HVAC Systems - Automatic: Removal & Installation Chrysler Concorde II

REMOVAL & INSTALLATION

A/C pressure transducer is located on a valve on the discharge line. Open hood and disconnect the negative battery remote terminal. Disconnect the harness connector from the A/C pressure transducer. It is not necessary to discharge the refrigerant system. Remove the transducer with a using a 14 mm open-end wrench. To install, reverse removal procedures. Tighten pressure transducer to 50 INCH. Lbs. (6 N.m).

Disconnect negative battery remote terminal, located on right strut tower. Remove lower right underpanel silencer duct. Disconnect blower motor resistor connector. Remove blower motor resistor. To install, reverse removal procedure.

Disconnect negative battery remote terminal, located on right strut tower. Remove lower right underpanel silencer duct. Disconnect blower motor power module connector. Remove blower motor power module. To install, reverse removal procedure.

Disconnect negative battery remote terminal. Loosen and remove drive belts and disconnect compressor clutch wire lead. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove refrigerant lines from compressor and disconnect harness connector. If system is left open, place cap over open lines. Remove compressor attaching bolts. Remove compressor. If refrigerant lines were not removed, lift compressor/clutch assembly and tie it to a suitable component. For installation, reverse removal procedure. Torque compressor bolts to 21 Ft lbs. (28 N.m).

1. Remove refrigerant from A/C system using a refrigerant recovery machine. Remove engine air inlet tube and air distribution duct on vehicles equipped with 3.2/3.5L engine. Remove one nut to A/C lines at expansion valve. Loosen bolt at Filter/Drier to pivot lines away from expansion valve. Place plug/cap over open end of refrigerant lines. Gently pull A/C line out of expansion valve. Remove two #30 torx bolts retaining expansion valve to evaporator coil. Remove expansion valve from vehicle
2. Always install new O-rings when replacing expansion valve. For installation, reverse the above procedures.

Open hood and disconnect the negative battery cable remote terminal from the remote battery post. Remove instrument panel top cover. See INSTRUMENT PANEL . Remove two Sun Sensor mounting screws. Lift sensor out of instrument panel and disconnect wiring. Remove sensor from vehicle.

The sun sensor must protrude approximately 1/4 inch above the instrument panel top cover. This will ensure proper operation. For installation, reverse the above procedures.

Removal

Compressor assembly must be removed from mounting. Although, refrigerant discharge is not necessary.

1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s).
2. Remove pulley retaining snap ring with Snap Ring Pliers (C-4574), and slide pulley assembly off of compressor. Remove coil wire bracket/ground clip screw and wire harness. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing.
3. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. Check bearing for roughness or excessive leakage of grease. Replace bearing as required.

Installation

1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten the diode and coil wire bracket with retaining screw. Install field coil retaining snap ring with Snap Ring Pliers (C- 4574). Press snap ring to make sure it is properly seated in the groove.
2. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. Install pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers (C-4574). Press the snap ring to make sure it is properly seated in the groove.
3. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the shaft against the shoulder. Install front plate assembly onto shaft.
4. If installing a new front plate and/or pulley assembly, the gap between front plate and pulley face must be checked. Use the following procedure: Attach a dial indicator to front plate so that movement of the plate can be measured. With the dial indicator zeroed on the front plate, energize the clutch and record the amount of movement. The readings should be 0.35 to 0.65 mm (0.014 to 0.026 in.) If proper reading is not obtained, add or subtract shims until desired reading is obtained. Install compressor shaft bolt. Tighten to 17.5 ±2 N.m (155 ±20 in. lbs.). NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.

1. Open hood and disconnect the negative battery remote terminal. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove five push pin fasteners retaining the center front fascia. Remove two right wheel well push pin fasteners retaining front fascia. Remove right headlight housing. Remove two push pin fasteners for air flow deflectors. Remove upper radiator core support.
2. If equipped with 3.2/3.5L engine, remove two engine oil cooler lines and the hose retainer. Remove upper hose to auxiliary transmission cooler. Remove upper A/C discharge line fastener at condenser. Remove lower A/C liquid line fastener at condenser. On 300M, lower fastener may be more easily accessed by removing passenger side fog lamp.
3. On all models, remove both auxiliary transmission cooler lines. Remove auxiliary transmission cooler zip ties. Remove two bolts retaining condenser to radiator. Separate condenser from radiator. Transfer auxiliary transmission cooler to new condenser. For installation, reverse removal procedure. Use new zip ties, provided with replacement condenser.

1. Remove HVAC unit housing from vehicle. See «UNIT HOUSING»(ref-92518-S20167103782008070900000) . Remove recirculation door actuator retaining screws. Pull actuator straight off recirculation door shaft. Note actuator shaft position so it can be oriented the same way for installation.
2. Remove recirculation door and housing. Remove upper housing retaining screws. Remove upper half of heater housing. Lift evaporator out of lower housing. Transfer evaporator probe to same location on new evaporator. To install, reverse removal procedure.

