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LOW OR DIFFERENTIAL PRESSURE CUT-OFF SWITCH

REMOVAL AND INSTALLATION

WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THE REFRIGERANT SERVICE PROCEDURES SECTION.

(1)Disconnect the boot like wire connector at the cut-off switch.

(2)Using a sender unit type socket, remove the switch from the expansion valve (Fig. 18 or 19).

Fig. 18 Low Pressure Cut-Off Switch and Expansion

ValveÐTypical

Fig. 19 Differential Pressure Cut-Off Switch and

Expansion ValveÐTypical

To install, assure an adequate seal by using a small amount of thread sealing tape on the replacement switch and reverse the preceding steps.

Evacuate and charge the system.

HEATING AND AIR CONDITIONING 24 - 51

EXPANSION VALVE

REMOVAL

WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THE REFRIGERANT SERVICE PROCEDURES SECTION.

(1)Remove the boot-type wire connector from the pressure cut-off switch.

(2)Remove the attaching bolt in center of refrigerant line-plumbing sealing plate (Fig. 20).

Fig. 20 Expansion Valve

(3)Carefully pull the refrigerant line-sealing plate assembly from the expansion valve towards front of vehicle. Do Not scratch the expansion valve sealing surfaces with pilot tubes.

(4)Cover the openings on A/C line-sealing plate assembly to prevent contamination.

(5)Remove two screws securing the expansion valve to the evaporator sealing plate.

(6)Carefully remove valve.

INSTALLATION

(1)Remove and replace the aluminum gasket on the evaporator sealing plate.

(2)Carefully hold the expansion valve to the evaporator sealing plate (do not scratch sealing surface).

Install two attaching screws and tighten to 11 6 3 NIm (100 6 30 inch lbs.).

(3)Remove and replace the aluminum gasket (Fig.

15)on the refrigerant line-sealing plate assembly.

(4)Carefully hold the refrigerant line-sealing plate

assembly to the expansion valve, install bolt and tighten to 23 6 3 NIm (200 6 30 inch lbs.).

(5)Connect wires to low pressure cut-off switch.

(6)Evacuate and recharge system.

FILTER-DRIER ASSEMBLY

REMOVAL AND INSTALLATION

WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THIS GROUP.

(1) Remove the two high pressure lines from the sides of the filter-drier assembly (Fig. 1). Then carefully separate the lines from filter-drier. Discard old gaskets.

Fig. 1 Filter-DrierÐTypical

(2)Cover the open ends of the A/C lines to minimize system contamination.

(3)Remove two mounting strap bolts and lift the filter-drier from vehicle. If replacing the filter-drier assembly, transfer the mounting strap to replacement part.

To install, replace both refrigerant line to filterdrier gaskets, and reverse the preceding operation.

Evacuate and recharge system.

CONDENSER ASSEMBLY

The A/C condenser is mounted to the radiator with bolts (upper) and mounting pads (lower).

WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PRO-

REMOVAL AND INSTALLATION

(1)Discharge A/C system.

(2)Remove the refrigerant line mounting nut (Fig.

2)and separate the refrigerant lines from condenser sealing plate.

Fig. 2 A/C Condenser Refrigerant LinesÐTypical

(3)Cover the open ends of the A/C lines and condenser to minimize system contamination.

(4)Remove the coolant overflow bottle, electric cooling fans and radiator assembly. Also remove the turbocharger inter-cooler if equipped. Refer to Group 7, Cooling System.

On some models, complete removal of the radiator, or coolant drainage is not necessary. The radiator may be moved slightly rearward to remove the condenser.

(5)Remove the two bolts securing the condenser assembly to the radiator.

(6)Slip the condenser from the lower radiator mounting brackets.

(7)Remove condenser.

To install, replace all O-rings and gaskets and coat sealing surfaces with approved refrigerant oil. Then reverse the preceding operation. When installing a new condenser, refer to Oil Level in the Refrigerant section. Tighten the refrigerant line mounting nut to 23 NIm (200 inch pounds).

Evacuate and recharge system.

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BLOWER MOTOR

REMOVAL AND INSTALLATION

(1)Disconnect the negative battery cable.

(2)Remove the glove box. Refer to Group 8E, Instrument Panel.

(3)On vehicles equipped with A/C, disconnect the two vacuum

lines from the recirculating air door actuator. Disconnect blower lead wire connector.

(4)Remove two screws at the top of the blower housing, securing it to the unit cover.

