Dodge Neon / Neon SRT-4. Manual - part 438

PAG refrigerant oil is much more hygroscopic than

mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.

STANDARD PROCEDURE

REFRIGERANT OIL LEVEL

WARNING: Review safety precautions and warnings
in this group before performing this procedure
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNINGS) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAUTIONS).
Failure to follow the warnings and cautions could
result in possible personal injury or death.

CAUTION: The oil used in the A/C compressor is
ND-8 PAG R-134a refrigerant oil. Only refrigerant oil
of the same type should be used to service the A/C
system. Do not use any other refrigerant oil. The oil
container should be kept tightly capped until it is
ready for use and then tightly capped after use to
prevent

contamination

from

dirt

and

moisture.

Refrigerant oil will quickly absorb any moisture it
comes in contact with, therefore, special effort must
be used to keep all R-134a system components
moisture-free. Moisture in the refrigerant oil is very
difficult to remove and will cause a reliability prob-
lem with the A/C compressor.

NOTE: Most reclaim/recycling equipment will mea-
sure the lubricant being removed during recovery.
This amount of lubricant should be added back into
the system. Refer to the reclaim/recycling equip-
ment manufacturers instructions.

It will not be necessary to check the oil level in the

A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to component
replacement, or a rupture or leak from a refrigerant
line, connector fitting, component or component seal.
If a leak occurs, add 30 milliliters (1 fluid ounce) of
the recommended refrigerant oil to the refrigerant
system after the repair has been made. Refrigerant
oil loss will be evident at the leak point by the pres-
ence of a wet, shiny surface around the leak.

Refrigerant oil must be added when an accumula-

tor, A/C evaporator or A/C condenser is replaced. See
the Refrigerant Oil Capacities chart. When an A/C
compressor is replaced, the refrigerant oil must be
drained from the old compressor and measured.

Drain all of the refrigerant oil from the new A/C com-
pressor, then fill the new compressor with the same
amount of refrigerant oil that was drained out of the
old compressor.

REFRIGERANT OIL CAPACITIES

Component

Total System Fill

180

6.1

Accumulator, receiver/
drier

1.0

Condenser

1.0

Evaporator

2.0

Compressor

Drain and measure the
oil from the old
compressor - see text.

SUCTION LINE

DESCRIPTION

The A/C suction line is the refrigerant line that

goes from the accumulator tube tapping plate to the
A/C compressor. The A/C suction line is serviced in
two sections. On 2.4L and RHD models, the rear sec-
tion of the suction line contains the low side service
port is only serviced with the liquid line as an assem-
bly, except for the rubber O-ring seals and the service
port valve core.

CAUTION: Use only O-ring seals specified for the
vehicle. Failure to use correct O-ring seal will cause
the refrigerant system connection to leak.

The O-ring seals used on the connections are made

from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals must be replaced when-
ever the suction line is removed and installed.

The A/C suction line cannot be repaired and, if

leaking or damaged, it must be replaced.

REMOVAL

WARNING: Review the warnings and cautions in the
front of this section before performing the following
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - WARNING - A/C SYSTEM) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION - A/C SYSTEM).

2.0L LHD MODELS

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

24 - 60

PLUMBING

PL/SRT-4

REFRIGERANT OIL (Continued)

(2) Remove the bolt that secures the suction line

fitting to the top of the A/C compressor (Fig. 26).

(3) Disconnect the A/C suction line from the A/C

compressor and remove and discard the O-ring seal.

(4) Install plugs in, or tape over the opened suc-

tion line fitting and the compressor inlet port.

(5) Disconnect the front suction line from the mid-

line connector block and remove and discard the
O-ring seal (Fig. 27).

(6) Install plugs in, or tape over the opened suc-

tion line fitting and the mid-line connector block.

(7) Remove the suction line retaining brackets as

required and remove the front suction line from the
engine compartment.

(8) Remove the nut that secures the A/C suction

line to the accumulator.

(9) Remove the A/C suction line from the accumu-

lator and remove and discard the O-ring seals.

(10) Install plugs in, or tape over the opened suc-

tion line fitting and accumulator outlet port.

(11) Remove the rear suction line from the engine

compartment.

2.4L AND RHD MODELS

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Remove the bolt that secures the A/C suction

line to the A/C compressor (Fig. 26).

(3) Disconnect the A/C suction line from the A/C

compressor and remove and discard the O-ring seal.

(4) Install plugs in, or tape over the opened suc-

tion line fitting and the compressor inlet port.

(5) Disconnect the front suction line from the mid-

line connector block of the rear suction line assembly
and remove and discard the O-ring seal (Fig. 28).

(6) Install plugs in, or tape over the opened suc-

tion line fitting and the mid-line connector block.

(7) Remove the suction line from the retaining

brackets as required and remove the front suction
line from the engine compartment.

(8) If equipped, relocate the vehicle speed control

servo as necessary to access the receiver/drier.

(9) Remove the bolt that secures the rear section

of the liquid line to the receiver/drier.

(10) Remove the rear section of the liquid line

from the receiver/drier and remove and discard the
O-ring seals.

(11) Install plugs in, or tape over the opened liquid

line fitting and receiver/drier outlet port.

(12) Remove the bolt that secures the rear suction

and liquid line assembly to the A/C expansion valve.

(13) Disconnect the rear suction and liquid line

assembly from the A/C expansion valve.

(14) Remove the gasket from the A/C expansion

valve and discard.

