HVAC Systems - Service Information Chrysler Crossfire I final

Scheme 1

The Residual Engine Heat System (REST) system enables the vehicle to be heated with the Ignition "OFF". The REST switch (4) in the Heater-A/C Controls activates this system.

HEATING & AIR CONDITIONING

A manual dual-zone temperature control type heating-air conditioning system is standard on this model.

Scheme 2

This vehicle is equipped with a common HVAC housing assembly. The system combines Air Conditioning, Heating, and Ventilating capabilities in a single unit housing mounted under the Instrument Panel.

COOLING SYSTEM REQUIREMENTS

To maintain the performance level of the Heating and Air Conditioning System, the engine cooling system must be properly maintained. Any obstructions in front of the radiator or condenser will reduce the performance of the Air Conditioning and Engine Cooling Systems.

The engine cooling system includes the heater core and the heater hoses. Refer to COOLING - SERVICE INFORMATION article for more information before attempting any service to the Engine Cooling System.

REFRIGERANT SYSTEM SERVICE PORT

Note. Unique service port coupler sizes are used on the R-134a system to ensure that the refrigerant system is not accidentally contaminated by the use of the wrong refrigerant (R-12), or refrigerant system service equipment.

The two refrigerant system service ports are used to charge, recover/recycle, evacuate, and test the air conditioning refrigerant system.

Scheme 3

The high pressure service port (1) is located on the liquid line near the front of the engine compartment behind the front grille.

Scheme 4

The low pressure service port (1) is located on the suction line on the left side of the engine compartment near the shock mounting.

RESIDUAL ENGINE HEAT SYSTEM (REST) SYSTEM

The REST system is activated by a switch in the Heater-A/C Controls when the ignition is turned "OFF". This system circulates residual heat from the engine to the Heater Core. The coolant is recirculated by an auxiliary coolant pump mounted below the right front headlamp. The temperature is automatically adjusted according to the temperature setting in the Heater-A/C Controls. The REST system will automatically be shut off when

1. The Ignition Key is Turned "ON"
2. After Approximately 30 Minutes of Operation
3. If Battery Voltage Falls Below 11.5 Volts

Outside fresh air enters the vehicle through the cowl top opening at the base of the windshield (1), and passes through a plenum chamber to the HVAC housing. Air flow can then be adjusted by the blower motor (2) speed switch on the A/C Heater Control Panel. The fresh air then travels through the evaporator (6) and the heater core (5) then out into the vehicle through the side and floor vents (3-4).

It is also important to keep the air intake openings clear of debris because leaf particles and other debris that is small enough to pass through the cowl plenum screen can accumulate within the HVAC housing. This closed, warm, damp and dark environment created within the HVAC housing is ideal for the growth of certain molds, mildews and other fungi. Any accumulation of decaying plant matter provides an additional food source for fungal spores, which can enter the housing with the fresh air. Excess debris, as well as objectionable odors created by decaying plant matter and growing fungi can be discharged into the passenger compartment during HVAC system operation.

Scheme 5

The A/C Compressor (8) is driven by the engines accessory drive belt. The A/C compressor (8) compresses the gaseous refrigerant (7) which heats up and flows into the condenser (6). The heat resulting from the compression is absorbed from the refrigerant by the surface of the condenser (6). As the refrigerant cools down it liquefies becoming a high-pressure liquid (4). As the refrigerant (4) flows through the receiver/drier (5) it is purified of chemical and mechanical impurities. It then travels to the expansion valve (3) which sprays the cooled, low pressure liquid (4) into the evaporator (1), located in the fresh air flow. The refrigerant (4) evaporates in the evaporator (1). This evaporation process absorbs heat from the fresh air flowing across the system of tubes and honeycombs, therefore cooling the air that is blown into the passenger compartment. The low pressure gas then returns to the A/C compressor.

Scheme 6

The moisture in the fresh air is condensed out and the condensation drained to the outside through a drain in the HVAC housing. The air is dried. The A/C compressor sucks in the refrigerant which has become gaseous due to the absorption of heat and compresses it again. When the engine is running and with blower switched on, cooled air can flow into the passenger compartment through various outlet openings. The intensity of cooling depends on the passenger compartment temperature set and the blower output.

The mode control on the A/C Heater Control Panel is used to direct the conditioned air to the selected system outlets. The mode control switches directs engine vacuum to control the mode doors, which are operated by vacuum actuators. The mode control switches electrical current to control the mode doors, which are operated by actuators.

1. Mode Control (1)
2. Passenger Temperature Control (2)
3. Air Conditioning Button (3)
4. REST Button (4)
5. Driver's Temperature Control (5)
6. Fan Control (6)
7. Rear Defogger Button (7)

Scheme 7

The Water Pump (7) pumps coolant through the engine (3). There the coolant absorbs heat from the engine (3), heating up the coolant. Then the heated coolant flows through into the Heater Core (4) where the heat is transferred to the air in the passenger compartment. The coolant flowing through the Heater Core (4) is controlled by a Coolant Circulation Valve (6) located in the coolant return. The coolant can be controlled separately for the left and right sides.

The coolant returns to the Water Pump (7) via the coolant return hose. A Coolant Circulation Pump (5) is installed between the Coolant Circulation Valve (6) and the Water Pump (7). The Coolant Circulation Pump (5) serves for maintaining a uniform flow of heating water through the Heater Core (4) even at low engine speeds and in the Residual Engine Heat Utilization (REST) mode. The major portion of the coolant flows from the engine (3) to the Thermostat (2) instead of flowing through the Heater Core (4). The Thermostat (2) routes the water through the radiator (8) or directly to the Water Pump (7) depending on the temperature.

Scheme 8

In a blend-air system, a Blend Door controls the amount of unconditioned air (or cooled air from the Evaporator) that is allowed to flow through, or around, the Heater Core (3). A temperature control knob on the A/C Heater Control Panel determines the discharge air temperature by energizing the Blend Door Actuator, which operates the Blend Door. This allows an almost immediate control of the output air temperature of the system.

REST SYSTEM

The Coolant Circulation Pump pumps the heated coolant to the Heater Core when the engine is off. When the REST button (4) is pressed the temperature is controlled by the A/C Heater Control Module (in the same manner as when the Ignition is ON). The A/C Heater Control module switches the Coolant Circulation Pump on which drives the impeller via a magnetic clutch. A light in the switch will illuminate indicating that the REST system is active.

HEATING & AIR CONDITIONING - A/C PERFORMANCE TESTING

The Air Conditioning System is designed to provide the passenger compartment with low temperature and low humidity air. The Evaporator (6), located in the HVAC housing behind the Instrument Panel, is cooled to temperatures near the freezing point. As warm damp air passes through the cooled Evaporator (6), the air transfers its heat to the refrigerant in the Evaporator (6) and the moisture in the air condenses on the Evaporator fins.

Humidity has an important bearing on the temperature of the air delivered to the interior of the vehicle. It is important to understand the effect that humidity has on the performance of the Air Conditioning System. When humidity is high, the evaporator has to perform a double duty. It must lower the air temperature, and it must lower the temperature of the moisture in the air that condenses on the evaporator fins. Condensing the moisture in the air transfers heat energy into the Evaporator fins and tubing. This reduces the amount of heat the Evaporator can absorb from the air. High humidity greatly reduces the ability of the Evaporator to lower the temperature of the air.

However, Evaporator capacity used to reduce the amount of moisture in the air is not wasted. Wringing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers. Although, an owner may expect too much from their Air Conditioning System on humid days. A performance test is the best way to determine whether the system is performing up to standard. This test also provides valuable clues as to the possible cause of trouble with the Air Conditioning System.