(5)Remove five screws from around the blower housing and separate the blower housing from the unit (Fig. 3).

HEATING AND AIR CONDITIONING 24 - 53

BLOWER MOTOR WHEEL ASSEMBLY

REMOVAL AND INSTALLATION

Blower motor must be removed from vehicle before performing this operation. Refer to Blower Motor Removal and Installation.

(1) Remove the spring type retaining ring from the center of the blower wheel (Fig. 5). Note the location of the blower wheel on the blower motor shaft.

Fig. 3 Blower HousingÐTypical

(6) Remove three screws securing the blower and wheel assembly to the heater or A/C unit housing. Then separate the assembly from the unit (Fig. 4).

Fig. 4 Blower Motor and Wheel Assembly

To install, reverse the preceding operation.

Fig. 5 Blower Wheel Retaining Ring Removal and

Installation

(2) Remove blower wheel from blower motor shaft. To install, reverse the preceding operation. To prevent noise or vibration, rotate the blower wheel by

hand to check for rubbing.

HEATER-A/C UNIT ASSEMBLYÐREMOVAL AND INSTALLATION

AP, AC, AY BODY PROCEDURE

WARNING: IF EQUIPPED WITH A/C, THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THIS GROUP.

(1)Disconnect battery NEGATIVE cable.

(2)Drain radiator and disconnect heater hoses at unit. Tape heater tubes to keep from leaking during removal. Refer to Group 7, Cooling System.

(3)Remove A/C condensate drain and disconnect vacuum lines.

(4)Inside passenger compartment, perform as follows, according to body designation.

(a)AC-body, remove right upper and lower un- der-panel silencers.

(b)AP & AC-bodies, remove steering column cover.

(c)AC-body, remove left under-panel silencer.

(5)Position front seat or right front seat full rear.

(a)AP-body, remove right A-pillar trim.

(b)Remove right cowl side trim.

(6)Remove glove box.

24 - 54 HEATING AND AIR CONDITIONING

(a)AC-body, remove right instrument panel reinforcement.

(7)AP-body only:

(a)Remove right instrument panel lower mounting screw.

(b)Remove center bezel.

(c)Remove lower center module cover.

(d)Remove floor console.

(e)Remove instrument panel support brace (from steering column opening to right cowl side at bottom of instrument panel).

(f)Remove instrument panel to support bracket (below glove box opening).

(g)Remove ash receiver.

(h)Remove radio.

(i)Remove panel top cover.

(j)Remove three right side panel to fence (below windshield) attaching screws.

(8)AC-body, remove ash receiver.

(9)AP body, pull right lower side of instrument panel rearward.

(10)Remove center distribution and defroster adapter ducts.

(11)AP and AC-bodies, disconnect relay module.

(12)AP-body, remove instrument panel to unit bracket.

(13)AP-body, remove lower air distribution duct.

(14)Disconnect blower motor wire connector.

(15)Disconnect demister hoses from top of unit.

(16)For Non-ATC equipped vehicles, disconnect the temperature control cable flag from the bottom of the heater-A/C unit. Then un-clip the cable from the left side of the heat distribution duct. Swing the cable out of the way to the left. Disconnect the vacuum lines at the unit.

(17)For ATC equipped vehicles, disconnect the instrument panel wiring from the rear face of the ATC control unit.

(18)AC body, disconnect right 25-way connector bracket and fuse block from panel.

(19)Fold floor right side carpet back (except AC

body).

(20)From engine compartment, remove four unit attaching nuts.

(21)Remove unit hanger strap lower screw, and rotate strap.

(22)Move heater-A/C unit rearward to clear mounting studs, and lower unit.

(23)AP-body, remove demister adapter from top of

unit.

(24)While pulling the lower right of instrument panel rearward:

(a)Slide unit upright from under instrument panel for AP-body.

(b)Except for AP-body, rotate unit while pulling from under instrument panel.

To install, reverse the preceding operation.

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AA BODY PROCEDURE

WARNING: IF EQUIPPED WITH A/C, THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THIS GROUP.

Refer to Group 8E and Group 23 for component removal and installation when performing this operation.

(1)Perform steps 1 through 7 of Blower Motor removal and installation.

(2)Remove relay panel above glove compartment opening.

(3)Disconnect the A/C vacuum line connector and radio noise capacitor connectors.

(4)Remove left windshield pillar trim cover.

(5)Remove left lower side cowl trim cover.

(6)Remove hood release handle mechanism attaching screws.

(7)Remove steering column trim covers.