Fig. 26 A/C Compressor - Refrigerant Lines

1 - LIQUID LINE
2 - SUCTION LINE
3 - BOLTS (2)
4 - A/C COMPRESSOR
5 - DISCHARGE LINE

Fig. 27 Suction Line - 2.0L LHD Models

1 - LIQUID LINE MOUNTING CLIP
2 - A/C CHARGE PORT
3 - A/C LOW PRESSURE SWITCH
4 - A/C LOW PRESSURE SWITCH CONNECTOR
5 - ACCUMULATOR

PL/SRT-4

PLUMBING

24 - 61

SUCTION LINE (Continued)

(15) Install plugs in, or tape over the opened rear

suction and liquid line fittings and both expansion
valve ports.

(16) Disengage the rear suction and liquid line

assembly from the retaining clips as required and
remove the rear suction and liquid line assembly
from the engine compartment.

INSTALLATION

2.0L LHD MODELS

(1) Position the rear suction line into the engine

compartment.

(2) Remove the tape or plugs from the suction line

fitting and accumulator outlet port.

(3) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the suction line fit-
tings. Use only the specified O-rings as they are
made of a special material for the R-134a system.
Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.

(4) Connect the A/C suction line to the accumula-

tor.

(5) Install the nut that secures the A/C suction

line to the accumulator. Tighten the nut to 2.3 N·m
(20 in. lbs.).

(6) Position the front suction line into the engine

compartment.

(7) Remove the tape or plugs from the front suc-

tion line fitting and the mid-line connector block.

(8) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the suction line fit-
ting. Use only the specified O-rings as they are made
of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

(9) Connect the front suction line fitting to the

mid-line connector block.

(10) Install the nut that secures the front suction

line fitting to the mid-line connector block. Tighten
the nut to 4.5 N·m (40 in. lbs.).

(11) Remove the tape or plugs from the A/C com-

pressor suction port and the suction line fitting.

(12) Lubricate a new rubber O-ring seal with clean

(13) Connect the A/C suction line to the A/C com-

pressor.

(14) Install the bolt that secures the A/C suction

line to the A/C compressor. Tighten the bolt to 12
N·m (108 in. lbs.).

(15) Install the suction line retaining brackets as

required.

(16) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE).

(17) Recharge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE

REFRIGERANT

SYSTEM

CHARGE).

2.4L AND RHD MODELS

(1) Position the rear suction and liquid line assem-

bly into the engine compartment.

(2) Engage the rear suction and liquid line assem-

bly to the retaining clips as required.

(3) Remove the tape or plugs from the liquid and

suction line fittings and both ports on the front of the
A/C expansion valve.

(4) Install a new gasket onto the A/C expansion

valve.

(5) Connect the liquid and suction line fitting to

the A/C expansion valve.

Fig. 28 Suction Line - 2.4L LHD Shown, RHD Typical

1 - RECEIVER/DRIER
2 - SUCTION AND LIQUID LINE ASSEMBLY (REAR)
3 - BOLT
4 - RECEIVER/DRIER MOUNTING GROMMET
5 - A/C LOW PRESSURE SWITCH
6 - CONDENSATE DRAIN TUBE
7 - A/C EXPANSION VALVE
8 - BOLT
9 - LIQUID LINE (FRONT)
10 - SUCTION LINE (FRONT)

24 - 62

PLUMBING

PL/SRT-4

SUCTION LINE (Continued)

(6) Install the bolt that secures the suction and

liquid line fitting to the A/C expansion valve. Tighten
the bolt to 20 N·m (15 ft. lbs.).

(7) Position the front suction line into the engine

compartment.

(8) Remove the tape or plugs from the front suc-

tion line fitting and the mid-line connector block.

(9) Lubricate a new rubber O-ring seal with clean

(10) Connect the front suction line fitting to the

mid-line connector block.

(11) Install the nut that secures the front suction

line fitting to the mid-line connector block. Tighten
the nut to 4.5 N·m (40 in. lbs.).

(12) Remove the tape or plugs from the opened liq-

uid line fitting and receiver/drier outlet port.

(13) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the liquid line fitting.
Use only the specified O-rings as they are made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.

(14) Connect the A/C liquid line to the receiver/

drier.

(15) Install the bolt that secures the A/C liquid

line to the receiver/drier. Tighten the bolt to 2.3 N·m
(20 in. lbs.).

(16) If equipped, reinstall the vehicle speed control

servo.

(17) Remove the tape or plugs from the compressor

suction port and the suction line fitting.

(18) Lubricate a new rubber O-ring seal with clean

(19) Connect the A/C suction line to the A/C com-

pressor.

(20) Install the bolt that secures the A/C suction

line to the A/C compressor. Tighten the bolt to 12
N·m (108 in. lbs.).

(21) Install the suction line retaining brackets as

required.

(22) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE).

(23) Recharge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING - STANDARD
PROCEDURE

REFRIGERANT

SYSTEM

CHARGE).

SERVICE PORT VALVE CORE

DESCRIPTION

The A/C service port valve cores are serviceable

items (Fig. 29). On 2.0L LHD models, the low side
valve is located on the liquid line between the A/C
condenser and the evaporator and, the high side
valve is located on the discharge line fitting at the
A/C condenser. On 2.4L and RHD models, the low
side valve is located on the suction line near the
receiver/drier and, the high side valve is located on
the liquid line fitting at the receiver/drier outlet port
(Fig. 29).

REMOVAL

(1) Remove the protective cap from the low and/or

high side service port as necessary.

(2) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT

STANDARD

PROCEDURE - REFRIGERANT SYSTEM RECOV-
ERY).

(3) Using a standard Schrader-type valve core tool,

remove the valve core from the service port as
required.

Fig. 29 A/C Service Ports - Typical

1 - A/C SERVICE PORTS
2 - RECEIVER/DRIER

PL/SRT-4

PLUMBING

24 - 63

SUCTION LINE (Continued)

Content .. 436 437 438 439 ..