The air temperature in the test room and in the vehicle must be a minimum of 21° C (70° F) for this test.

1. Connect a manifold gauge set.
2. Set the A/C Heater mode control switch knob (2) in the Panel position, the temperature control knob (7) in the full cool position, the A/C button in the On position, and the blower motor switch knob (6) in the highest speed position.
3. Start the engine and hold the idle at 1,300 RPM with the compressor clutch engaged.
4. The engine should be at operating temperature. The doors and windows must be open.
5. Insert a thermometer in the driver side center A/C (panel) outlet. Operate the engine for five minutes.
6. The compressor clutch may cycle, depending upon the ambient temperature and humidity.
7. With the compressor clutch engaged, record the discharge air temperature and the compressor discharge pressure.
8. Compare the discharge air temperature to the Performance Temperature and Pressure chart. Performance Temperature and Pressure Ambient Air Temperature and Humidity 21° C (70° F @ 80% humidity) 27° C (80° F @ 80% humidity) 32° C (90° F @ 80% humidity) 38° C (100° F @ 50% humidity) 43° C (110° F @ 20% humidity) Air Temperature at Center Panel Outlet 10 to 13° C (50 to 55° F) 14 to 17° C (58 to 63° F) 15 to 18° C (60 to 65° F) 17 to 20° C (63 to 68° F) 14 to 17° C (58 to 63° F) Evaporator Inlet Pressure at Charge Port 241 to 276 kPa (35 to 40 psi) 262 to 290 kPa (38 to 42 psi) 269 to 296 kPa (39 to 43 psi) 275 to 303 kPa (40 to 44 psi) 262 to 290 kPa (38 to 42 psi) Compressor Discharge Pressure 1241 to 1792 kPa (180 to 260 psi) 1380 to 1930 kPa (200 to 280 psi) 1380 to 1930 kPa (200 to 280 psi) 1655 to 2206 kPa (240 to 320 psi) 1567 to 2068 kPa (220 to 300 psi) Note: The discharge air temperatures will be lower if the humidity is less than the percentages shown.
9. Compare the compressor discharge pressure to the Performance Temperature and Pressure chart. If the compressor discharge pressure is high, see the Pressure Diagnosis chart below.

Scheme 9

Before performing the following tests, refer to COOLING - SERVICE INFORMATION article for the procedures to check the radiator coolant level, serpentine drive belt tension, radiator air flow and the radiator fan operation. Also be certain that the accessory vacuum supply line is connected at the engine intake manifold for the manual temperature control system.

MAXIMUM HEATER OUTPUT

Engine coolant is delivered to the Heater Core through two heater hoses. With the engine idling at normal operating temperature, set the temperature control knob (2 and 5) in the full hot position, the Mode Control Switch Knob (1) in the floor heat position, and the Blower Motor Switch Knob (6) in the highest speed position. Using a test thermometer, check the temperature of the air being discharged at the HVAC housing floor outlets. Compare the test thermometer reading to the Temperature Reference chart.

If the floor outlet air temperature is too low, refer to COOLING - SERVICE INFORMATION article to check the engine coolant temperature specifications. Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than the coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine coolant flow obstruction in the cooling system. Refer to the COOLING - SERVICE INFORMATION article for the procedures.

OBSTRUCTED COOLANT FLOW

Possible locations or causes of obstructed coolant flow

1. Pinched or kinked heater hoses.
2. Improper heater hose routing.
3. Plugged heater hoses or supply and return ports at the cooling system connections.
4. A plugged heater core.

If proper coolant flow through the cooling system is verified, and heater outlet air temperature is still low, a mechanical problem may exist.

MECHANICAL PROBLEMS

Possible locations or causes of insufficient heat

1. An obstructed cowl air intake.
2. Obstructed heater system outlets.
3. A blend door not functioning properly.
4. An air-bound system.

TEMPERATURE CONTROL

If the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the A/C Heater control panel, the following could require service

1. The A/C heater control.
2. The blend door actuator(s).
3. The wire harness circuits for the A/C heater control or the blend door actuator(s).
4. The blend door(s).
5. Improper engine coolant temperature.

SPECIFICATIONS - A/C APPLICATION

SPECIFICATIONS - CHARGE CAPACITY

The R-134a refrigerant system charge capacity for this vehicle is 0.850 kilograms (1.875 lbs.).

SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

Scheme 10

The pulley (1) on the A/C compressor drive shaft (4) is driven by the poly-V-belt. The clutch turns on the ball bearing (3) around the magnetic coil (5) fastened to the A/C compressor housing. The pressure plate (6) with rubber insert (7) is connected to the A/C compressor drive shaft (4) by splines (8) allowing it to move in the axial direction.

OPERATION - A/C COMPRESSOR CLUTCH

In order to start operating the refrigerant compressor, the heater A/C control module actuates the electromagnetic clutch and the solenoid (5) is supplied with electrical current. The magnetic force attracts the pressure plate (6) against the rubber insert (7) and holds it securely. This creates the connection between the engine and the compressor. If the solenoid (5) is de-energized, then the pressure plate (6) is pressed back by the rubber insert (7) into its rest position and the connection is interrupted.

The clutch also preforms a safety shutoff of the compressor. To prevent a mechanical defect in the compressor from causing the accessory drive belt to jump loose, the electromagnetic clutch releases itself automatically. With a mechanical defect, the compressor rotates more sluggishly or even locks completely. The heat generated at the friction surface causes the melting fuse (2) in the solenoid (5) to melt. The current supply to the solenoid (5) is interrupted and the frictional connection is released.

The A/C compressor clutch is not serviced separately. The A/C compressor clutch must be replaced as a unit with the A/C compressor.

TESTING - A/C COMPRESSOR CLUTCH

For circuit descriptions and diagrams, refer to the appropriate wiring diagrams. The battery must be fully-charged before performing the following tests. Refer to BATTERY SYSTEM article for more information.

1. Connect an ammeter (0 to 10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0 to 20 volt scale) with clip-type leads for measuring the voltage across the battery and the compressor clutch coil.
2. With the a/c heater mode control switch in any a/c mode, the a/c heater control a/c switch in the ON position, and the blower motor switch in the lowest speed position, start the engine and run it at normal idle.
3. The compressor clutch coil voltage should read within 0.2 volts of the battery voltage. If there is voltage at the clutch coil, but the reading is not within 0.2 volts of the battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as required. If there is no voltage reading at the clutch coil, use a scan tool and the appropriate diagnostic information for testing of the compressor clutch circuit. The following components must be checked and repaired as required before you can complete testing of the clutch coil: A/C Heater Control Module Mode Control Switch A/C Pressure Transducer A/C Evaporator Temperature Sensor
4. The compressor clutch coil is acceptable if the current draw measured at the clutch coil is 2.0 to 3.9 amperes with the electrical system voltage at 11.5 to 12.5 volts. This should only be checked with the work area temperature at 21° C (70° F). If system voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the system voltage drops below 12.5 volts. If the clutch coil current reading is four amperes or more, the coil is shorted and should be replaced. If the clutch coil current reading is zero, the coil is open and should be replaced.

A/C COMPRESSOR CLUTCH BREAK-IN

After a new compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C Heater control in the Recirculation Mode, the A/C button in the on position, the blower motor switch in the highest speed position, and the engine speed at 1500 to 2000 RPM. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability.

