A/c-Heater System - Automatic: Removal & Installation Dodge Intrepid I

Removal & Installation

Turn ignition switch to OFF position. Remove trim ring and retaining screws. Remove control panel and disconnect both connectors. To install, reverse removal procedure. (Scheme 2)

Scheme 2

Disconnect harness connector. Rotate transducer counterclockwise using 3/4" open end wrench. There may be a slight discharge of trapped pressure from fitting. It is not necessary to discharge refrigerant system. To install, reverse removal procedure. Tighten transducer to 50 INCH lbs. (5.6 N.m).

1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Drain coolant. Remove air cleaner hose and air distribution duct from engine.
2. Disconnect heater hoses at dashboard, and plug heater core inlet and outlet tubes. Use care not to spill coolant inside vehicle. Remove both A/C lines from expansion valve. Cap expansion valve and A/C line openings. NOTE: Refrigerant oil will absorb moisture. Do not leave any portion of system open for extended periods of time.
3. Remove 3 nuts on engine side of firewall from studs projecting through firewall. Use screwdriver to pry off both instrument panel trim end caps and both interior door post kick panels. Remove right side instrument panel and radio center bezels. Remove radio and A/C-heater control panel. Pry center instrument panel bezel from panel. Remove center console from vehicle, if equipped.
4. Passenger-side air bag is located behind glove box (if equipped). To remove passenger-side air bag, lower glove box by pressing in on sides. Remove 4 screws located behind glove box and close glove box. Remove lower knee bolster panel screws. Lower knee bolster panel and disconnect trunk release and glove box light connectors. Remove lower knee bolster panel. (Scheme 2)
5. Remove top instrument panel cover. Pry upward at each end of cover until clips release. Slowly pry rear edge of top cover along entire width of panel. Remove right and left windshield "A" pillar trim covers. Remove 5 instrument panel to cowling bolts located at base of windshield.
6. Disconnect data link (diagnostic) connector from brace. Remove instrument panel ground strap located on lower left side of center console. Remove left knee bolster support bracket. Remove under column duct and left floor duct. Disconnect instrument panel 60-pin connector and all related connectors. Disconnect fuse panel connectors and brakelight switch connector.
7. Remove steering column covers and bolts. Lower steering column to floor, but DO NOT remove. Remove steering column wiring and air bag connectors (if equipped). Remove right side floor air duct. Disconnect 10-pin connector, blower module and blower motor connectors from A/C-heater assembly.
8. Remove BCM. Disconnect right side and antenna connectors. Remove right and left side upper instrument panel screws located in door jam. With an assistant, remove upper instrument panel with all harnesses and gauges installed. Remove bracket/push pin and rear heater vents.
9. Remove passenger-side air bag module and brace. Remove 3 heater housing-to-dash panel bolts. Remove A/C-heater housing using care not to spill coolant. Install drain tube from under vehicle after A/C-heater housing is reinstalled. To install, reverse removal procedure. Evacuate and recharge A/C system. Fill cooling system.

Remove right side instrument panel trim end cap and trim bezel from instrument panel. Remove sensor screws, pull out sensor, and disconnect wiring. To install, reverse removal procedure.

Remove lower right underpanel access cover silence duct. Unplug blower motor power module connector. Remove blower motor power module. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove floor console or instrument panel center lower cover and lower instrument panel assembly. Remove BCM at right side of instrument panel.
2. Remove actuator screws and pull outside air/recirculation door actuator straight off door shaft. Note shaft key position for installation. Disconnect actuator connector. To install, reverse removal procedure. When installing actuator, shaft must be reinstalled in original position.

1. Disconnect negative battery cable. Remove left and right underpanel silencer/ducts and floor console. Remove center floor heat adaptor duct and rear seat heat forward adaptor duct. Loosen center support bracket and pry rearward to gain access to actuator.
2. Remove actuator screws and pull actuator straight down. Note shaft key position for installation. Disconnect actuator connector. To install, reverse removal procedure. When installing actuator, shaft must be reinstalled in original position.

Remove left and right underpanel silencer/ducts. Remove 3 actuator screws. Pull actuator straight down. Note shaft key position for installation. Disconnect actuator connector. To install, reverse removal procedure. When installing actuator, shaft must be reinstalled in original position.

