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

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

(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

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

(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.

(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

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.

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

PLUMBING

24 - 49

A/C EVAPORATOR (Continued)

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