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Scheme 14

1. Remove the lower instrument panel cover (2) from the instrument panel (1). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Disconnect the blower motor electrical connector (1) from the relief in the blower motor door.
3. Slide the motor door catch mounts (1) to the sides.
4. Swing the blower motor door down. NOTE: The electrical leads are a one-way connection to the blower motor.
5. Disconnect the electrical leads blue (2) and red (3).
6. Remove the screws (1) attaching the blower motor resistor (4) to the blower motor assembly.
7. Remove the blower motor (4) resistor from the assembly.

BLOWER MOTOR RESISTOR

1. Install the blower motor resistor assembly (4) to the heater case.
2. Install the screws (1) attaching the blower motor resistor to the blower motor assembly. NOTE: The electrical leads are a one-way connection to the blower motor.
3. Connect the electrical leads blue (2) and red (3).
4. Swing the blower motor door up.
5. Slide the motor door catch mounts (1) to the inside.
6. Connect the blower motor electrical connector (1).
7. Install the lower instrument panel cover. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

DESCRIPTION - A/C HEATER CONTROL MODULE

The manual temperature control HVAC system uses a combination of electrical, and vacuum controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. Refer to the owner's manual for more information on the suggested operation and use of these controls.

Both A/C heater control module panels are located on the instrument panel inboard of the steering column and above the radio. The A/C heater control panel contains two rotary-type temperature control knobs (2 and 5), a rotary-type mode control switch knob (1), a rotary-type blower motor speed switch knob (6) and an air conditioning compressor push button switch (3).

OPERATION - A/C HEATER CONTROL MODULE

Dual zone temperature control provides a side-to-side variation in comfort temperatures to exceed the needs of either front seat occupant.

The A/C Heater Control Module panels are serviced only as complete units and cannot be repaired. If faulty or damaged, the entire A/C Heater Control Module must be replaced.

The A/C Heater Control Module makes it possible to make adjustments coming from the driver such as

1. "Temperature" by setting the temperature thumb-wheels. (2 and 5)
2. "Air quantity" by adjusting the blower switch setting. (6)
3. "Air distribution" by setting the air distribution switch. (1)
4. "Recirculating air" by pressing the recirculating air push-button. (4)
5. Activating the residual engine heat utilization system with the ignition switched off by pressing the REST button. (4)
6. Switching off the A/C by pressing the EC button (3).

The A/C Heater Control Module integrated in the push-button control module looks after all system regulation and control functions, such as

1. Automatic switch over from fresh air to recirculated air mode.
2. Electrical control of the A/C compressor.
3. Control of the electric fan for the engine/air conditioning system.

REMOVAL - A/C HEATER CONTROL MODULE

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1. Disconnect the negative battery cable.
2. Remove the radio. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/antenna-systems/#audio-system-service-information) .
3. Remove the center console panel screws (1). Position aside the finish panel (2). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
4. Pull out the A/C heater control module by pressing in the catch lugs (1) at the sides.
5. Disconnect the electrical connector (1) by swinging the retaining bow down.
6. Remove the A/C heater control module.

INSTALLATION - A/C HEATER CONTROL MODULE

1. Connect the electrical connector (1) by swinging the retaining bow up.
2. Install the A/C heater control module (2) by pressing in the catch lugs (1) at the sides.
3. Install the center console panel screws (1-2). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
4. Install the radio. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/antenna-systems/#audio-system-service-information) .
5. Connect the negative battery cable.

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Scheme 20

1. Disconnect the negative battery cable.
2. Remove the engine compartment lower panel.
3. Open the installation flap for left fog lamp located in the left inner fenderwell towards the front.
4. Disconnect the ambient air temperature harness connector (2) located next to the front fascia mount (1).
5. Unclip the ambient air temperature from the front bumper support.

INSTALLATION - AMBIENT TEMP SENSOR

1. Clip the ambient air temperature to the front bumper support.
2. Connect the ambient air temperature harness connector (2).
3. Close the installation flap for left fog lamp located in the left inner fenderwell.
4. Install the engine compartment lower panel.
5. Connect the negative battery cable.

Scheme 21

1. Remove the center console. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Remove the evaporator temperature sensor located on the left side of the heater A/C case.
3. Disconnect the evaporator temperature sensor harness connector from the sensor.

Scheme 22

1. Connect the evaporator temperature sensor harness to the evaporator temperature sensor (1).
2. Push the evaporator temperature sensor (1) into the A/C heater case.
3. Install the center console. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

Scheme 23

1. Remove the center console. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Remove the heater core temperature sensor (1) located on the front of the heater A/C case (2).
3. Disconnect the heater core temperature sensor harness connector from the sensor.

INSTALLATION - HEATER CORE TEMPERATURE SENSOR

1. Connect the heater core temperature sensor harness connector to the sensor.
2. Install the heater core temperature sensor (1) to the front of the heater A/C case (2).
3. Install the center console. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

Scheme 24

1. Evacuate the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Disconnect the A/C pressure transducer harness connector (2).
3. Remove the A/C pressure transducer from the receiver/dryer (1).

INSTALLATION - A/C PRESSURE TRANSDUCER

1. Install the A/C pressure transducer to the receiver/dryer (1).
2. Connect the A/C pressure transducer harness connector (2).
3. Charge the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

Scheme 25

1. Remove the glove compartment. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Disconnect the vacuum lines (1) from the recirculation switchover valve.
3. Disconnect the recirculation switchover valve harness connector from the recirculation switchover valve.
4. Remove the recirculation switchover valve.

INSTALLATION - RECIRCULATION AIR SWITCHOVER VALVE

1. Install the recirculation switchover valve.
2. Connect the recirculation switchover valve harness connector to the recirculation switchover valve.
3. Connect the vacuum lines (1) to the recirculation switchover valve.
4. Install the glove compartment. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

Scheme 26

1. Remove the lower instrument panel cover (2) from the instrument panel (1). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Disconnect the blower motor electrical connector (1) from the relief in the blower motor door.
3. Slide the blower motor door catch mounts (1) to the inside.
4. Swing the blower motor door down.
5. Remove the screws (1) attaching the blower motor to the heater housing.
6. Remove the blower motor and squirrel cage as an assembly.

Scheme 27

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Scheme 30

1. Disconnect the negative battery cable.
2. Remove the left lower instrument panel cover (2) from the instrument panel (1).
3. Disconnect the blower motor harness connector (1) from the relief in the blower motor door.
4. Slide the blower motor door catch mounts (1) to the sides.
5. Swing the blower motor door down.
6. Remove the screws (1) attaching the blower motor to the heater housing.
7. Remove the blower motor and squirrel cage as an assembly.

Scheme 31

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Scheme 33

1. Install the blower motor and squirrel cage as an assembly.
2. Install the screws (1) attaching the blower motor to the heater housing.
3. Swing the blower motor door up.
4. Install the blower motor door catch mounts (1) by sliding them over to the detents.
5. Connect the blower motor harness connector (1).
6. Install the left lower instrument panel cover (2).
7. Connect the negative battery cable.

