WITHOUT AIR CONDITIONING Chrysler PT Cruiser I

WITHOUT AIR CONDITIONING

1. Disconnect and isolate the negative battery cable.
2. Disconnect the blower motor wire harness connector.
3. Grasp the blower motor while pulling down on the locking tab. Turn the blower motor approximately 1/8 turn counterclockwise. (Scheme 24)
4. Remove the blower motor from the HVAC housing.

Scheme 24

1. Position the blower motor into the HVAC housing.
2. Install the blower motor retaining screws. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the blower motor wire harness connector.
4. Reposition the carpet.
5. Install the door sill scuff plate.
6. Reconnect the negative battery cable.

1. Position the blower motor into the housing.
2. Rotate the blower motor clockwise until the tab snaps into the locked position, approximately 1/8 turn.
3. Connect the blower motor wire harness connector.
4. Reconnect the negative battery cable.

1. Remove the instrument panel from the vehicle «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
2. Remove the defroster duct from the top of the HVAC housing. (Scheme 25)

Scheme 25

1. Install the defroster duct onto the top of the HVAC housing. Snap the retainers into place.
2. Install the instrument panel «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) .

1. Remove the center floor console (Refer to «INTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) ).
2. Remove the screws that secure the left and right floor distribution ducts to the floor. (Scheme 26)
3. Disengage the floor distribution ducts from each other.
4. Disengage the floor distribution duct from the rear seat elbow duct located at the bottom of the HVAC housing.
5. Remove both floor distribution ducts from the vehicle.
6. If necessary, remove the rear seat elbow duct from the bottom of the HVAC housing.

Scheme 26

1. If removed, install the rear seat elbow duct to the bottom of the HVAC housing.
2. Position both floor distribution ducts into the vehicle.
3. Engage the floor distribution duct to the rear seat elbow duct located at the bottom of the HVAC housing.
4. Engage the floor distribution ducts to each other.
5. Install the screws that secure the left and right floor distribution ducts to the floor. Tighten the screws to 2 N.m (17 in. lbs.).
6. Install the center floor console (Refer to «INTERIOR»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior) ).

Note. The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service access of the heater core, A/C evaporator and the mode, recirculation and blend-air doors.

Scheme 27

Scheme 28

Scheme 29

1. Recover the refrigerant from the refrigerant system «(Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information).
2. Partially drain the engine cooling system «(Refer to COOLING/ENGINE/COOLANT - STANDARD PROCEDURE - DRAINING COOLING SYSTEM)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
3. Disconnect and isolate the negative battery cable.
4. Remove the coolant recovery container (Refer to «COOLANT RECOVERY CONTAINER»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) (1.6L SOHC) or «COOLANT RECOVERY CONTAINER»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system) (2.0/2.4L DOHC).
5. Remove the screw that secures the accumulator mounting bracket to the body.
6. Remove the two bolts securing the accumulator tubes to the evaporator terminal block and disconnect the tubes from the terminal block.
7. Remove the seals from the refrigerant lines fittings and discard.
8. Install plugs in, or tape over all of the opened refrigerant line fittings and evaporator tubes.
9. Disconnect the vacuum harness at the power brake booster. (Scheme 27) 1 - BRAKE POWER BOOSTER 2 - A/C VACUUM CHECK VALVE 3 - VACUUM HARNESS
10. Remove the rubber drain tube extension from the condensation drain tube. (Scheme 28)
11. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
12. Remove three HVAC housing retaining nuts located on the dash panel in the engine compartment. 1 - BLOWER RESISTOR 2 - EVAPORATOR TAPPING PLATE 3 - DRAIN TUBE 4 - DASH PANEL 5 - HEATER HOSES 6 - RETAINING NUTS (3)
13. Remove the instrument panel from vehicle «(Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
14. Remove the mode door and temperature control cables from the mode door and blend-air door levers and the HVAC housing «(Refer to HEATING & AIR CONDITIONING/CONTROLS/MODE DOOR CABLE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) and «(Refer to HEATING & AIR CONDITIONING/CONTROLS/TEMPERATURE CONTROL CABLES - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information).
15. Remove the defroster and floor distribution ducts from the HVAC housing «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DEFROSTER DUCTS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) and «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/FLOOR DISTRIBUTION DUCTS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information).
16. Disconnect the wire harness connectors.
17. Remove the outboard HVAC housing retaining screw located in the passenger compartment. (Scheme 29) 1 - OUTBOARD RETAINING SCREW 2 - HOUSING SCREW BOSSES 3 - DASH PANEL STUD AND NUT
18. Remove the remaining nut located on the dash panel stud. NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.
19. Remove the HVAC housing from the vehicle.

Scheme 30

1. Remove the HVAC housing from the vehicle «(Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information).
2. Place the HVAC housing in the upright position on a workbench, making allowance for leakage of fluids.
3. Separate the air distribution foam seals at the case parting line. (Scheme 30) 1 - AIR DISTRIBUTION 2 - RECIRCULATION DOOR VACUUM ACTUATOR 3 - AIR INLET 4 - BLOWER MOTOR 5 - CONTROL CABLES 6 - VACUUM HARNESS
4. Remove the evaporator and heater core tube foam seals from the housing. (Scheme 31)
5. Remove the retaining clips and screws that hold the upper and lower housing together.
6. Separate the two halves of the housing.
7. Remove the heater core and evaporator from the lower housing as necessary.

Scheme 31