HVAC Systems - Automatic: Removal & Installation Chrysler LHS II

REMOVAL & INSTALLATION

Note. For removal and installation procedures not covered, see MANUAL A/C-HEATER SYSTEMS - CONCORDE & INTREPID article.

A/C pressure transducer is located on a valve on the discharge line. Open hood and disconnect the negative battery remote terminal. see scheme 3 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).

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.

Disconnect negative battery remote terminal. see scheme 3 Remove ashtray. Remove center instrument panel trim bezel. (Scheme 6) Remove two electrical connectors from back of the control head and traction control switch (if equipped). Remove 6 retaining screws from rear of ATC control head and remove from the bezel. To install, reverse removal procedure.

Removal

1. Remove HVAC unit housing. See «HVAC UNIT HOUSING»(ref-211-S14562008792002021100000). Place unit housing assembly on workbench. Remove heater core retaining screws. Pull back on retaining tabs and remove heater core from housing. Remove harness connectors from recirculation door actuator. see scheme 2 Remove actuator from recirculation housing. Remove lower distribution housing. Remove mode door actuator. Remove blend air door actuator. Remove recirculation housing screws and clip.
2. Remove blower motor wiring at resistor. Squeeze blower motor wiring grommet and push grommet through blower motor cover. Remove blower motor cover. Remove blower motor mount screws. Remove blower motor.
3. Remove wiring at evaporator temperature probe. Using a screwdriver, pry up on tab at evaporator probe. Turn probe counterclockwise and push tab into the housing. Pull the evaporator probe needle out of the evaporator fins. Remove the evaporator probe through the opening at the blower motor housing.
4. Remove vent door seal from housing. Remove evaporator seal from housing. see scheme 2 Remove upper housing screws and clips. Separate upper housing from lower housing. Remove evaporator assembly from lower housing. Remove blend air door from lower housing. Using a flat blade screwdriver, pinch in the retaining tab at the base of the tent door. Pull up on door and remove from housing. Remove mode door actuating cam.
5. Remove screw at defrost door actuating arm. Remove defrost door link from arm. Remove defrost door arm from lower housing. Remove link and defrost door from housing. Remove vent door actuating arm from lower housing.

Installation

1. Connect vent door actuating arm to lower housing. Connect defrost door link to defrost door. Install door and link into HVAC unit housing. Install defrost door actuating arm with one screw at HVAC unit housing.
2. Install defrost door link to actuating arm. Line up the slots to the pegs on the mode door cam. Install the mode door cam. Turn housing over and snap the vent door on to the vent door arm. Install blend-air door in the housing. Install evaporator into the lower housing. Put upper and lower housings together and install retaining screws.
3. Install evaporator and vent door seals for the HVAC housing. Reinstall HVAC unit housing. See «HVAC UNIT HOUSING»(ref-211-S14562008792002021100000) .

Disconnect the negative battery remote terminal. see scheme 3 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.

Disconnect negative battery remote terminal, located on right strut tower. see scheme 3 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. see scheme 3 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. Open hood and disconnect the negative battery remote terminal. see scheme 3 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 one upper bolt to A/C suction line to compressor. Remove one bolt to lower A/C suction line from evaporator to condenser.
3. 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 «HVAC UNIT HOUSING»(ref-211-S14562008792002021100000) . 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.

The evaporator temperature sensor is located on the lower right side of the heater housing. Open hood and disconnect the negative battery remote terminal. see scheme 3 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.

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 instrument panel from vehicle. See «INSTRUMENT PANEL»(ref-211-S05788043182002021100000) . 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.
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 6) 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. Gently pry up on center bezel, remove wiring harness and remove center bezel. (Scheme 6) Gently pry up on shifter bezel, disconnect 2 harness connectors, one light bulb socket and remove shifter bezel. Remove 2 screws from for left console side cover, pull outward and remove from vehicle. Open glove box door. Remove 2 screws to right console, pull outward and remove from vehicle. Remove 2 front center console bracket screws. Open inside center console bin and remove 2 screws.
3. 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. see scheme 4 Remove steering column from vehicle. See STEERING COLUMN under REMOVAL & INSTALLATION in STEERING COLUMNS - AVENGER, SEBRING COUPE & TALON article, under STEERING.
4. Disconnect duct system from under column and remove from vehicle. 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 6

Open hood and disconnect the negative battery remote terminal. see scheme 3 Remove center bezel which snaps on and holds the ATC control panel. (Scheme 6) Disconnect ATC control panel harness connector. If the ATC in-car temperature sensor (fault 26) is verified to be faulty, then the ATC control section of the assembly must be replaced. If the ATC in-car sensor does not pass the paper test, then the problem may only be with the ATC In-car sensor fan motor assembly. Remove 2 screws and remove the fan-motor assembly from the ATC control panel. Replace only the fan-motor assembly if control does not pass the paper test, but fault code 26 (bad thermistor) does not exist. For installation, reverse removal procedure.

Open hood and disconnect the negative battery remote terminal. see scheme 3 Remove left and right underpanel ducts. Remove floor console. Remove center floor heat adaptor duct. Remove rear seat heat forward adaptor duct. Loosen center support bracket and pry rearward to gain access to the actuator. Remove actuator retaining screws and pull actuator straight down. Upon removal, note the shaft position of the actuator because the shaft on this motor is keyed. Install new actuator shaft in the same position. Remove harness connector on actuator. To install, reverse removal procedure.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove engine air inlet tube and the air distribution duct on vehicles equipped with 3.2/3.5 liter engines. Remove one 8mm hex bolt to receiver/drier bracket. Remove one A/C lines to expansion valve retaining nut. Gently pry receiver/drier bracket out of strut tower. Remove receiver/drier to condenser A/C line tubing. Remove receiver/drier from vehicle. Transfer small line from receiver/drier to expansion valve to new receiver/drier. Plug or cap liquid line fittings while system is open to prevent moisture intrusion. To install, reverse removal procedure.

Open hood and disconnect the negative battery remote terminal. see scheme 3 Remove instrument panel. See INSTRUMENT PANEL. Remove recirculation door actuator retaining screws. Pull actuator straight off recirculation door shaft. Upon removal, note the shaft position of the actuator, because the shaft on this motor is keyed. Install new actuator in same position. Disconnect harness connector. Remove recirculation door motor from vehicle. To install, reverse removal procedure.

1. Disconnect negative battery cable remote terminal located on right strut tower. see scheme 3 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.

Remove left and right underpanel silencer/ducts. Remove two screws from actuator which are accessible from the right side of center stack. Remove one screw from actuator on left side. Pull actuator straight down from shaft and disconnect harness connector. Upon removal, note the shaft position of the actuator, because the shaft on this motor is keyed. Install new actuator in same position. To install, reverse removal procedure.

Automatic A/C-Heater System Wiring Diagram (Concorde, Intrepid, LHS & 300M). Scheme 7