Scheme 34

1. Install the blower motor and squirrel cage as an assembly.
2. Install the screws (1) attaching the blower motor to the heater housing.
3. Swing the blower motor door up.
4. Install the blower motor door catch mounts (1) by sliding them over to the detents.
5. Connect the blower motor electrical connector (1).
6. Install the lower instrument panel cover (2). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

HVAC HOUSING - LHD

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1. Disconnect the negative battery cable.
2. Evacuate the refrigerant from the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) . CAUTION: Do not open cooling system unless coolant temperature is below 90° C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.
3. Relieve the pressure in the cooling system by turning the cap on supply reservoir to catch "1" and then tightening it back to its rest position.
4. Drain the coolant from the engine cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
5. Remove the hot water hose clamp (1) located inboard from the brake booster on the bulkhead, then remove and plug off the hot water hose.
6. Remove the two hot water hose clamps (1) from hot water hoses located on the right side of the bulkhead, then remove the two A/C hoses from the expansion valve.
7. Remove the instrument panel top section (1). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
8. Remove the lower instrument panel (2). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
9. Remove the lower instrument panel (2). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
10. Remove the instrument cluster cover (1). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
11. Remove the green insulating mats.
12. Remove the nuts for the instrument cluster holder then remove instrument cluster. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#instrument-cluster-service-information) .
13. Remove the Sentry Key Remote Entry Module (SKREEM) by: Disconnect the 2-pin CAN harness connector from the SKREEM (1). Disconnect the 2-pin harness connector for the transponder coil (1). Disconnect the 18-pin harness connector (1). Press the retaining tabs apart (1). Remove the SKREEM control module from the base plate. NOTE: This is necessary to remove the instrument panel support from the vehicle.
14. Remove all of the wiring harness nylon ties attaching the wiring harnesses on the instrument panel support.
15. Remove any harness connectors (1) or electric leads on the body transmission tunnel.
16. Remove the bolts and nuts (1) attaching the steering column to the instrument panel support. NOTE: It is not necessary to fully remove the steering column from the vehicle.
17. Relocate the steering column out of the working area. WARNING: Be sure you have taken the necessary precautions to disable the airbag system.
18. Remove the electrical harness connector (1) on passenger airbag module.
19. Remove the heater ducts on left and right side of the instrument panel support.
20. Remove the nuts (1) on the heater case attaching it to the instrument panel support.
21. Remove the bolts from the instrument panel support attaching it to the body transmission tunnel.
22. Remove the bolts (1) attaching the instrument panel support to the front of the vehicle bulkhead.
23. Remove the bolts (1) attaching the instrument panel support to the A-pillars.
24. Disconnect the connectors (1) from the vacuum reservoir. CAUTION: To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support.
25. Remove the instrument panel support.
26. Remove the electrical harness connector on heater core temperature sensor located on the front of the heater housing and the evaporator temperature sensor (1) located on the left side of the heater case.
27. Disconnect the electrical harness connector from the fresh air/recirculating air flap switchover valve (1) located on the right front of the heater housing where the vacuum lines for the reservoir where removed.
28. Remove all the nylon ties on the heater housing attaching any wiring harnesses. CAUTION: To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support. CAUTION: Be sure not to spill any residual coolant from the heater housing into the passenger compartment of the vehicle.
29. Remove the heater housing from the vehicle by tipping it forward and removing through the passenger side door.

HVAC HOUSING - RHD

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Disconnect the negative battery cable (1).
2. Evacuate the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
3. Disconnect the A/C lines from the A/C expansion valve (2). See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
4. Drain the cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
5. Disconnect the right side heater hoses (1).
6. Disconnect the heater hose behind the battery on the left side of the engine compartment.
7. Remove the steering wheel and steering column. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
8. Remove the instrument cluster bezel (1) by removing the five screws then pulling out at the bottom and down at the top. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
9. Remove the front and rear center consoles. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
10. Remove the I/P top cover. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
11. Remove the instrument cluster and bracket assembly. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
12. Disconnect the SKREEM harness connectors and remove SKREEM module and mounting bracket. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/door-locks-anti-theft-systems/#vehicle-theft-security-system-service-information) .
13. Remove the glove box assembly. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
14. Disconnect the passenger side air bag harness connector (1).
15. Disconnect the vacuum reservoir solenoid connector and vacuum hose (2) then remove the vacuum reservoir.
16. Disconnect the recirculated air switchover valve connector (3).
17. Remove the center I/P support to bulkhead bolts and nuts (2).
18. Disconnect the heater core temperature sensor (1).
19. Disconnect the evaporator temperature sensor (1).
20. Remove the I/P support bolts (4) to the A-pillar on the right and left sides of the I/P support.
21. Remove the I/P support.
22. Disconnect the HVAC unit drain tubes.
23. Remove the HVAC unit from vehicle.

1. Install the HVAC unit into vehicle.
2. Connect the HVAC unit drain tubes.
3. Install the I/P support bar into the vehicle.
4. Install the I/P support bar bolts (4) attaching the support bar to the A-pillar on the right and left sides of the support bar.
5. Connect the evaporator temperature sensor (1).
6. Connect the heater core temperature sensor (1).
7. Install the center I/P support bar to bulkhead bolts and nuts (2).
8. Connect the recirculated air switchover valve connector (3).
9. Install the vacuum reservoir then connect the vacuum reservoir solenoid connector and vacuum hose (2).
10. Connect the passenger side air bag harness connector (1).
11. Install the glove box assembly. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
12. Install the SKREEM module and mounting bracket. Then connect the SKREEM harness connectors. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/door-locks-anti-theft-systems/#vehicle-theft-security-system-service-information) .
13. Install the instrument cluster and bracket assembly. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
14. Install the I/P top cover. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
15. Install the front and rear center consoles. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
16. Install the instrument cluster bezel (1). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
17. Install the right and left lower instrument panel covers.
18. Install the steering column and wheel. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
19. Connect the heater hose (1) behind the battery.
20. Connect the A/C lines to the A/C expansion valve (2). Then connect the two heater hoses (1) to the HVAC case.
21. Connect the negative battery cable (1).
22. Charge the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
23. If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
24. Fill the cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .

Scheme 53

Note. Open and close catches with a plastic wedge or a suitable coin.

1. Turn the plugs (1) 90° to the left and remove the fuse cover (3).
2. Remove the screw located in the upper bezel of the air nozzle (2), tilt the deflector up to reveal the screw (arrow).
3. Pull the air nozzle out toward the rear.

Scheme 54

1. Remove the cover on the center console. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .
2. Remove the screws attaching the center air nozzle to the center console cover (2).
3. Disconnect the air nozzle catch clips (3).
4. Remove the air nozzle from the center console cover (4).

INSTALLATION - AIR OUTLETS - CENTER AIR NOZZLE

1. Connect the air nozzles catch clips (3).
2. Install the screws (2) attaching the center air nozzle (1) to the center console cover (4).
3. Install the cover on the center console. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/gauges-instrument-panels/#body-interior-exterior-service-information) .

INSTALLATION - AIR OUTLETS - SIDE AIR NOZZLE

Note. When installing connect the air nozzle to the air duct.

1. Install the side air nozzle to the vehicle.
2. Install the screw located in the upper bezel of the air nozzle (2), tilt the deflector up to reveal the screw hole.
3. Turn the plugs (1) 90° to the right to install the fuse cover.

Scheme 55

1. The defroster duct is part of the upper top section of the instrument panel. There are plastic trim pieces which make up the final duct distribution. These trim pieces can be removed by, removing the screws (1) in the outside edge of the trim piece the inner edge is held into place by a tab slid under the top section of the instrument panel.

INSTALLATION - DEFROSTER DUCTS

1. Install the defroster duct trim piece into the top section of the instrument panel. Then install the screw (1).

Scheme 56

Scheme 57

Scheme 58

1. Turn the screw 90° (1) on the vent (4) to the left and remove the front cover (3) away from the rear portion (2).
2. Remove the screw (1) attaching the footwell air outlet cover to the center console (2).
3. Slide the panel (2) forward to release the hooks and then remove from the center console (1).

