2000 DODGE NEON Service Repair Manual

INSTALLATION
For installation, reverse the above procedures.
DISASSEMBLY AND ASSEMBLY
HEATER-A/C HOUSING
Use this procedure if any or all of the following
items require service:
²Heater core
²Evaporator
²HVAC housing
The HVAC housing must be removed from the
vehicle before beginning with this procedure. Refer to
Unit Housing in this section for removal procedure.
DISASSEMBLY
(1) Separate the air distribution outlet foam seals
at the case parting line (Fig. 52).
(2) Remove the evaporator lines foam seal, and
heater core tubes foam seal from the unit (Fig. 53).
(3) Remove the retaining clips and screws that
hold the upper and lower housings together.
(4) Separate the two halves of the housing.
(5) Lift the heater core/evaporator out of the case.
ASSEMBLY
To reassemble, reverse the above procedures.
ADJUSTMENTS
MODE CONTROL CABLE
(1) Engage cable to actuator arm lever on mode
door and attach to housing (Fig. 47).
(2) Attach other end of cable to instrument panel
control (Fig. 43).
(3) Turn the mode knob completely counterclock-
wise.
(4) While holding the knob in the counterclockwise
position, pull on the gray casing of the mode cable.
This will take up any free play in the cable and index
the mode door to the mode knob.
(5) Then snap the cable hold down clip into posi-
tion.
TEMPERATURE CONTROL CABLE
(1) Engage cable to actuator arm on temperature
door and attach to housing (Fig. 47).
(2) Attach other end of cable to instrument panel
control (Fig. 43).
(3) Turn the temperature knob completely counter-
clockwise.
Fig. 52 HVAC Housing Air Distribution Foam Seals
1 ± AIR DISTRIBUTION
2 ± RECIRCULATION DOOR VACUUM ACTUATOR
3 ± AIR INLET
4 ± BLOWER MOTOR
5 ± EVAPORATOR PROBE CONNECTOR
6 ± CONTROL CABLES
7 ± VACUUM HARNESS
Fig. 53 HVAC Housing Evaporator Connection and
Heater Core Tube Seals
1 ± EVAPORATOR AND CONNECTION
2 ± FOAM SEALS
3 ± HEATER CORE AND TUBES
4 ± HVAC HOUSING LOWER CASE
5 ± HOUSING MOUNTING STUDS
6 ± HOUSING DRAIN
7 ± WIRING
8 ± BLOWER MOTOR AND WHEEL
24 - 34 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

(4) While holding the knob in the counterclockwise
position, pull on the gray casing of the temperature
cable. This will take up any free play in the cable
and index the temperature door to the temperature
knob.(5) Then snap the cable hold down clip into posi-
tion.
(6) Remount control.
PLHEATING AND AIR CONDITIONING 24 - 35
ADJUSTMENTS (Continued)

HEATING AND AIR CONDITIONING
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
EVAPORATOR CORE ± R. H. D...............1
HEATER CORE ± R. H. D....................3SPECIFICATIONS
TORQUE SPECIFICATIONS..................6
REMOVAL AND INSTALLATION
EVAPORATOR CORE ± R. H. D.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M ± PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK OR DISCONNECT COOLANT HOSES WHEN
THE COOLING SYSTEM IS HOT AND UNDER PRES-
SURE. SERIOUS BURNS FROM COOLANT CAN
OCCUR.
WARNING: READ ALL SAFETY PRECAUTIONS AND
WARNINGS BEFORE PROCEEDING WITH THIS
OPERATION.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system. Refer to Group 7,
Cooling System for the procedure.
(3) Evacuate the refrigerant system.
(4) Remove the instrument panel. Refer to Group
8E, Instrument Panel and Systems for the procedure.
(5) Remove the refrigerant line retaining bolt from
the expansion valve (Fig. 1). Remove the refrigerant
lines from the expansion valve.
(6) Disconnect the electrical connector from the
bottom of the expansion valve (Fig. 1).
(7) Remove the expansion valve retaining bolts
and remove the valve from the vehicle.
(8) Remove the heater core coolant supply hoses
from the heater core (Fig. 2).(9) Working from inside the engine compartment,
remove the A/C-Heater housing retaining fasteners
from the bulkhead.
(10) Remove the A/C-Heater housing drain tube.
Remove the spring clip and pull the hose from the
housing nipple.
(11) Working from inside the vehicle, remove the
defroster duct from the A/C-Heater housing and body
attachment point.
(12) Remove the A/C-Heater housing retaining
bolts.
(13) Disconnect the electrical connectors from the
A/C-Heater housing.
(14) Remove the A/C-Heater housing from the
vehicle and place the assembly on a bench.
Fig. 1 Refrigerant Lines at Bulkhead
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
PLHEATING AND AIR CONDITIONING 24 - 1

(15) Remove the heater core cover from the hous-
ing assembly.
(16) Remove the coolant lines from the heater core.
(17) Remove the screws necessary to disassemble
the A/C-Heater housing assembly.
(18) Remove the evaporator coil from the A/C-
Heater housing (Fig. 3).
INSTALLATION
NOTE: When the evaporator coil is replaced, some
refrigerant oil will remain in the old evaporator. This
oil must be replaced before the system is operated.
(1) Install the evaporator coil in the A/C-Heater
housing (Fig. 4). Be certain all seals are replaced in
there original positions.
(2) Reassemble the A/C-Heater housing.
(3) Install the housing in the vehicle and install
the retaining bolts. Torque the bolts to 20 N´m (177
in. lbs.).
(4) Connect the electrical connectors on the A/C-
Heater housing.
(5) Install the defroster duct on the A/C-Heater
housing and secure at the body attachment point.
(6) Working from inside the engine compartment,
install the A/C-Heater housing drain tube and retain-
ing clip.
Fig. 2 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 3 A/C - Heater Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
Fig. 4 A/C - Heater Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
24 - 2 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

