Chrysler PT Cruiser. Manual - part 982

of the accumulator provides the port through which
the A/C low pressure switch monitors the refrigerant
system pressures.

The accumulator cannot be repaired and, if faulty

or damaged, it must be replaced. The acummulator
tapping block and refrigerant lines, the rubber
O-rings and the A/C low pressure switch are avail-
able for service replacement.

OPERATION

Refrigerant enters the accumulator through the

inlet tube as a low pressure vapor. Any liquid, oil-
laden refrigerant falls to the bottom of the accumu-
lator, which acts as a separator. A desiccant bag
located inside the accumulator absorbs any moisture
which may have entered and become trapped within
the refrigerant system.

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.

NOTE: The Accumulator tubes can be serviced sep-
arately from the accumulator.

(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) If equipped, relocate the vehicle speed control

servo as necessary to access the accumulator (Refer
to 8 - ELECTRICAL/SPEED CONTROL/SERVO -
REMOVAL).

(4) Disconnect the wire harness connector from the

A/C low pressure switch (Fig. 14).

(5) Remove the nuts that secure the A/C suction

line and the A/C liquid line to the accumulator tube
tapping block.

(6) Disconnect the A/C suction line and the A/C liq-

uid line from the accumulator tube tapping block and
remove and discard the O-ring seals.

(7) Install plugs in, or tape over the opened suc-

tion and liquid line fittings and the accumulator tap-
ping block ports.

(8) Remove the bolt that secures the accumulator

bracket to the frame rail.

(9) Remove the two bolts securing the accumulator

tubes to the evaporator tube tapping block.

(10) Disconnect the accumulator tubes from the

evaporator tube tapping block and remove and dis-
card the gasket.

(11) Install a plug in, or tape over the opened

accumulator tube fittings and the evaporator ports.

(12) Remove the accumulator and evaporator tubes

as an assembly from the engine compartment and
place them on a workbench.

(13) Remove the bolts that secure the accumulator

tubes to the accumulator.

(14) Disconnect the accumulator tubes from the

accumulator and remove and discard the O-ring
seals.

(15) Install plugs in, or tape over the opened accu-

mulator tube fittings and the accumulator ports.

(16) Remove the A/C low pressure switch from the

accumulator and remove and discard the O-ring seal.

Fig. 13 Accumulator - Typical

1 - A/C LOW PRESSURE SWITCH
2 - PRESSURE SWITCH FITTING
3 - OUTLET TO COMPRESSOR
4 - ANTI-SIPHON HOLE
5 - DESICCANT BAG
6 - OIL RETURN ORIFICE FILTER
7 - VAPOR RETURN TUBE
8 - ACCUMULATOR DOME
9 - O-RING SEAL
10 - INLET FROM EVAPORATOR

24 - 50

PLUMBING

ACCUMULATOR (Continued)

INSTALLATION

NOTE: If the accumulator 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.

NOTE: The Accumulator tubes can be serviced sep-
arately from the accumulator.

(1) Install the A/C low pressure switch onto the

accumulator using a new O-ring seal. Hand-tighten
the switch securely.

(2) Remove the tape or plugs from the opened

accumulator tube fittings and the accumulator ports.

(3) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them onto the accumulator
tube fittings. Use only the specified O-rings as they
are 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 accumulator tubes to the accumu-

lator.

(5) Install the two bolts that secure the accumula-

tor tubes to the accumulator. Tighten the bolts to 11
N·m (97 in. lbs.).

(6) Position

the

accumulator

and

accumulator

tubes into the engine compartment as an assembly.

(7) Remove the tape or plugs from the opened

accumulator tube fittings and the evaporator ports.

(8) Lubricate a new gasket with clean refrigerant

oil and install it onto the evaporator tube tapping
block. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.

(9) Connect the accumulator tubes to the evapora-

tor tube tapping block.

(10) Install the two bolts that secure the accumu-

lator tubes to the evaporator tube tapping block.
Tighten the bolts to 11 N·m (97 in. lbs.).

(11) Install the bolt that secures the accumulator

bracket to the frame rail. Tighten the bolt to 10 N·m
(89 in. lbs.).

(12) Remove the tape or plugs from the opened

suction and liquid line fittings and the accumulator
tube tapping block.

(13) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them on the suction and
liquid line fittings. Use only the specified O-rings as
they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.

(14) Connect the A/C suction line and the A/C liq-

uid line to the accumulator tube tapping block.

(15) Install the nuts that secure the A/C suction

line and the A/C liquid line to the accumulator tube
tapping block. Tighten the nuts to 5 N·m (44 in. lbs.).

(16) Connect the wire harness connector to the A/C

low pressure switch.

(17) If equipped, reinstall the vehicle speed control

servo (Refer to 8 - ELECTRICAL/SPEED CONTROL/
SERVO - INSTALLATION).

(18) Reconnect the negative battery cable.
(19) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE).