1. Remove refrigerant from A/C system using a refrigerant recovery machine. Remove engine air inlet tube and air distribution duct on vehicles equipped with 3.2/3.5 liter engine. Remove one 8mm hex bolt to filter/drier bracket.
2. Remove one nut retaining A/C lines to expansion valve. Gently pry filter/drier bracket out of strut tower. Remove one A/C line at filter/drier (tubing to condenser). Remove filter/drier from vehicle. Transfer small line from filter/drier to expansion valve to new filter/drier. Always install new O-rings when replacing filter/drier.
3. Plug or cap liquid line fittings while system is open to prevent moisture intrusion. For installation, reverse above procedures. Upon installation, loosely fit all parts and lines together before individually tightening them to prevent damage. Torque filter/drier plumbing fasteners to 10 ft - lbs.

The mode door actuator is an electric motor. It mechanically positions A/C unit panel/bi-level door and floor/defrost door. This actuator contains a feedback strip which allows computer control to know exact position of mode door at all times. Mode door actuator is not serviceable and must be replaced if found to be defective. Mode door actuator is located on lower left side of HVAC unit housing.

1. Open hood and disconnect negative battery cable remote terminal from remote battery post. Remove left and right underpanel ducts. Remove floor console. Remove center floor heat adaptor duct. Remove rear seat heat forward adaptor duct.
2. Loosen center support bracket and pry rearward to gain access to actuator. Remove actuator retaining screws. Then pull actuator straight down. Upon removal, note shaft position of actuator, because shaft on this motor is keyed.
3. When installing new actuator, its shaft must be positioned in same location. Remove electrical connection on actuator. For installation, reverse above procedures.

Recirculation door actuator is located on right side of heater housing. Recirculation door actuator is an electric motor. It mechanically positions recirculation door in either open or closed position. Recirculation door actuator does not have a feedback signal. Outside Air/Recirc door actuator is not serviceable and must be replaced if found to be defective.

1. Open hood and disconnect negative battery cable remote terminal from remote battery post. Remove instrument panel. See «INSTRUMENT PANEL»(ref-92518-S13878750672008071100000) . Remove actuator retaining screws. Pull actuator straight off recirculation door shaft. Upon removal, note shaft position of actuator, because shaft on this motor is keyed.
2. When installing new actuator, its shaft must be positioned in same location. Disconnect electrical connection. Remove recirculation door motor from vehicle. For installation, reverse above procedures.

Blend-air (temperature) door actuator is an electric motor which mechanically positions temperature door. A feedback strip in actuator allows computer control to know exact position of temperature door at all times. Blend-air door actuator is not serviceable and must be replaced if found to be defective. Temperature door actuator is located at bottom of heater housing at center tunnel.

1. Open hood and disconnect negative battery cable remote terminal from remote battery post. Remove left and right underpanel silencer/ducts. Remove two screws from actuator which are accessible from right side of center stack. Remove one screw from actuator on left side. Pull actuator straight down from shaft and disconnect electrical connection.
2. Upon removal, note shaft position of actuator, because shaft on this motor is keyed. When installing new actuator, its shaft must be positioned in same location. For installation, reverse above procedures.

1. Disconnect negative battery cable to prevent accidental air bag deployment. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-96526-S40034165492001041800000) . Remove instrument panel from vehicle. See «INSTRUMENT PANEL»(ref-92518-S13878750672008071100000) . Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine cooling system. Remove air filter hose and air distribution duct from engine. Remove spring type fasteners from heater hoses and remove hoses from dashboard. Plug hoses to prevent spilling coolant in vehicle interior. 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.
2. Remove one nut retaining both hoses to expansion valve and cap lines to prevent moisture from entering A/C lines. Remove 3 nuts from studs projecting through firewall into engine compartment retaining HVAC unit housing. Remove 2 screws to defrost duct and remove duct. Remove 2 nuts and 2 screws attaching HVAC unit housing to dashboard. Remove nuts retaining rear seat heater duct and remove. Remove rear seat heater duct elbow push pin fastener.
3. Disconnect harness connector from HVAC unit housing. Gently pull HVAC unit housing rearward from dash panel, taking care hot to spill any coolant into passenger compartment. To install, reverse removal procedure.