INSTALLATION - FLOOR DISTRIBUTION DUCTS - FOOTWELL AIR OUT COVER

1. Install the cover by sliding the panel rearward.
2. Install the screw attaching the footwell air outlet cover to the center console.
3. Install the cover then turn the screw 90° to the right.

DESCRIPTION - REFRIGERANT LINES/HOSES/TUBES

The refrigerant lines and hoses are used to carry the refrigerant between the various Air Conditioning System components

1. Evaporator (1)
2. Expansion Valve (3)
3. Receiver/Drier (5)
4. Condenser (6)
5. A/C Compressor (8)

A barrier hose design with a nylon tube, which is sandwiched between rubber layers, is used for the R-134a air conditioning systems. This nylon tube helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum or steel, and commonly use braze-less fittings.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

There are two types of refrigerant fittings

1. All fittings with O-rings need to be coated with refrigerant oil before installation. Use only O-rings that are the correct size and approved for use with R-134a refrigerant. Failure to do so may result in a leak.
2. Unified plumbing connections with gaskets cannot be serviced with O-rings. The gaskets are not reusable and new gaskets do not require lubrication before installing.

Using the proper tools when making a refrigerant plumbing connection is very important. Improper tools or improper use of the tools can damage the refrigerant fittings. Always use two wrenches when loosening or tightening tube fittings. Use one wrench to hold one side of the connection stationary, while loosening or tightening the other side of the connection with a second wrench.

The refrigerant must be recovered completely from the system before opening any fitting or connection. Open the fittings with caution, even after the refrigerant has been recovered. If any pressure is noticed as a fitting is loosened, tighten the fitting and recover the refrigerant from the system again.

Do not discharge refrigerant into the atmosphere. Use an R-134a refrigerant recovery/recycling device that meets SAE Standard J2210.

The refrigerant system will remain chemically stable as long as pure, moisture-free R-134a refrigerant and refrigerant oil is used. Dirt, moisture, or air can upset this chemical stability. Operational troubles or serious damage can occur if foreign material is present in the refrigerant system.

When it is necessary to open the refrigerant system, have everything needed to service the system ready. The refrigerant system should not be left open to the atmosphere any longer than necessary. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture. All lines and components in parts stock should be capped or sealed until they are to be installed.

All tools, including the refrigerant recycling equipment, the manifold gauge set, and test hoses should be kept clean and dry. All tools and equipment must be designed for R-134a refrigerant.

WARNINGS

CAUTIONS

LEAK TESTING

If the air conditioning system is not cooling properly, determine if the refrigerant system is fully-charged. See DIAGNOSIS AND TESTING .

An electronic leak detector designed for R-134a refrigerant is recommended for locating and confirming refrigerant system leaks. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

An oily residue on or near refrigerant system lines, connector fittings, components, or component seals can indicate the general location of a possible refrigerant leak. However, the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement.

To detect a leak in the refrigerant system, perform one of the following procedures

SYSTEM EMPTY

1. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Connect and dispense 0.283 kilograms (0.625 pounds or 10 ounces) of R-134a refrigerant into the evacuated refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
4. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components.
5. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, the A/C button in the On position, and select the Recirculation Mode.

SYSTEM LOW

1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run with the air conditioning system turned on for five minutes.
3. With the engine not running, use an electronic R-134a leak detector and search for leaks. Because R-134a refrigerant is heavier than air, the leak detector probe should be moved slowly along the bottom side of all refrigerant lines, connector fittings and components.
4. To inspect the evaporator coil for leaks, insert the electronic leak detector probe into the center instrument panel outlet. Set the blower motor switch to the lowest speed position, the A/C button in the On position, and select the Recirculation Mode.

REFRIGERANT SYSTEM EVACUATION PROCEDURE

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be charged. If moisture and air enters the system and becomes mixed with the refrigerant, the compressor head pressure will rise above acceptable operating levels. This will reduce the performance of the air conditioner and damage the compressor. Evacuating the refrigerant system will remove the air and boil the moisture out of the system at near room temperature. To evacuate the refrigerant system, use the following procedure

1. Connect a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 and a manifold gauge set to the refrigerant system of the vehicle.
2. Open the low and high side valves and start the charging station vacuum pump. When the suction gauge reads 88 kPa (26 in. Hg.) vacuum or greater, close all of the valves and turn off the vacuum pump. If the refrigerant system fails to reach the specified vacuum, the system has a leak that must be corrected. See «DIAGNOSIS AND TESTING»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) . If the refrigerant system maintains the specified vacuum for five minutes, restart the vacuum pump, open the suction and discharge valves and evacuate the system for an additional ten minutes.
3. Close all of the valves, and turn off the charging station vacuum pump.
4. The refrigerant system is now ready to be charged with R-134a refrigerant. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

DESCRIPTION - REFRIGERANT SYSTEM SERVICE EQUIPMENT

When servicing the air conditioning system, a R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used. Contact an automotive service equipment supplier for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

A manifold gauge set may be needed with some recovery/recycling/charging equipment. The service hoses on the gauge set being used should have manual (turn wheel), or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere.

MANIFOLD GAUGE SET CONNECTIONS

LOW PRESSURE GAUGE HOSE

The low pressure hose (Blue with Black stripe) attaches to the suction service port. This port is located on the suction line near the driver side of the engine compartment.

HIGH PRESSURE GAUGE HOSE

The high pressure hose (Red with Black stripe) attaches to the discharge service port. This port is located on the discharge line between the compressor and the condenser inlet behind the front grille.

RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE

The center manifold hose (Yellow, or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.

REFRIGERANT SYSTEM RECHARGING PROCEDURE

After the refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system.

A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.

PARTIAL CHARGE METHOD

The partial charge method is used to add a partial charge to a refrigerant system that is low on refrigerant. To perform this procedure the evaporator inlet and outlet tube temperatures are measured. The temperature difference is measured with a temperature meter with one or two clamp-on thermocouple probes. The difference between the evaporator inlet and outlet tube temperatures will determine the amount of refrigerant needed.

Before adding a partial refrigerant charge, check for refrigerant system leaks. See DIAGNOSIS AND TESTING . If a leak is found, make the necessary repairs before attempting a full or partial refrigerant charge.