(20) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE

REFRIGERANT

SYSTEM

CHARGE).

CONDENSATION DRAIN TUBE

DESCRIPTION

Condensation that accumulates in the HVAC hous-

ing is drained out of the housing through a tube and
on to the ground. The condensation drain tube must

Fig. 14 Accumulator and Accumulator tubes - LHD

shown, RHD similar

1 - A/C SUCTION LINE
2 - A/C LIQUID LINE
3 - NUT (2)
4 - ACCUMULATOR TUBES
5 - BOLTS (2)
6 - A/C LOW PRESSURE SWITCH
7 - EVAPORATOR TUBE TAPPING BLOCK
8 - FRAME RAIL
9 - BOLT (2)
10 - ACCUMULATOR
11 - BOLT
12 - WIRE HARNESS CONNECTOR

PLUMBING

24 - 51

ACCUMULATOR (Continued)

be kept open to prevent condensate water from col-
lecting in the bottom of the HVAC housing.

The tapered end of the drain tube is designed to

keep contaminants from entering the HVAC housing.
If the tube is pinched or blocked, condensate cannot
drain, causing water to back up and spill into the
passenger compartment. It is normal to see conden-
sate drainage below the vehicle in warm weather. If
the tube is damaged, it should be replaced.

REMOVAL

(1) Raise vehicle on a hoist.
(2) Locate the condensate water drain tube on

right side of dash panel under the hood (Fig. 15).

(3) Squeeze the retaining clamp and remove drain

tube.

INSTALLATION

(1) Position the condensate water drain tube over

the HVAC housing drain.

(2) Squeeze the retaining clamp and install the

condensate water drain tube onto the HVAC housing
drain.

(3) Lower the vehicle.

HEATER CORE

DESCRIPTION

The heater core (Fig. 16) is located in the HVAC

housing, behind the instrument panel. It is a heat
exchanger made of rows of tubes and fins. One end of
the core is fitted with a molded plastic tank that
includes the integral heater core tubes.

OPERATION

Engine coolant is circulated through the heater

hoses and heater core at all times. As the coolant
flows through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend door
allows control of the heater output air temperature
by regulating the amount of air that is flowing
through the heater core within the HVAC housing.
The blower motor speed controls the volume of air
flowing through the HVAC housing.

The heater core 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.

Fig. 15 Condensate Water Drain Tube – Typical

1 - DASH PANEL
2 - RETAINING CLAMP
3 - CONDENSATE WATER DRAIN TUBE
4 - HVAC HOUSING DRAIN

Fig. 16 Heater Core - LHD Shown, RHD Typical

1 - LOWER HVAC HOUSING
2 - HEATER CORE TUBES
3 - HEATER CORE

24 - 52

PLUMBING

CONDENSATION DRAIN TUBE (Continued)

(1) Remove the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).

(2) Disassemble the HVAC housing to access the

heater core (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).

(3) Lift the heater core out of the lower half of the

HVAC housing (Fig. 17).

INSTALLATION

(1) Install the heater core into the bottom half of

the HVAC housing.

(2) Assemble the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).

NOTE: If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/RE-
VERSE FLUSHING).

(3) Install the HVAC housing (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).

HEATER INLET HOSE

REMOVAL

(1) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).

(2) Remove the heater hose retainer and separate

the heater inlet and return hoses (Fig. 18).

(3) Using spring tension clamp pliers, compress

and slide the clamps off of each end of the hose being
removed.

CAUTION:
DO NOT apply excessive pressure on heater tubes
or

connections

when

removing

heater

hoses.

Excessive pressure may damage or deform the
tubes/heater core, causing an engine coolant leak.

(4) Disconnect each hose end by carefully twisting

the hose back and forth on the tube, while gently
pulling it away from the end of the tube.

(5) If necessary, carefully cut the hose end and

peel the hose off of the tube.

NOTE:
Replacement of the heater inlet hose will be
required if the hose ends are cut for removal.

(6) Remove the heater inlet hose from the engine

compartment.

INSTALLATION

(1) Position the heater inlet hose into the engine

compartment.

(2) Using spring tension clamp pliers, compress

and slide each clamp away from the end of the hose
being installed.

(3) Install each hose end by carefully twisting the

hose back and forth while gently pushing it onto the
tube.

(4) Using spring tension clamp pliers, compress

and slide the clamps onto each end of the hose being
installed.

Fig. 17 Lower HVAC Housing - LHD Shown, RHD

Typical

1 - EVAPORATOR AND TUBES
2 - FOAM SEALS
3 - HEATER CORE AND TUBES
4 - HVAC HOUSING LOWER CASE
5 - HOUSING MOUNTING STUDS
6 - HOUSING DRAIN
7 - WIRING
8 - BLOWER MOTOR AND WHEEL

PLUMBING

24 - 53

HEATER CORE (Continued)

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