2000 DODGE NEON Service Repair Manual

GENERAL INFORMATION
A/C APPLICATION TABLE
Item Description Notes
Vehicle PL Neon
System expansion valve
Total Refrigerant
CapacityR134a 765 grams / 27 oz / 1.69 lbs
Total Oil Capacity ND-8 PAG oil 180 ml / 6.10 oz
Compressor Nippondenso 10S17
Freeze-up Control Fin sensor-3 wire input to PCM, evaporator mounted, cycles
clutch off below 34É F, cycles back on
above 45É F
Low psi Control opens < 14 psi, resets > 38 psi expansion valve mounted
High psi Control opens > 470 psi, resets < 370 - 330 psi compressor mounted switch
Control head manual type
Mode Door cable
Blend Air Door cable
Fresh/Recirc door vacuum actuator
Blower Motor control head switched resistor block
Cooling Fan variable speed PCM controlled ISO solid state fan relay
Clutch
Control relay PCM
Draw 2.5 amps @ 12V60.5V @ 70É F
Gap 0.014º - 0.0269
DRB IIIT
Reads TPS, RPM, A/C switch test, fin sensor
A/C & fan relays
Actuators fan & clutch relays
HEATER AND AIR CONDITIONING CONTROL
Both the heater-only and heater-A/C systems use a
combination of, electrical, cable, and vacuum con-
trols. These controls provide the vehicle operator
with a number of setting options to help control the
climate and comfort within the vehicle. Refer to the
owner's manual in the vehicle glove box for more
information on the features, use, and suggested oper-
ation of these controls.
The heater-only or heater-A/C control panel is located
to the right of the instrument cluster on the instrument
panel. The control panel contains rotary-type knobs.
There is a blower motor speed switch, mode control
switch, temperature control, and airflow control.
The heater-only or heater-A/C control panel cannot
be repaired. If faulty or damaged, the entire unit
must be replaced. The control knobs and the illumi-
nation lamps are available for service replacement.
HEATER AND AIR CONDITIONING
All vehicles are equipped with a common heater-
A/C housing assembly (Fig. 1). The system combines
air conditioning, heating, and ventilating capabilities
in a single unit housing mounted under the instru-
ment panel. On heater-only systems, the evaporator
coil is omitted from the housing and replaced with an
air restrictor plate.
Outside air enters the vehicle through the cowl top
opening at the base of the windshield, and passes
through a plenum chamber to the heater-A/C system
blower housing. Air flow velocity can then be
adjusted with the blower motor speed selector switch
on the heater-A/C control panel. The air intake open-
ings must be kept free of snow, ice, leaves, and other
obstructions for the heater-A/C system to receive a
sufficient volume of outside air.
24 - 2 HEATING AND AIR CONDITIONINGPL

It is also important to keep the air intake openings
clear of debris because leaf particles and other debris
that is small enough to pass through the cowl ple-
num screen can accumulate within the heater-A/C
housing. The closed, warm, damp and dark environ-
ment created within the heater-A/C housing is ideal
for the growth of certain molds, mildews and other
fungi. Any accumulation of decaying plant matter
provides an additional food source for fungal spores,
which enter the housing with the fresh air. Excess
debris, as well as objectionable odors created by
decaying plant matter and growing fungi can be dis-
charged into the passenger compartment during
heater-A/C system operation.
The heater and optional air conditioner are blend-
air type systems. In a blend-air system, a blend-air
door controls the amount of unconditioned air (or
cooled air from the evaporator on models with air
conditioning) that is allowed to flow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determines the dis-
charge air temperature by moving a cable, which
operates the blend-air door. This allows an almost
immediate manual control of the output air tempera-
ture of the system.
The mode control knob on the heater-only or heat-
er-A/C control panel is used to direct the conditioned
air to the selected system outlets. The mode control
switch uses a cable to control the mode door, while
the recirculation air door is operated by a vacuum
actuator motor.On air conditioned vehicles, the outside air intake
can be shut off by selecting the recirculation mode
(Recirc) with the mode control knob. This will oper-
ate a vacuum actuated recirculating air door that
closes off the outside fresh air intake and recirculates
the air that is already inside the vehicle.