(7) Install the A/C-Heater housing retaining fas-
teners. Torque the fasteners to 20 N´m (177 in. lbs.).
(8) Install the heater core coolant supply hoses on
the heater core (Fig. 5).
(9) Install the expansion valve (Fig. 6), gasket and
retaining bolts. Torque the bolts to 11 N´m (97 in.
lbs.).
(10) Connect the electrical connector on the bottom
of the expansion valve (Fig. 6).
(11) Install the refrigerant lines and retaining bolt
(Fig. 6). Torque the bolt to 23 N´m (203 in. lbs.).
CAUTION: Be certain the refrigerant line sealing
O-rings are well lubricated and free of tears.
(12) Install the instrument panel. Refer to Group
8E, Instrument Panel and Systems for the procedure.
(13) Charge the refrigerant system.
(14) Fill the cooling system. Refer to Group 7,
Cooling System for the procedure.
(15) Connect the negative battery cable.
HEATER CORE ± R. H. D.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M ± PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: DO NOT OPEN THE RADIATOR DRAIN-
COCK OR DISCONNECT COOLANT HOSES WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
(1) Disconnect the negative battery cable.
(2) Drain the cooling system. Refer to Group 7,
Cooling System for the procedure.
(3) Evacuate the refrigerant system.
(4) Remove the instrument panel. Refer to Group
8E, Instrument Panel and Systems for the procedure.
(5) Remove the refrigerant line retaining bolt from
the expansion valve (Fig. 7). Remove the refrigerant
lines from the expansion valve.
(6) Disconnect the electrical connector from the
bottom of the expansion valve (Fig. 7).
(7) Remove the expansion valve retaining bolts
and remove the valve from the vehicle.
Fig. 5 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 6 Refrigerant Lines at Bulkhead
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
PLHEATING AND AIR CONDITIONING 24 - 3
REMOVAL AND INSTALLATION (Continued)

(8) Remove the heater core coolant supply hoses
from the heater core (Fig. 8).
(9) Working from inside the engine compartment,
remove the A/C-Heater housing retaining fasteners
from the bulkhead.
(10) Remove the A/C-Heater housing drain tube.
Remove the spring clip and pull the hose from the
housing nipple.
(11) Working from inside the vehicle, remove the
defroster duct from the A/C-Heater housing and body
attachment point.
(12) Remove the A/C-Heater housing retaining
bolts.
(13) Disconnect the electrical connectors from the
A/C-Heater housing.
(14) Remove the A/C-Heater housing from the
vehicle and place the assembly on a bench.
(15) Remove the heater core cover from the hous-
ing assembly.
(16) Remove the heater core coolant lines from the
heater core.
(17) Remove the screws necessary to disassemble
the A/C-Heater housing assembly (Fig. 9).
(18) Remove the heater core from the A/C-Heater
housing (Fig. 9).
Fig. 7 Expansion Valve Position & Orientation
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
Fig. 8 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 9 Heater - A/C Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
24 - 4 HEATING AND AIR CONDITIONINGPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install the heater core in the A/C-Heater hous-
ing.
(2) Reassemble the A/C-Heater housing.
(3) Install the housing in the vehicle and install
the retaining bolts. Torque the bolts to 20 N´m (177
in. lbs.).
(4) Connect the electrical connectors on the A/C-
Heater housing.
(5) Install the defroster duct on the A/C-Heater
housing and secure at the body attachment point.
(6) Install the A/C-Heater housing drain tube and
retaining clip.
(7) Install the A/C-Heater housing retaining fas-
teners. Torque the fasteners to 20 N´m (177 in. lbs.).
(8) Install the heater core coolant supply hoses on
the heater core (Fig. 11).
(9) Install the expansion valve, gasket and retain-
ing bolts. Torque the bolts to 11 N´m (97 in. lbs.).
(10) Connect the electrical connector on the bottom
of the expansion valve (Fig. 12).
CAUTION: Be certain the refrigerant line sealing
O-rings are well lubricated and free of tears.
(11) Install the refrigerant lines and retaining bolt
(Fig. 12). Torque the bolt to 23 N´m (203 in. lbs.).
Fig. 10 Heater - A/C Housing
1 ± BLOWER MOTOR
2 ± EVAPORATOR COIL
3 ± HEATER CORE
4 ± A/C - HEATER HOUSING
Fig. 11 Heater Core Coolant Supply Lines
1 ± HEATER CORE COOLANT LINE SUPPORT BRACKETS
BOLTS
2 ± HEATER CORE COOLANT SUPPLY LINES
Fig. 12 Expansion Valve Position & Orientation
1 ± EXPANSION VALVE
2 ± REFRIGERANT LINE MANIFOLD RETAINING BOLT
3 ± BATTERY
4 ± LOW PRESSURE CUTOUT SWITCH ELECTRICAL
CONNECTOR
PLHEATING AND AIR CONDITIONING 24 - 5
REMOVAL AND INSTALLATION (Continued)