Content .. 156 157 158 159 ..

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

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

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

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

24 - 32

HEATING AND AIR CONDITIONING

REMOVAL AND INSTALLATION (Continued)

Content .. 156 157 158 159 ..