The optional air conditioner for all models is
designed for the use of non-CFC, R-134a refrigerant.
The air conditioning system has an evaporator to cool
and dehumidify the incoming air prior to blending it
with the heated air. This air conditioning system
uses an evaporator probe to maintain minimum
evaporator temperature and prevent evaporator
freezing, and cycles the compressor clutch.
INTRODUCTION
Both the heater and the heater/air conditioning
systems share many of the same functioning compo-
nents. This group will deal with both systems
together when component function is common, and
separately when they are not.
For proper operation of the instrument panel con-
trols, refer to the Owner's Manual provided with the
vehicle.
To service the heater core or evaporator, the unit
housing must be removed from the vehicle (Fig. 2).Fig. 1 Common Blend-Air HVAC (Heating,
Ventilation, Air Conditioning) System - Typical
1 ± TEMPERATURE BLEND/AIR DOOR
2 ± EVAPORATOR CORE
3 ± BLOWER
4 ± PANEL DEFROST DOOR
5 ± HEAT DEFROST DOOR
6 ± HEATER CORE
7 ± RECIRCULATING AIR DOOR
Fig. 2 HVAC Unit Housing
1 ± AIR DISTRIBUTION
2 ± RECIRCULATION DOOR VACUUM ACTUATOR
3 ± AIR INLET
4 ± BLOWER MOTOR
5 ± EVAPORATOR PROBE CONNECTOR
6 ± CONTROL CABLES
7 ± VACUUM HARNESS
PLHEATING AND AIR CONDITIONING 24 - 3
GENERAL INFORMATION (Continued)

SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SER-
VICING THE AIR CONDITIONING REFRIGERANT
SYSTEM. SERIOUS EYE INJURY CAN RESULT
FROM EYE CONTACT WITH REFRIGERANT. IF EYE
CONTACT IS MADE, SEEK MEDICAL ATTENTION
IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC TYPE
LEAK DETECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF REFRIGERANT AT
AVERAGE TEMPERATURE AND ALTITUDE IS
EXTREMELY HIGH. AS A RESULT, ANYTHING THAT
COMES IN CONTACT WITH THE REFRIGERANT
WILL FREEZE. ALWAYS PROTECT SKIN OR DELI-
CATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT. R-134a SERVICE EQUIPMENT OR
VEHICLE A/C SYSTEM SHOULD NOT BE PRES-
SURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR.
SOME MIXTURES OF AIR and R-134a HAVE BEEN
SHOWN TO BE COMBUSTIBLE AT ELEVATED
PRESSURES. THESE MIXTURES ARE POTENTIALLY
DANGEROUS AND MAY RESULT IN FIRE OR
EXPLOSION CAUSING INJURY OR PROPERTY
DAMAGE.
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE
COOLANT AND IS HARMFUL IF SWALLOWED OR
INHALED. SEEK MEDICAL ATTENTION IMMEDI-
ATELY IF SWALLOWED OR INHALED. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PER-
SONAL INJURY CAN RESULT.
CAUTION: The engine cooling system is designed
to develop internal pressure of 97 to 123 kPa (14 to
18 psi). Allow the vehicle to cool a minimum of 15
minutes before opening the cooling system. Refer
to Group 7, Cooling System.
DESCRIPTION AND OPERATION
A/C REFRIGERANT LINES
DISCHARGE LINE
The discharge line is the line that goes from the
compressor to the condenser (Fig. 3). It has no ser-
viceable parts except the rubber O-rings. If the line
is found to be leaking or is damaged it must be
replaced as an assembly.
LIQUID LINE
The liquid line is the line that goes from the con-
denser to drier (Fig. 3). It has no serviceable parts
except the rubber O-rings. If the line is found to be
leaking or is damaged it must be replaced as an
assembly.