(8)Disconnect parking brake release mechanism connecting rod. Gain access through fuse panel opening.

(9)Remove lower left instrument panel silencer.

(10)Remove lower left instrument panel reinforce-

ment.

(11)Remove instrument panel center (radio) bezel.

(12)Remove forward floor console.

(13)Remove the radio.

(14)Remove the heater-A/C control.

(15)Remove cigar lighter.

(16)Remove message center/trip computer, if equipped.

(17)Disconnect side window demister tubes from top of heat A/C unit.

(18)Remove steering column upper attaching bolts and allow the steering wheel to rest on the driver seat cushion.

(19)Remove upper instrument panel (defroster outlet) cover.

(20)Remove upper instrument panel attaching screws from below the windshield opening.

(21)Loosen (do not remove) the left lower cowl instrument panel attaching screw.

(22)Remove the right lower cowl instrument panel attaching screw.

CAUTION: Protect the passenger seat cover from soiling or damage using a suitable cover.

(23) Carefully pull the right side of the instrument panel away from the vehicle. Allow the instrument panel to rest on the passenger seat cushion.

CAUTION: Before proceeding with the next operation, review the Safety Precautions and Warnings at the front of this Group.

(24)From the engine compartment, drain the cooling system and disconnect the heater hoses from the heater core nipples. Plug the nipples to avoid spilling coolant inside the vehicle.

(25)Disconnect the refrigerant lines from the ex- pansion-valve at the dash panel on the right side of the vehicle. Seal the refrigerant lines to prevent contamination.

(26)Remove the expansion valve from the evaporator plate. Seal the valve to avoid contamination.

(27)Remove the condensate drain tube.

(28)Remove heater-A/C unit to dash panel attaching nuts.

(29)From inside the vehicle, pull rearward on the heater-A/C unit to clear the dash panel silencer and remove the unit from the vehicle.

To install, reverse the preceding operation. Refill cooling system and test for leaks. Evacuate and charge the refrigerant system and test overall performance.

AG, AJ BODY PROCEDURE

WARNING: IF EQUIPPED WITH A/C, THE REFRIGERATION SYSTEM MUST BE COMPLETELY DISCHARGED BEFORE PROCEEDING WITH THIS OPERATION. REFER TO DISCHARGING REFRIGERATION SYSTEM IN THIS GROUP.

(1)Disconnect the battery negative cable.

(2)Drain the coolant from cooling system. Refer to Group 7, Cooling System.

(3)Remove the air-conditioner expansion valve (if equipped).

(4)Disconnect the heater hoses from heater core. Then plug or cap the tubes on heater core. This will prevent spilling coolant into the interior of vehicle during unit removal.

(5)Remove the condensate drain tube.

(6)Disconnect the A/C-heater vacuum supply line from vacuum supply nipple (in the engine compartment).

(7)Remove the four A/C-heater assembly-to-dash panel attaching nuts.

(8)Remove the passenger side front seat. Refer to Group 23, Body.

(9)Remove the kick panel/sill cover at right door opening.

(10)Remove the body computer (Fig. 6) located at the lower right section of the right front door pillar.

(11)Remove the glove box assembly. Refer to Group 8E, Instrument Panel.

(12)Remove the carpeted panels from both sides of the console.

(13)Un-clip the radio antenna cable from the metal support (Fig. 6) located behind and below the glove box opening.

(14)Instrument panel removal is not necessary to remove the A/C-heater assembly from the vehicle. Although, part of the lower instrument panel must be cut. The cut line is marked: CUT HERE FOR A/C HTR REMOVAL.

This cut line is stamped (indented) into the rightouter side of the instrument panel padding (outboard of the glove box opening). Using a hacksaw blade, cut the instrument panel padding along the indented line from point A to point B (Fig. 6). CUT THE PLASTIC ONLY. Do not cut the metal support behind the instrument panel padding.

Fig. 6 Cut Line For A/C-heater RemovalÐAG/AJ

Body

(15)Remove the metal support behind and below the glove box opening, and the previously cut piece of the instrument panel that is riveted to it.

(16)Remove the radio choke, security alarm module and the lamp outage module from above the glove box opening (if equipped).

(17)Remove the plastic cover under the steering column.

(18)Remove the metal support under the steering column.

(19)AJ Body only: Remove the under-panel silencer pad from under the glove box opening.

(20)Remove the lower heat distribution duct (3 screws).

(21)Remove the air distribution duct through the opening at the left side of instrument panel.