1. Attach a manifold gauge set to the refrigerant system service ports.
2. Attach the two clamp-on thermocouple probes to the inlet and outlet tubes of the evaporator coil. If a single thermocouple probe is used, attach the probe to the evaporator inlet tube just before the collar of the refrigerant line connector fitting. The probe must make contact with the bottom surface of the evaporator inlet tube. If dual thermocouple probes are used, attach probe 1 to the evaporator inlet tube, and probe 2 to the evaporator outlet tube. Attach both probes to the evaporator tubes just before the collar of the refrigerant line connector fittings. The probes must make contact with the bottom surfaces of the evaporator inlet and outlet tubes.
3. Open all of the windows or doors of the passenger compartment.
4. Set the A/C button on the A/C Heater controls to the on position, the temperature control knob in the full cool position, select Recirculation Mode, and place the blower motor switch in the highest speed position.
5. Start the engine and hold the engine idle speed at 1,000 RPM. Allow the engine to warm up to normal operating temperature.
6. The compressor clutch may cycle, depending upon ambient temperature, humidity, and the refrigerant system charge level.
7. Hold the engine idle speed at 1,000 RPM.
8. Allow three to five minutes for the refrigerant system to stabilize, then record the temperatures of the evaporator inlet and outlet tubes. If a single probe is used, record the temperature of the evaporator inlet tube. Then remove the probe from the inlet tube and attach it to the evaporator outlet tube just before the collar of the refrigerant line connector fitting. The probe must make contact with the bottom surface of the evaporator outlet tube. Allow the thermocouple and meter time to stabilize, then record the temperature of the evaporator outlet tube. Subtract the inlet tube temperature reading from the outlet tube temperature reading. If dual probes are used, record the temperatures of both the evaporator inlet and outlet tubes. Then subtract the inlet tube temperature reading from the outlet tube temperature reading.
9. If the measured temperature differential is higher than 22° C to 26° C (40° F to 47° F), add 0.4 kilograms (14 ounces) of refrigerant.
10. Allow three to five minutes for the refrigerant system to stabilize, then take a second set of thermocouple measurements. Record the temperature difference to determine if an additional charge is required.
11. Record the compressor discharge pressure. If the reading is higher than the pressure shown in the COMPRESSOR DISCHARGE PRESSURE CHART below, the system could be overcharged. If the reading is equal to, or lower than the pressure shown in the chart below, continue with this procedure. Compressor Discharge Pressure Chart Ambient Temperature 16°C (60°F) 21°C (70°F) 27°C (80°F) 32°C (90°F) 38°C (100°F) 43°C (110°F) Compressor Discharge Pressure 1378 kPa (200 psi) 1516 kPa (220 psi) 1723 kPa (250 psi) 1930 kPa (280 psi) 2206 kPa (320 psi) 2413 kPa (350 psi) EXAMPLE: The ambient temperature is 21° C (70° F). The evaporator inlet tube temperature is 12° C (54° F) and the evaporator outlet tube temperature is 10° C (50° F). Subtract the inlet tube temperature from the outlet tube temperature. The difference is -2° C (-4° F). With a -2° C (-4° F) temperature differential at 21° C (70° F) ambient temperature, the system is fully charged.
12. Add enough refrigerant to bring the refrigerant system up to a full charge.
13. Remove the jumper wire from the low pressure cycling clutch switch wire harness connector and plug the connector back into the switch.

REFRIGERANT RECOVERY PROCEDURE

A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to recover the refrigerant from an R-134a refrigerant system. Refer to the operating instructions supplied by the equipment manufacturer for the proper care and use of this equipment.

DESCRIPTION - A/C COMPRESSOR

The Air Conditioning System uses a Nippondenso, double-acting swash plate-type compressor. This compressor has a fixed displacement of 170 cubic centimeters (10.374 cubic inches). A label identifying the use of R-134a refrigerant is located on the underhood fuse panel cover.

The A/C system uses 1.97 Lbs. (0.88 Kg.) of R-134a type refrigerant.

Scheme 59

After the Electromagnetic Clutch has produced the frictional connection between the engine and the compressor, the drive shaft (1) drives the swash plate (3). The rotation of the inclined swash plate (3) causes the pistons (4) to move in strokes. During the intake stroke, refrigerant vapor is sucked in via the inlet valve (6). If the piston (4) moves in the counter direction, it delivers the refrigerant vapor via the pressure control valve (7), with the vapor being compressed and heating up, into the refrigerant line to the condenser.

A/C COMPRESSOR NOISE TESTING

When investigating an air conditioning related noise, you must first know the conditions under which the noise occurs. These conditions include: weather, vehicle speed, transmission in gear or neutral, engine speed, engine temperature, and any other special conditions. Noises that develop during air conditioning operation can often be misleading. For example: What sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose compressor clutch assembly.

Drive belts are speed sensitive. At different engine speeds and depending upon belt tension, belts can develop noises that are mistaken for a compressor noise. Improper belt tension can cause a misleading noise when the compressor clutch is engaged, which may not occur when the compressor clutch is disengaged. Check the accessory drive belt condition and tension as described in the Cooling article before beginning this procedure. Refer to DIAGNOSIS AND TESTING .

Scheme 60

1. Select a quiet area for testing. Duplicate the complaint conditions as much as possible. Switch the compressor on and off several times to clearly identify the compressor noise. Listen to the compressor while the clutch is engaged and disengaged. Probe the compressor with an engine stethoscope or a long screwdriver with the handle held to your ear to better localize the source of the noise.
2. Loosen all of the compressor mounting hardware and retighten. Tighten the compressor clutch mounting nut. Be certain that the clutch coil is mounted securely to the compressor, and that the clutch plate and pulley are properly aligned and have the correct air gap.
3. To duplicate a high-ambient temperature condition (high head pressure), restrict the air flow through the condenser. Install a manifold gauge set to be certain that the discharge pressure does not exceed 2760 kPa (400 psi).
4. Check the refrigerant system plumbing for incorrect routing, rubbing or interference, which can cause unusual noises. Also check the refrigerant lines for kinks or sharp bends that will restrict refrigerant flow, which can cause noises.
5. If the noise is from opening and closing of the high pressure relief valve, reclaim, evacuate, and recharge the refrigerant system. If the high pressure relief valve still does not seat properly, replace the a/c compressor. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
6. If the noise is from liquid slugging on the suction line, check the refrigerant oil level and the refrigerant system charge.
7. If the noise continues, replace the compressor and repeat. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

REMOVAL - A/C COMPRESSOR

1. Evacuate the refrigerant from the system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Disconnect the negative battery cable.
3. Remove the accessory drive belt. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
4. Raise and support the vehicle.
5. Remove the lower engine compartment panel.
6. Remove the three compressor bolts (1) attaching it to the engine block.
7. Remove the bolts on the high side and the low side pressure lines.
8. Disconnect the A/C harness connector from the compressor.

INSTALLATION - A/C COMPRESSOR

1. Connect the A/C harness connector to the compressor.
2. Install the bolts on the high side and the low side pressure lines. Tighten to 23 N.m (17 ft. lbs.).
3. Install the A/C compressor then install the three bolts (1). Tighten to 23 N.m (17 ft. lbs.).
4. Install the lower engine compartment panel.
5. Install the accessory drive belt. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
6. Connect the negative battery cable.
7. Charge the refrigerant to the system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

DESCRIPTION - COOLANT CIRCULATION PUMP

The Coolant Circulation Pump is used to maintain a uniform flow of coolant through the Heater Core even at low engine speeds and in the Residual Engine Heat Utilization mode (R.E.S.T.).

FUNCTION IN HEATING MODE

The quantity of coolant pumped into the heater core with the engine running depends on the coolant pump. The coolant circulation pump ensures that the water flows through the heater core uniformly without bubbles even at low speeds. The coolant circulation pump is controlled by the A/C heater control module.

FUNCTION WITH RESIDUAL ENGINE HEAT UTILIZATION

The coolant circulation pump, pumps the heated coolant to the heater core when the engine is OFF. When the R.E.S.T. button is pressed the temperature is controlled by the A/C heater control module (in the same manner as when the ignition is ON). The A/C heater control module switches the electric motor for the coolant circulation pump which drives the impeller via a magnetic clutch.

Scheme 61

1. Drain the coolant system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
2. Remove the headlamp assembly (4) from the right side of the vehicle. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/exterior-lights/#lighting-systems-exterior-service-information) .
3. Disconnect the coolant circulation pump harness connector from the coolant circulation pump (3).
4. Disconnect the two hoses (2) from the coolant circulation pump (3).
5. Remove the two bolts (1) from the coolant circulation pump (3).
6. Remove the coolant circulation pump (3).

