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Home >> Chrysler >> 2001 >> PT Cruiser L4-2.4L VIN B >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement
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Removal and Replacement

The heater-A/C unit housing must be removed from the vehicle and disassembled to provide service access to the heater core or the evaporator.

WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL
1. If the vehicle is equipped with the optional heater-A/C system, recover the refrigerant from the refrigerant system. Refer to Refrigerant Recovery for the proper procedures.
2. Drain the engine cooling system. Refer to Cooling System for the proper procedures.Service and Repair
3. Disconnect and isolate the battery negative cable.
4. Remove the instrument panel from the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

5. Disconnect the heater hoses from the heater core nipples at the dash panel. Refer to Heater Hose for the proper procedures.Service and Repair
6. Install plugs in the heater core nipples to prevent engine coolant spillage during heater-A/C unit housing removal.
7. If the vehicle is so equipped, relocate the vehicle speed control servo as necessary to access the right side of the dash panel. Refer to Vehicle Speed Control System for the proper procedures.Service and Repair
8. If the vehicle is equipped with the optional heater-A/C system.
a. Remove the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator.
b. Disconnect the suction and liquid line assembly evaporator connector block from the evaporator.
c. Remove the gasket from the suction and liquid line assembly evaporator connector block arid discard.
d. Install plugs in, or tape over the opened suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports.
e. Remove the condensate drain tube from the heater-A/C unit housing drain. Refer to Condensate Drain Tube for the proper procedures.

Fig.67 Heater-A/C Vacuum Harness:




f. Disconnect the vacuum harness connector from the A/C vacuum check valve nipple near the power brake booster.
9. Remove the defroster duct from the heater-A/C unit housing. Refer to Ducts for the proper procedures.Service and Repair

Fig.68 Heater-A/C Unit Housing Remove/Intsall:




10. Remove the three nuts that secure the heater- A/C unit housing to the engine compartment side of the dash panel.
11. Remove the screw that secures the right end of the heater-A/C unit housing to the weld flange of the dash panel and cowl plenum panel in the passenger compartment.
12. Remove the nut that secures the heater-A/C unit housing to the cowl plenum bracket and stud on the passenger compartment side of the dash panel.
13. Remove the heater-A/C unit housing from the vehicle.

INSTALLATION
1. Position the heater-A/C unit housing into the vehicle. Be certain that the housing studs, heater core nipples and, if equipped, the heater-A/C unit housing drain, vacuum harness and evaporator inlet and outlet connector block are all inserted/routed through the proper openings of the dash panel.
2. Loosely install the nut that secures the heater- A/C unit housing to the cowl plenum bracket and stud on the passenger compartment side of the dash panel.
3. Loosely install the screw that secures the right end of the heater-A/C unit housing to the weld flange of the dash panel and cowl plenum panel in the passenger compartment.
4. Install and tighten the three nuts that secure the heater-A/C unit housing to the engine compartment side of the dash panel. Tighten the nuts to 5.1 Nm (45 in. lbs.).
5. Tighten the screw that secures the right end of the heater-A/C unit housing to the weld flange of the dash panel and cowl plenum panel in the passenger compartment to 5.1 Nm (45 in. lbs.).
6. Tighten the nut that secures the heater-A/C unit housing to the cowl plenum bracket and stud on the passenger compartment side of the dash panel to 5.1 Nm (45 in. lbs.).
7. Reinstall the defroster duct onto the heater-A/C unit housing. Refer to Ducts for the proper procedures.Service and Repair
8. If the vehicle is equipped with the optional heater-A/C system:
a. Reconnect the vacuum harness connector to the A/C vacuum check valve nipple near the power brake booster.
b. Reinstall the condensate drain tube onto the heater-A/C unit housing drain. Refer to Condensate Drain Tube for the proper procedures.
c. Remove the tape or plugs from the suction and liquid line assembly evaporator connector block ports and the evaporator inlet and outlet ports.
d. Align the suction and liquid line assembly evaporator connector block and a new gasket to the evaporator inlet and outlet ports.
e. Install and tighten the two screws that secure the suction and liquid line assembly evaporator connector block to the evaporator.Tighten the upper screw first to 11.3 Nm (100 in. lbs.), then tighten the lower screw.
9. If the vehicle is so equipped, reinstall the vehicle speed control servo. Refer to Vehicle Speed Control System for the proper procedures.Service and Repair
10. Remove the plugs from the heater core nipples.

11. Reconnect the heater hoses to the heater core nipples at the dash panel. Refer to Heater Hose for the proper procedures.Service and Repair
12. Reinstall the instrument panel to the vehicle. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel Service Procedures, Instrument Panel Assembly Replacement, Instrument Panel Assembly

13. Reconnect the battery negative cable.
14. Refill the engine cooling system. Refer to Cooling System for the proper procedures.Service and Repair
15. If the vehicle is equipped with the optional heater-A/C system, evacuate the refrigerant system. Refer to Refrigerant System Evacuate for the proper procedures.Service and Repair

NOTE: If the evaporator is replaced, add 59 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

16. If the vehicle is equipped with the optional Heater-A/C system, charge the refrigerant system. Refer to Refrigerant System Charge for the proper procedures.Service and Repair

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