1. Disconnect negative battery cable to prevent accidental air bag deployment. See DISABLING & ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove one Allen screw from shifter knob. Remove left and right instrument panel end covers. (Scheme 13) On LHS/300M vehicles, center bezel must be removed prior to shifter bezel. Using a trim stick (special tool #C-4755), gently pry up on shifter bezel, disconnect two wire connectors, one illumination bulb socket and remove. Remove 2 screws from lower instrument panel cover (outside end) and disconnect trunk lid release switch harness connector. Pull rearward on lower instrument panel cover releasing clips. Remove cable to brake release handle. Pull rearward and remove instrument panel cover from vehicle.
2. On six passenger vehicles, remove the lower floor bin and proceed with next step. On five passenger vehicles, use trim stick to gently remove center bezel. Disconnect wire harnesses connected to HVAC control and traction control switch. Remove bezel from vehicle. Remove two screws to left console side cover, pull outboard and remove from vehicle. Lower glove box door. Remove two screws to right console side cover, pull outboard and remove from vehicle. Remove two front bracket screws and two screws inside console bin to remove console.
3. On all models, remove 2 nuts attaching lower center instrument panel. Remove 4 bolts to steel reinforcement from bottom of lower instrument panel cover. Disconnect 16-way Data Link Connector (DLC) from steel reinforcement. Remove one screw to left floor duct/silencer pad and remove from vehicle. Remove steering column from vehicle. See «REMOVAL & INSTALLATION»(ref-91316-S21120431862001030700000).
4. Disconnect 2 harness connectors to HVAC housing. Disconnect Air Bag Control Module (ACM) and 2 ground wires on left of floor tunnel near bulk-head. Gently pry out on both left and right "A" pillar trim moldings and slide rearward to remove. Gently pry up on instrument panel top cover and remove toward rear of vehicle. Remove one screw from right and left scuff plates. Gently pry out on both scuff plates to remove.
5. Remove 3 screws from both left and right kick panels and remove. Remove right side under dash silencer pad. Disconnect 2 harness connectors to radio antenna and amplifier DIN cable on right side. Disconnect harness connectors to Body Control Module (BCM). Remove 8 remaining screws retaining instrument panel to body. Pull rearward on instrument panel.
6. Ensure all harnesses are free and clear from obstructions. Remove instrument panel from vehicle. To install, reverse removal procedure.

Scheme 13

The ambient temperature sensor is located on the inside of right front bumper beam. Remove sensor mounting screw and disconnect sensor harness connector. To install, reverse removal procedure.

Heater A/C Control Head is located in instrument panel center bezel. See INSTRUMENT PANEL for Removal and Installation procedures.

The evaporator temperature sensor is located on the lower right side of the heater housing. Open hood and disconnect the negative battery remote terminal. Remove right under panel silencer. Disconnect harness connector for evaporator probe. At center of heater housing, locate evaporator probe access plate. Using a flat blade pry tool, pull back on the locking tab. Twist the access plate counter clockwise one-quarter turn and remove plate. Pull probe out of evaporator core. The plate must be pushed inside the A/C unit and orientated in such a way that the plate can be removed.

To install, reverse removal procedure. The new probe must not go into the same hole (in the evaporator coil) that the old probe was removed. The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole.

Disconnect the negative battery remote terminal. Remove lower right under panel duct. Remove blower motor connector from resistor block/power module. Squeeze blower motor wiring grommet and push grommet through blower motor housing cover. Remove blower motor housing cover. Remove blower motor retaining screws. Lower blower motor from housing. To install, reverse removal procedure.

ATC In-Car Temperature Sensor is located in Control Head. Control Head must be removed for service to sensor.

1. Open hood and disconnect the negative battery cable remote terminal from the remote battery post. Remove snap-on center bezel which holds the ATC Control. Disconnect the ATC Control from the vehicle wiring harness.
2. If ATC in-car temperature sensor (fault 26) is verified to be bad, then ATC control section of assembly must be replaced. If ATC in-car sensor does not pass paper test, see «IN-CAR TEMPERATURE SENSOR AIRFLOW CHECK»(ref-92518-S40019581142001033000000) , then problem may only be with ATC In-Car Sensor Fan-Motor assembly.
3. Remove fan-motor assembly from ATC control with two screws located on back of ATC control. Replace only fan-motor assembly if control does not pass paper test, but passes with no fault code 26 (bad thermistor). For installation, reverse above procedures. NOTE: Retest control. If ATC control still fails paper test, then replace ATC control and fan-motor assembly. ATC Control must be replaced if part fails fault code 26 (after confirming proper wiring connections).

Disconnect negative battery cable remote terminal, located on right strut tower. Remove lower right underpanel silencer duct. Disconnect blower motor power module connector. Remove blower motor power module. To install, reverse removal procedure.

Remove ATC control panel. Locate in-car temperature sensor aspirator fan assembly at back of ATC control panel. Remove aspirator fan assembly screws and remove aspirator fan assembly. To install, reverse removal procedure.

1. Disconnect negative battery cable remote terminal located on right strut tower. Remove instrument panel top cover. Remove sun load sensor mounting screws. Lift sun load sensor from instrument panel and disconnect connector.
2. To install, reverse removal procedure. Ensure sun load sensor protrudes about 0.25" (6.4 mm) above instrument panel top cover. If necessary, two 1/4-20 nuts and longer screws can be used to shim sensor higher.

Automatic A/C-Heater System Wiring Diagram (2000 Concorde, Intrepid, LHS & 300M). Scheme 14

Automatic A/C-Heater System Wiring Diagram (2001 Concorde, Intrepid, LHS & 300M). Scheme 15