INSTALLATION - COOLANT CIRCULATION PUMP

1. Install the coolant circulation pump (3) into the vehicle.
2. Install the two bolts (1) attaching the coolant circulation pump (3) to the vehicle.
3. Install the coolant circulation pump harness connector to the coolant circulation pump (3).
4. Install the two hoses (2) the coolant circulation pump (3).
5. Install the headlamp assembly to the vehicle. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/exterior-lights/#lighting-systems-exterior-service-information) .
6. Fill the coolant system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .

Scheme 62

The A/C Condenser is located in the air flow in front of the engine cooling radiator. The Condenser transforms the refrigerant from gaseous into liquid. It is attached to the vehicle with two bolts (1) and to the A/C lines with fittings.

OPERATION - A/C CONDENSER

When the refrigerant gas (7) gives up its heat, it condenses. When the refrigerant leaves the Condenser (6), it has become a high-pressure liquid refrigerant (4). The volume of air flowing over the Condenser fins (6) is critical to the proper cooling performance of the Air Conditioning System. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the Condenser fins (6) that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or condenser service.

The Condenser (6) cannot be repaired and, if faulty or damaged, it must be replaced. See REMOVAL .

REMOVAL - A/C CONDENSER

Scheme 63

Scheme 64

1. Disconnect the negative battery cable.
2. Evacuate the refrigerant from the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) . WARNING: Open the cooling system only when the coolant temperature is below 90°C. Open the cap slowly and reduce the pressure. Wear protective gloves, protective clothing and protective goggles.
3. Relieve pressure in cooling system by turning the radiator cap on the reservoir to catch "1".
4. Remove the radiator fan. Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
5. Remove the coolant reservoir (1). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
6. Remove the refrigerant lines (1) from the condenser.
7. Loosen the mount for the condenser connection fittings (1-2).
8. Tilt the radiator forward and remove the condenser.

Scheme 65

Scheme 66

Scheme 67

1. Install the condenser.
2. Tighten the mount for the condenser connection fittings (1-2).
3. Install the refrigerant lines (1) to the condenser. Tighten to 24 N.m (18 ft. lbs.).
4. Install the radiator. Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
5. Install the lower radiator hose to the radiator.
6. Install the upper radiator hose (1) to the radiator.
7. Install the radiator fan (1). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
8. Install the coolant reservoir (1). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
9. Fill the coolant. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
10. Charge the refrigerant in the refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
11. Connect the negative battery cable.

DESCRIPTION - A/C EVAPORATOR

The Evaporator Coil is located in the HVAC housing, under the Instrument Panel. The Evaporator Coil is positioned in the HVAC housing so that all air that enters the housing must pass over the fins of the Evaporator before it is distributed through the system ducts and outlets. However, air passing over the Evaporator Coil fins will only be conditioned when the compressor is engaged and circulating refrigerant through the Evaporator Coil tubes.

OPERATION - A/C EVAPORATOR

Refrigerant enters the Evaporator from the orifice tube as a low-temperature, low-pressure liquid. 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 vaporize. The refrigerant becomes a low-pressure gas before it leaves the evaporator.

The Evaporator Coil cannot be repaired and, if faulty or damaged, it must be replaced. See REMOVAL .

REMOVAL - A/C EVAPORATOR

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. Remove the HVAC housing. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Remove the heater core. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
3. Remove the valve strip on the top of the HVAC housing by removing the four screws and removing the aluminum lines from the housing.
4. Disconnect the vacuum lines from the vacuum element (2).
5. Separate the blower housing from air distribution housing, unclip the two sliding clips (1).
6. Remove the four spring clips.
7. Remove the screw (1) behind the expansion valve.
8. Remove the foam gasket.
9. Remove the air distribution housing upper section by removing the spring clips.
10. Remove the evaporator from the housing.

INSTALLATION - A/C EVAPORATOR

1. Install the evaporator to the housing.
2. Install the air distribution housing upper section by installing the spring clips.
3. Install the foam gasket.
4. Install the screw (1) behind the expansion valve.
5. Connect the blower housing to air distribution housing, clip the two sliding clips (1).
6. Install the four spring clips.
7. Connect the vacuum lines to the vacuum element.
8. Install the valve strip.
9. Install the heater core. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
10. Install the HVAC housing. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

REMOVAL - LIQUID LINE

Scheme 72

1. Evacuate the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Raise and support the vehicle.
3. Remove the left front wheel and tire assembly.
4. Remove the front inner wheel well panel.
5. Remove the liquid line (1) from the receiver/dryer.
6. Remove the liquid line (1) from the condenser.

INSTALLATION - LIQUID LINE

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

1. Install the liquid line (1) to the condenser. Tighten to 24 N.m (18 ft. lbs.).
2. Install the liquid line (1) to the receiver/dryer. Tighten to 17 N.m (12 ft. lbs.).
3. Install the front inner wheel well panel.
4. Install the left front wheel and tire assembly.
5. Charge the A/C system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

REMOVAL - SUCTION LINE

Scheme 73

1. Disconnect the negative battery cable.
2. Recover the refrigerant from the refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
3. Remove the retainer nut (1) from the expansion valve (3).
4. Slide the suction line off the stud and liquid line. Remove the lines from the clip.
5. Raise and support the vehicle.
6. Remove the A/C compressor bolts (1).
7. Remove the suction line from the compressor.
8. Remove the suction line assembly from the vehicle.

INSTALLATION - SUCTION LINE

1. Install the suction line to the compressor. Tighten the mounting bolt to 23 N.m (18 ft. lbs.).
2. Install the A/C compressor bolts (1). See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
3. Slide the suction line and the liquid line over the expansion valve stud. Tighten the nut (1) to 10 N.m (88 in. lbs.).
4. Connect the negative battery cable.
5. Evacuate the refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
6. Charge the refrigerant system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

DESCRIPTION - A/C EXPANSION VALVE

The Expansion Valve is located at the front of the heater-A/C housing between the liquid and suction lines and the Evaporator Coil. The expansion valve sprays the refrigerant into the Evaporator.

The Expansion Valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced. See REMOVAL .

Scheme 74

When the A/C compressor is switched on the pressure in the evaporator decreases causing the diaphragm (1) to flex downward in an arch. The tappet (3) follows the motion of the diaphragm and presses the valve ball (4) away from its seat against the force of the spring (5). The refrigerant is sprayed into the evaporator through the open valve. Since the motion of the diaphragm (1) is dependent on the intake pressure as well as the temperature at the evaporator output, only the quantity of refrigerant which can be evaporated optimally is injected.

A/C EXPANSION VALVE TESTING

The Expansion Valve is located on the engine side of the dash panel near the shock tower.

The Expansion Valve can fail in three different positions (open, closed or restricted).

1. Open Position : this will result in a noisy compressor or no cooling. The cause can be a broken spring, broken ball or excessive moisture in the A/C system. If the spring or ball are found to be defective, replace the expansion valve. If excessive moisture is found in the A/C system, recycle the refrigerant.
2. Closed Position : There will be low suction pressure and no cooling. This may be caused by a failed power dome or excessive moisture in the A/C system. If the power dome on the expansion valve is found to be defective replace the expansion valve. If excessive moisture is found recycle the refrigerant.
3. Restricted Orifice : There will be low suction pressure and no cooling. This may be caused by debris in the refrigerant system. If debris is believed to be the cause, recycle the refrigerant and replace the expansion valve and the receiver/drier.

REMOVAL - A/C EXPANSION VALVE

1. Evacuate the refrigerant from the system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Remove the nut (1).
3. Pull the pressure lines off.
4. Remove the screws (2).
5. Remove the expansion valve (3) off of the pressure lines.