SUCTION LINE
The suction line is the large line that connects to
the expansion valve and goes to the compressor (Fig.
3). It also has a small line that goes to the filter/
drier. The suction line uses a gasket on the expan-
sion valve side and rubber O-rings on all other
connections.
There are no serviceable parts on the suction line
other than the rubber O-rings and expansion valve
gasket. If the line is found to be leaking or is dam-
aged it must be replaced as an assembly.
Fig. 3 A/C Compressor Lines
1 ± CONDENSER LIQUID LINE
2 ± SUCTION LINE
3 ± COMPRESSOR MANIFOLD SCREWS
4 ± COMPRESSOR
5 ± DISCHARGE LINE
24 - 4 HEATING AND AIR CONDITIONINGPL
GENERAL INFORMATION (Continued)

A/C SERVICE PORT VALVE CORES
The A/C service port valve cores are serviceable
items (Fig. 4). The high side valve is located on the
filter-drier, and the low side valve is situated on the
suction line, near the washer fluid reservoir filler.
BLOWER MOTOR RESISTOR
The blower motor resistor is located in the cowl, at
the base of the windshield (Fig. 5). There are two dif-
ferent resistor blocks depending on whether the vehi-
cle is equipped with A/C or not. The blower motor
resistors will get hot when in use (Fig. 6). Do not
touch resistor block if the blower motor has been
running.
COMPRESSOR
The compressor used on this vehicle is a Nippon-
denso 10S17. This compressor uses an aluminum
swash plate, teflon coated pistons and aluminum
sleeveless cylinder walls.
NOISE
Excessive noise that occurs when the air condition-
ing is being used may be caused by:
²Loose bolts
²Mounting brackets
²Loose compressor clutch
²Excessive high refrigerant operating pressureVerify the following before compressor repair is
performed:
(1) Compressor drive belt condition
(2) Proper refrigerant charge
(3) Thermal expansion valve (TXV) operating cor-
rectly
(4) Head pressure is normal
Fig. 4 A/C Service Port Valves
1 ± A/C SERVICE PORTS
2 ± FILTER/DRIER
Fig. 5 Blower Motor Resistor Block
1 ± RESISTOR BLOCK
2 ± ELECTRICAL CONNECTOR
Fig. 6 Blower Motor Resistors
1 ± RESISTOR BLOCK
2 ± RESISTORS
PLHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)

COMPRESSOR FRONT SHAFT SEAL
The compressor front shaft seal is not serviceable.
If a leak is detected at the shaft seal, the compressor
must be replaced as a unit.
CONDENSATION DRAIN TUBE
Condensation that accumulates in the evaporator
housing is drained from a tube through the dash and
on to the ground. This tube must be kept open to
prevent condensate water from collecting in the bot-
tom of the housing.
The tapered end of the drain tube is designed to
keep contaminants from entering the heater A/C unit
housing. If the tube is pinched or blocked, condensate
cannot drain, causing water to back up and spill into
the passenger compartment. It is normal to see con-
densate drainage below the vehicle. If the tube is
damaged, it should be replaced.
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain ample temperature levels from the
heating-A/C system, the cooling system must be in
proper working order. Refer to Group 0, Lubrication
and Maintenance or Group 7, Cooling System of this
manual.
The use of a bug screen is not recommended. Any
obstructions forward of the condenser can reduce the
effectiveness of the air conditioning system.
EVAPORATOR PROBE
The evaporator probe can be replaced without hav-
ing to remove the unit housing from the vehicle.
The evaporator probe is located in the unit housing
and placed in the evaporator fins. The probe prevents
evaporator freeze-up. This is done by cycling the com-
pressor clutch OFF when evaporator temperature
drops below freeze point. It cycles ON when the
evaporator temperature rises above freeze point. The
evaporator probe uses a thermistor probe in a capil-
lary tube. The tube is inserted between the evapora-
tor fins in the heater-A/C unit housing.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HIGH PRESSURE CUT OUT SWITCH
The high pressure cut out switch is located on the
rear of the compressor (Fig. 7). It turns off the com-
pressor if the system pressure exceeds 3240 kPa (470
psi).