1. Disconnect negative battery cable. Remove lower right underpanel silencer duct and blower motor housing cover. Remove blower motor screws, and lower blower motor from housing. To install, reverse removal procedure.
2. A whistling noise may be noticed on some vehicles. This noise is most noticeable with blower motor at middle speeds and temperature set to hot. Remove blower motor assembly. Apply strip caulking to all seam areas around blower motor wheel and evaporator housing.

Remove lower right underpanel silencer duct. Disconnect connectors on resistor. Remove blower motor resistor screws, and pull resistor from heater housing. To install, reverse removal procedure.

1. Disconnect negative battery cable. Loosen and remove drive belts. Disconnect compressor clutch wire lead.
2. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove refrigerant lines. Plug or cap open lines if system is to be left open.
3. Disconnect electrical connector and remove mounting bolt. If refrigerant lines were not removed, lift compressor/clutch assembly and secure to a suitable location.
4. When replacing compressor, drain and measure old oil from suction port. Replace with new refrigerant oil, adding the same amount removed (not to exceed 4.5 ounces). To install, reverse removal procedure. Evacuate and recharge A/C system.

Discharge A/C system using approved refrigerant recovery/recycling equipment. High pressure relief valve is located on A/C compressor manifold. To remove, rotate relief valve counterclockwise. To install, reverse removal procedure using a new "O" ring. Evacuate and recharge A/C system.

Removal & Installation (Except New Yorker)

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines and receiver-drier at condenser. Plug or cap open lines. Remove bolts and inlet tube bracket screw.
2. Spread bracket open and remove condenser. Avoid bending or breaking condenser inlet tube. To install, reverse removal procedure. Add one ounce of refrigerant oil to new condenser. Evacuate and recharge A/C system.

Removal & Installation (New Yorker)

1. Disconnect negative battery cable. Remove radiator closure panel sight shield, and right and left headlamp modules. Drain engine coolant. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove upper radiator crossmember and radiator hoses. Disconnect and plug automatic transaxle cooler lines. Disconnect cooling fan connector from RFI module.
2. Disconnect refrigerant lines and receiver-drier at condenser. Plug or cap open lines. Access upper radiator mounting screws through headlamp module bracket and remove screws. Remove radiator and condenser assembly from vehicle. Separate radiator and condenser. Avoid bending or breaking condenser inlet tube.
3. To install, reverse removal procedure. Tighten radiator mounting screws to 105 INCH lbs. (12 N.m). Tighten radiator-to-condenser mounting screws to 45 INCH lbs. (5 N.m). Add one ounce of refrigerant oil to new condenser. Evacuate and recharge A/C system.

1. Disconnect negative battery cable. Remove A/C-heater assembly. See «A/C-HEATER ASSEMBLY»(ref-10857-S37450301922001011200000) .
2. Remove recirculation door actuator, recirculation door and housing. Remove upper housing screws and upper half of A/C-heater housing. Remove evaporator from lower half of housing.
3. Using a new gasket, transfer expansion valve onto new evaporator. Transfer evaporator temperature sensor to the same location as on previous evaporator. Ensure evaporator has 2 ounces of new refrigerant oil. To install, reverse removal procedure. Evacuate and recharge A/C system.

Removal

Disconnect negative battery cable. Remove right underpanel silencer. Remove evaporator temperature sensor (evaporator probe) connector. Twist evaporator probe access plate, located at center of A/C-heater housing, counterclockwise 1/4 turn and remove plate. Remove evaporator temperature sensor probe. Mark old hole.

Installation

There are 3 holes manufactured for evaporator probe insertion. Install new evaporator temperature sensor in uppermost new hole. DO NOT install in old hole(s). To complete installation, reverse removal procedure.

Discharge A/C system using approved refrigerant recovery/recycling equipment. On models with 3.5L engines, remove engine air inlet tube and air distribution duct. On all models, disconnect A/C lines from expansion valve. Remove 2 bolts and expansion valve. Remove and discard old gasket. To install, reverse removal procedure using new gasket. Evacuate and recharge A/C system.

Disconnect negative battery cable. Remove A/C-heater assembly. See A/C-HEATER ASSEMBLY. Pull back heater core clips and remove heater core. Install new heater core using new screws provided. To complete installation, reverse removal procedure.

Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove condenser bolt from module. Disconnect receiver-drier inlet and outlets. Remove receiver-drier. Ensure new receiver-drier has one ounce of new refrigerant oil. To install, reverse removal procedure. Evacuate and recharge A/C system.

Automatic A/C-Heater System Wiring Diagram. Scheme 3