Chrysler PT Cruiser. Manual - part 983

(5) Install the heater hose retainer.
(6) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

HEATER RETURN HOSE

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) 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. 19).

(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 return hose will be
required if the hose ends are cut for removal.

(6) Remove the heater return hose from the engine

compartment.

Fig. 18 Heater Hose Assembly- LHD 2.0L Shown,

RHD Typical

1 - HEATER HOSES
2 - HEATER HOSE CLAMPS
3 - HEATER HOSE RETAINER
4 - HEATER HOSE CLAMPS
5 - HEATER CORE TUBES
6 - ENGINE HEATER PIPES

Fig. 19 Heater Hose Assembly- LHD 2.0L Shown,

RHD Typical

1 - HEATER HOSES
2 - HEATER HOSE CLAMPS
3 - HEATER HOSE RETAINER
4 - HEATER HOSE CLAMPS
5 - HEATER CORE TUBES
6 - ENGINE HEATER PIPES

24 - 54

PLUMBING

HEATER INLET HOSE (Continued)

INSTALLATION

(1) Position the heater return 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.

(5) Install the heater hose retainer.
(6) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

LIQUID LINE

DESCRIPTION

The A/C liquid line is the refrigerant line that goes

from the A/C condenser to the accumulator tube ter-
minal block. The A/C liquid line contains the variable
orifice valve (VOV) and is only serviced as an assem-
bly, except for the rubber O-ring seals.

The A/C liquid line cannot be repaired and, if leak-

ing or damaged, it must be replaced.

REMOVAL

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING - STANDARD PROCEDURE - REFRIGERANT
SYSTEM RECOVERY).

(2) Remove the nut that secures the A/C liquid line

to the A/C condenser (lower port) (Fig. 20).

(3) Disconnect the A/C liquid line from the A/C

condense and remove and discard the O-ring seal.

(4) Install plugs in, or tape over the opened liquid

line fitting and the condenser outlet port.

(5) Remove the nut that secures the A/C liquid line

(outboard fitting) to the accumulator tube tapping
block (Fig. 21).

(6) Disconnect the A/C liquid line from the accu-

mulator tube tapping block and remove and discard
the O-ring seal.

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

line fitting and the accumulator tube tapping block
inlet port.

(8) Remove the A/C liquid line from the engine

compartment.

Fig. 20 A/C Condenser Refrigerant Lines - Typical

1 - A/C CONDENSER
2 - A/C LIQUID LINE
3 - A/C DISCHARGE LINE
4 - RADIATOR ASSEMBLY

Fig. 21 A/C Refrigerant Lines - Typical

1 - ACCUMULATOR TUBE TAPPING BLOCK
2 - NUT (2)
3 - A/C SUCTION LINE
4 - A/C LIQUID LINE

PLUMBING

24 - 55

HEATER RETURN HOSE (Continued)

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 liquid line into the engine

compartment.

(2) Remove the tape or plugs from the liquid line

fitting and the accumulator tube tapping block port.

(3) 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 A/C
compressor in the vehicle.

(4) Connect the A/C liquid line to the accumulator

tube.

(5) Install the nut that secures the A/C liquid to

the accumulator tube. Tighten the nut to 5 N·m (44
in. lbs.).

(6) Remove the tape or plugs from the condenser

outlet port and the liquid line fitting.

(7) Lubricate a new rubber O-ring seal with clean

(8) Connect the A/C liquid line to the A/C con-

denser.

(9) 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.).

(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 -

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

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

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE

REFRIGERANT

SYSTEM

CHARGE).

REFRIGERANT

DESCRIPTION

The refrigerant used in this air conditioning sys-

tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas. Even though
R-134a

does

not

contain

chlorine,

must

reclaimed and recycled just like CFC-type refriger-
ants. This is because R-134a is a greenhouse gas and
can contribute to global warming.

OPERATION

R-134a refrigerant is not compatible with R-12

refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.

R-134a refrigerant system service ports, service

tool couplers and refrigerant dispensing bottles have
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.

REFRIGERANT OIL

DESCRIPTION

The refrigerant oil used in R-134a refrigerant sys-

tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.

There are different PAG oils available, and each

contains a different additive package. The 10S15 and
10S17 compressors used in this vehicle is designed to
use an ND-8 PAG refrigerant oil. Use only refriger-
ant oil of this same type to service the refrigerant
system.

OPERATION

After performing any refrigerant recovery or recy-

cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.

PAG refrigerant oil is much more hygroscopic than

mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.

24 - 56

PLUMBING

LIQUID LINE (Continued)

STANDARD PROCEDURE

REFRIGERANT OIL LEVEL

CAUTION: The oil used in the A/C compressor is
ND-8 PAG R-134a refrigerant oil. Only refrigerant oil
of the same type should be used to service the A/C
system. Do not use any other refrigerant oil. The oil
container should be kept tightly capped until it is
ready for use and then tightly capped after use to
prevent

contamination

from

dirt

and

moisture.

Refrigerant oil will quickly absorb any moisture it
comes in contact with, therefore, special effort must
be used to keep all R-134a system components
moisture-free. Moisture in the refrigerant oil is very
difficult to remove and will cause a reliability prob-
lem with the A/C compressor.

NOTE: Most reclaim/recycling equipment will mea-
sure the lubricant being removed during recovery.
This amount of lubricant should be added back into
the system. Refer to the reclaim/recycling equip-
ment manufacturers instructions.

It will not be necessary to check the oil level in the

A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to component
replacement, or a rupture or leak from a refrigerant
line, connector fitting, component or component seal.
If a leak occurs, add 30 milliliters (1 fluid ounce) of
the recommended refrigerant oil to the refrigerant
system after the repair has been made. Refrigerant
oil loss will be evident at the leak point by the pres-
ence of a wet, shiny surface around the leak.

Refrigerant oil must be added when an accumula-

tor, A/C evaporator or A/C condenser is replaced. See
the Refrigerant Oil Capacities chart. When an A/C
compressor is replaced, the refrigerant oil must be
drained from the old compressor and measured.
Drain all of the refrigerant oil from the new A/C com-
pressor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the
old compressor.

REFRIGERANT OIL CAPACITIES

Component

Total System Fill

180

6.1

Accumulator, receiver/
drier

1.0

Condenser

1.0

Evaporator

2.0

Compressor

Drain and measure the
oil from the old
compressor - see text.

SUCTION LINE

DESCRIPTION

The A/C suction line is the refrigerant line that

goes from the accumulator tube terminal block to the
A/C compressor. The A/C suction line is only serviced
as an assembly, except for the rubber O-ring seals.

The A/C suction 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 suction

line to the top of the A/C compressor (Fig. 22).

(4) Disconnect the A/C suction line from the A/C

compressor and remove and discard the O-ring seal.

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

tion line fitting and the compressor inlet port.

(6) If equipped with the 2.4L Turbo engine, remove

the nut that secures the suction line retaining
bracket to the thermostat housing stud bolt.

(7) Remove the nut that secures the A/C suction

line (inboard fitting) to the accumulator tube tapping
block (Fig. 23).

PLUMBING

24 - 57

REFRIGERANT OIL (Continued)

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