LOW PRESSURE CUT OFF SWITCH
The Low Pressure Cut Off Switch (Fig. 8) monitors
the refrigerant gas pressure on the suction side of
the system. The low pressure cut off switch is located
on the expansion valve. The low pressure cut off
switch turns off voltage to the compressor clutch coil
when refrigerant gas pressure drops to levels that
could damage the compressor. The low pressure cut
out switch is a sealed factory calibrated unit. It must
be replaced if defective.
24 - 6 HEATING AND AIR CONDITIONINGPL
DESCRIPTION AND OPERATION (Continued)

SIDE WINDOW DEMISTERS
The demisters direct air from the unit housing
through the outlets located on the top corners of the
instrument panel. The demisters operate when the
mode selector is anywhere between floor and defrost
settings. Some air may be noticeable from the demis-
ter outlets when the mode selector is in the bilevel to
floor positions.
SYSTEM AIRFLOW
The system pulls outside (ambient) air through the
cowl opening at the base of the windshield. Then it
goes into the plenum chamber above the unit hous-
ing. On air conditioned vehicles, the air passes
through the evaporator. Air flow can be directed
either through or around the heater core. This is
done by adjusting the blend-air door with the TEMP
control on the instrument panel. The air flow can
then be directed from the panel, floor and defrost
outlets in various combinations using the mode selec-
tor. There are 17 different mode selections possible.
Air flow velocity can be adjusted with the blower
speed selector switch on the instrument panel.
On A/C equipped vehicles the ambient air intake
can be controlled by opening and closing the recircu-
lating air door. When placed in RECIRC, air that is
inside vehicle is removed continuously and recircu-
lated through unit housing. Ambient air cannot be
controlled on vehicles without A/C. The system uses
outside air at all times.
The air conditioning compressor can be engaged by
turning the fan switch counterclockwise from the off
position. It can also be engaged by placing the mode
control in the mix to defrost positions. This will
remove heat and humidity from the air before it is
directed through or around the heater core.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
capacity of the system and consequently result in
higher discharge air temperatures.
Fig. 7 High Pressure Cut Out Switch Location
1 ± DISCHARGE LINE
2 ± A/C COMPRESSOR
3 ± HIGH PRESSURE CUT OUT SWITCH
4 ± SUCTION LINE
Fig. 8 Low Pressure Cut Off Switch
1 ± EXPANSION VALVE
2 ± LOW PRESSURE CUTOFF SWITCH
3 ± LIQUID LINE
4 ± SUCTION LINE
PLHEATING AND AIR CONDITIONING 24 - 7
DESCRIPTION AND OPERATION (Continued)

NOTE: The oil used in the compressor is ND8 PAG
R-134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial effort must be used to keep all R-134a system
components moisture-free. Moisture in the oil is
very difficult to remove and will cause a reliability
problem with the compressor.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with R-134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and
components. The evaporator, condenser, and filter-
drier will retain a significant amount of oil, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent is replaced, the specified amount of refrigerant
oil must be added. When the compressor is replaced,
the amount of oil that is retained in the rest of the
system must be drained from the replacement com-
pressor. When a line or component has ruptured and
oil has escaped, the compressor should be removed
and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the sys-
tem, minus the amount of oil still in the remaining
components, can be measured and poured into the
suction port of the compressor.
VACUUM CONTROL SYSTEM
The neon uses vacuum to operate only the recircu-
lation door (Fig. 9). All other controls are cable.
When vacuum is supplied to the actuator, the door
moves to the Recirculation position (Fig. 10). Theactuator is spring loaded so the door moves to the
Outside-air position when there is no vacuum sup-
plied. The operation of the door can be viewed by
removing the blower motor and looking up into the
unit inlet.
