Refer to Installation AG,
AJ Body for instructions.
To install, reverse steps (28) through (13). If wrinkles
have appeared in the instrument panel, apply low heat
from a heat gun over the wrinkled area. Do not
overheat the instrument panel padding or the
surrounding area.
Reverse steps (12) through (1). If equipped with A/C,
evacuate and charge the refrigerant system.
HEATER-A/C UNIT RECONDITION
The following operation requires the removal of the
heater-A/C unit assembly from the vehicle. Refer to
Heater-A/C Unit Assembly removal and installation in
this Group.
DISASSEMBLE
(1) Place the heater-A/C unit on a suitable work
surface. (Fig. 1).
(2) Locate and remove one retaining nut from the
blend-air door pivot shaft.
Fig. 7 Cut Line For A/C-heater Removal—AG/AJ
Body
Fig. 1 Position Heater-A/C Unit for Disassembly and
Reassembly
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HEATING AND AIR CONDITIONING
24 - 63
(3) To remove the top cover from the A/C-heater
case, the crank arm must be removed (Fig. 2).
(4) Disconnect the vacuum lines from the defroster
and panel mode vacuum actuators and position them
out of the way.
(5) Remove three heater-A/C unit cover attaching
screws going upward at the defroster outlet chamber.
(6) Remove two heater-A/C unit cover attaching
screws going upward at the air inlet plenum.
(7) Remove eleven heater-A/C unit cover attaching
screws going downward into the housing. Then lift
the cover from the heater-A/C unit. (Fig. 3).
To reassemble, lower the heater-A/C unit cover
into place. Then guide the panel air mode door pivot
shaft into its socket and reverse the preceding oper-
ation.
BLEND-AIR DOOR
REMOVAL AND INSTALLATION
The following operation requires the removal of the
heater-A/C unit assembly from the vehicle. Refer to
Heater-A/C Unit Assembly removal and installation
in this Group.
(1) Remove Heater-A/C unit top cover.
(2) Remove the nut from bottom of the blend-air
door pivot shaft and lift the blend-air door from the
heater-A/C unit housing. (Fig. 4).
To install, reverse the preceding operation.
HEATER CORE
REMOVAL AND INSTALLATION
Refer to Heater A/C Unit Recondition in this
Group.
EVAPORATOR COIL
REMOVAL AND INSTALLATION
Refer to Heater A/C Unit Recondition in this
Group.
CONDENSATE DRAIN TUBE
Condensation that accumulates on the bottom of
the evaporator housing is drained from a rubber tube
through the dash panel and on to the ground. This
tube must be kept open to prevent condensate water
from collecting in the bottom of the heater A/C unit
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
Fig. 2 Blend-Air Door Crank Linkage Removal
Fig. 3 Heater-A/C Unit Cover Removal and
Installation
Fig. 4 Blend-Air Door Removal and Installation
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HEATING AND AIR CONDITIONING
Ä
the passenger compartment. It is normal to see con-
densate drainage below the vehicle. If the tube is
damaged, it should be replaced.
REMOVAL AND INSTALLATION
(1) Raise vehicle.
(2) Locate rubber Drain Tube on right side of dash
panel (Fig. 5).
(3) Squeeze clamp and remove drain tube.
To install, reverse the preceding operation. Check
the drain tube nipple on the heater-A/C housing for
any obstructions.
Fig. 5 Condensate Water Drain Tube—Typical
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HEATING AND AIR CONDITIONING
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