INSTALLATION - A/C EXPANSION VALVE

1. Install the expansion valve (3) to the pressure lines. NOTE: Tighten the screws evenly to avoid canting.
2. Install the bolts (2). Tighten to 8 N.m (71 in. lb.).
3. Replace the O-rings. Install the pressure lines.
4. Install the nut (1). Tighten to 10 N.m (88 in. lb.).
5. Charge the air conditioning, check for any leakage. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

DESCRIPTION - HEATER CORE

The Heater Core is located in the HVAC housing, under the Instrument Panel. It is a heat exchanger made of rows of tubes and fins.

OPERATION - HEATER CORE

Engine coolant is circulated through heater hoses to the Heater Core (3) at all times. As the coolant flows through the Heater Core (3), 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 temperature control door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the Heater Core (3). The blower motor (2) 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. See REMOVAL . Refer to COOLING - SERVICE INFORMATION article for more information on the engine cooling system.

REMOVAL - HEATER CORE

Scheme 75

Scheme 76

Scheme 77

1. Remove the HVAC housing. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Remove the bolts on the cover (1).
3. Unclip the spring clamps.
4. Remove the cover.
5. Remove the guide for the heating water flow pipe (2).
6. Remove the heating water return line (1).
7. Remove the heater core together with the heating water pipes.
8. Remove the retainer clip (1) and remove the pipe from the heater core.

INSTALLATION - HEATER CORE

1. Install the heating water pipes on the heater core then install the clip (1).
2. Install the heat exchanger together with the heating water pipes.
3. Connect the socket yoke for heating water flow pipe.
4. Install the heating water return line (1).
5. Install the guide (2) for the heating water flow pipe.
6. Install the cover (1).
7. Clip the spring clamps.
8. Install the bolts on the cover. NOTE: If the heater core is being replaced, flush the cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .
9. Install HVAC housing. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .

DESCRIPTION - RECEIVER / DRIER

The Receiver/Drier is mounted in the engine compartment between the Condenser and is part of the liquid line (1) assembly. The filter/drier cannot be repaired, if the filter/drier is faulty, damaged, left open to the atmosphere or contaminated the line assembly must be replaced. See REMOVAL .

OPERATION - RECEIVER / DRIER

The Receiver/Drier (5) performs a filtering action to prevent foreign material in the refrigerant from contaminating the Expansion Valve (3). A desiccant bag is mounted inside the Receiver/Drier canister (5) to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand A/C operation, the Receiver/Drier (5) acts as a reservoir to store surplus refrigerant. Refrigerant enters the Receiver/Drier (5) as a high-pressure, low-temperature liquid from the Condenser (6).

REMOVAL - RECEIVER / DRIER

1. Evacuate the refrigerant from the system. See «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/ac-compressor/#hvac-systems-service-information) .
2. Disconnect the electrical connector (2).
3. Remove the upper pressure line (1).
4. Remove the refrigerant pressure sensor (2).
5. Raise and support the vehicle.
6. Remove the wheel and tire assembly.
7. Remove left inner fender (front section) by removing the plastic nuts and the screws attaching the panel to the inner fender liner.
8. Remove the pressure line (1).
9. Remove the mounting nuts (2).
10. Remove the receiver/drier from the vehicle.

INSTALLATION - RECEIVER / DRIER

1. Install the receiver/drier to the vehicle.
2. Install the mounting nuts (2).
3. Install the lower pressure line (1). Tighten to 17 N.m (12 ft. lbs.).
4. Install left inner fender (front section).
5. Install the wheel and tire assembly.
6. Install the refrigerant pressure sensor (2).
7. Install the upper pressure line (1). Tighten to 17 N.m (12 ft. lbs.).
8. Connect the electrical connector (2).
9. Charge the refrigerant the system.

DESCRIPTION - REFRIGERANT

The refrigerant used in this Air Conditioning System 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-flammable, clear, and colorless liquefied gas.

Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming.

OPERATION - REFRIGERANT

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 refrigerant 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 vehicle and on the Compressor identifying to service technicians that the Air Conditioning System is equipped with R-134a.

DESCRIPTION - REFRIGERANT OIL

The refrigerant oil used in R-134a refrigerant systems 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 10PA17 Compressor used in this vehicle is designed to use an ND8 PAG refrigerant oil. Use only refrigerant oil of this same type to service the refrigerant system.

OPERATION - REFRIGERANT OIL

After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system 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 contamination.

REFRIGERANT OIL CHECKING PROCEDURE

When an Air Conditioning System is assembled at the factory, all components except the Compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the Compressor is dispersed throughout the refrigerant system. The Accumulator, Evaporator, Condenser, and Compressor will each retain a significant amount of the needed refrigerant oil.

It is important to have the correct amount of oil in the refrigerant system. This ensures proper lubrication of the Compressor. Too little oil will result in damage to the Compressor. Too much oil will reduce the cooling capacity of the Air Conditioning System.

It will not be necessary to check the oil level in the Compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak.

Refrigerant oil must be added when an Accumulator, Evaporator Coil, or Condenser are replaced. See the Refrigerant Oil Capacities chart below. When a Compressor is replaced, the refrigerant oil must be drained from the old Compressor and measured. Drain all of the refrigerant oil from the new Compressor, then fill the new Compressor with the same amount of refrigerant oil that was drained out of the old Compressor.

Scheme 78

The Coolant Circulation Valve (3) regulates the quantity of coolant flowing through the heater hoses (1-2) to the heater core.

OPERATION - COOLANT CIRCULATION VALVE

When the temperature dial is set to "MIN" the A/C Heater Control module switches the Coolant Circulation Valve (3) Solenoid to ground, the solenoid pulls in and blocks the coolant flow through the Heater Core (2) separately on the left and right sides. If the temperature dial is set to "MAX" the A/C Heater Control module interrupts the ground connection, current does not flow through the solenoid and the maximum quantity of coolant flows through the Heater Core (2).

In normal operation the A/C Heater Control module switches the ground connection intermittently. The locking and closing times of the Coolant Circulation Valve are subject to deviations between the actual temperature and set temperature.

RESIDUAL ENGINE HEAT UTILIZATION

In the residual engine heat utilization mode the interior temperature is controlled in the same manner as while driving; the coolant is circulated by the Coolant Circulation Pump.

REMOVAL - COOLANT CIRCULATION VALVE

Scheme 79

1. Relieve the pressure in the cooling system by, turning the radiator cap on the reservoir to catch "1".
2. Loosen the top screw for the heat shield. Then remove the heat shield.
3. Clamp off the hot water hoses.
4. Loosen the hose clamps on heater water hoses (2).
5. Remove the heater water hose.
6. Disconnect the electrical connector (1) on the coolant circulation valve.
7. Remove the rubber mounts (6) from the mounting points on the body side.
8. Remove the coolant circulation valve.

INSTALLATION - COOLANT CIRCULATION VALVE

1. Install the coolant circulation valve.
2. Install the rubber mounts to the mounting points on the body side.
3. Connect the electrical connector (1) on the coolant circulation valve.
4. Install the heater water hose (2).
5. Tighten the hose clamps on heater water hose.
6. Unclamp the hot water hose.
7. Tighten the top screw for the heat shield.
8. Top off the cooling system. Refer to «STANDARD PROCEDURE»(/chrysler/crossfire/i-final-2008-2008/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) .

See also:
• COOLING - SERVICE INFORMATION
• BATTERY SYSTEM
• REMOVAL
• RESTRAINTS - SERVICE INFORMATION
• REMOVAL
• REMOVAL
• REMOVAL
• REMOVAL
• REMOVAL
• STANDARD PROCEDURE