Content .. 434 435 436 437 ..

Dodge Neon / Neon SRT-4. Manual - part 436

(2) Position the accumulator into the engine com-

partment.

(3) Install

the

bolt

securing

the

accumulator

mounting bracket. Tighten the bolt to 11 N·m (97 in.
lbs.).

(4) Remove the tape or plugs from the opened suc-

tion and liquid line fittings and accumulator ports.

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

refrigerant oil and install them on the suction 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 recommended for
the compressor in the vehicle.

(6) Reconnect the suction line fittings to the accu-

mulator.

(7) Install the nuts that secure the suction line fit-

tings to the accumulator. Tighten the nuts to 2.3 N·m
(20 in. lbs.).

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

low pressure switch.

(9) If equipped, reinstall the vehicle speed control

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

(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).

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
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. 16).

(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. 17) 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.

Fig. 16 Condensate Water Drain Tube – Typical

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

24 - 52

PLUMBING

PL/SRT-4

ACCUMULATOR - 2.0L LHD MODELS (Continued)

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.

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) 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. 18).

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. 19).

Fig. 17 Heater Core - LHD Shown, RHD Typical

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

Fig. 18 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

PL/SRT-4

PLUMBING

24 - 53

HEATER CORE (Continued)

(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.

(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

(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. 20).

(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. 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

PL/SRT-4

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 tap-

ping block. On 2.0L LHD models, the liquid line con-
tains the variable orifice valve (VOV) and the low
side service port and is only serviced as an assembly,
except for the rubber O-ring seals and the service
port valve core. On 2.4L and RHD models, the liquid
line is serviced in two sections and contains the high
side service port.

CAUTION: Use only O-ring seals specified for the
vehicle. Failure to use correct O-ring seal will cause
the refrigerant system connection to leak.

The O-ring seals used on the connections are made

from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals must be replaced when-
ever the liquid line is removed and installed.

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

ing or damaged, it must be replaced.

REMOVAL

WARNING: Review the warnings and cautions in the
front of this section before performing the following
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING - A/C SYSTEM) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION - A/C SYSTEM).

2.0L LHD MODELS

(1) Recover the refrigerant from the refrigerant

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

(2) Remove the bolt that secures the liquid line fit-

ting to the condenser outlet port (upper fitting) (Fig.
21).

(3) Disconnect the liquid line fitting from the con-

denser outlet port 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 accumulator (Refer to 24 - HEAT-

ING & AIR CONDITIONING/PLUMBING/ACCU-
MULATOR - REMOVAL).

(6) Remove the two bolts that secure the suction

and liquid line fittings to the evaporator tube tapping
plate (Fig. 22).

(7) Disconnect the suction and liquid line fittings

from the evaporator tube tapping plate.

(8) Remove the gasket from the evaporator tube

tapping plate and discard.

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

tion and liquid line fittings and the evaporator tube
tapping plate ports.

(10) Remove the liquid line from the engine com-

partment.

Fig. 20 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

PL/SRT-4

PLUMBING

24 - 55

HEATER RETURN HOSE (Continued)

Content .. 434 435 436 437 ..