REFRIGERANT OIL CAPACITIES
Refrigerant Oil Capacities
Component ml oz
Total System 180ml 6.1 oz
Filter-Drier 30 ml 1.0 oz
Condenser 30 ml 1.0 oz
Evaporator 59 ml 2.0 oz
All Refrigerant Lines 44 ml 1.5 oz
Fig. 9 A/C Vacuum Line
1 ± BRAKE POWER BOOSTER
2 ± A/C VACUUM CHECK VALVE
3 ± VACUUM HARNESS
Fig. 10 Recirculation Air Door Vacuum Actuator
1 ± OUTSIDE AIR/RECIRC DOOR HOUSING
2 ± VACUUM ACTUATOR LINKAGE
3 ± FOAM SEAL
4 ± RECIRC DOOR VACUUM ACTUATOR
5 ± DOOR LEVER
6 ± DOOR LEVER
24 - 8 HEATING AND AIR CONDITIONINGPL
DESCRIPTION AND OPERATION (Continued)

Normally, vacuum is supplied to the actuator by
placing the Circulation control knob in the Recircula-
tion position. The Mode and the circulation control
are mechanically interlocked so the circulation con-
trol cannot be placed in the RECIRC position if the
mode control is at or between the mix and defrost
positions. Vacuum is supplied to the actuator only
when circulation control is at the RECIRC position.
If the circulation control is between the outside air
position and RECIRC position the system will be in
outside air. If the circulation control is in the
RECIRC position and the mode control is moved from
the floor to the defrost positions, the circulation con-
trol will move from the RECIRC position, to the out-
side air position beginning at the mix position. This
is to prevent window fogging.
DIAGNOSIS AND TESTING
A/C PERFORMANCE TEST
The air conditioning system is designed to remove
heat and humidity from the air entering the passen-
ger compartment. The evaporator, located in the
heater A/C unit, is cooled to temperatures near the
freezing point. As warm damp air passes over the
fins in the evaporator, moisture in the air condenses
to water, dehumidifying the air. Condensation on the
evaporator fins reduces the evaporators ability to
absorb heat. During periods of high heat and humid-
ity, an air conditioning system will be less effective.
With the instrument control set to RECIRC, only air
from the passenger compartment passes through theevaporator. As the passenger compartment air dehu-
midifies, A/C performance levels rise.
PERFORMANCE TEST PROCEDURE
Review Safety Precautions and Warnings in this
group before proceeding with this procedure. Air tem-
perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.
(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures chart.
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
A/C PERFORMANCE TEMPERATURES
Ambient Temperature 21ÉC (70ÉF) 26.5ÉC (80ÉF) 32ÉC (90ÉF) 37ÉC (100ÉF) 43ÉC (110ÉF)
Air Temperature at Left
Center Panel Outlet1-8ÉC
(34-46ÉF)3-9ÉC
(37-49ÉF)4-10ÉC
(39-50ÉF)6-11ÉC
(43-52ÉF)7-18ÉC
(45-65ÉF)
Compressor Discharge
Pressure After the Filter
Drier1034-1724 kPa
(150-250 PSI)1517-2275 kPa
(220-330 PSI1999-2620
kPa (290-380
PSI)2068-2965
kPa (300-430
PSI)2275-3421 kPa
(330-496 PSI)
Evaporator Suction
Pressure103-207 kPa
(15-30 PSI)117-221 kPa
(17-32 PSI)138-241 kpa
(20-35 PSI)172-269 kpa
(25-39 PSI)207-345 kPa
(30-50 PSI)
BLOWER MOTOR ELECTRICAL DIAGNOSIS
Refer to the Blower Motor Electrical System Diag-
nosis chart (Fig. 11) in this section. Also refer to
Group 8W, Wiring Diagrams for more information.
PLHEATING AND AIR CONDITIONING 24 - 9
DESCRIPTION AND OPERATION (Continued)