tow CHRYSLER CARAVAN 2003 Service Manual

(12) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(13) Pull both heater core tubes simultaneously
slightly away from the distribution housing and rear-
ward far enough to disengage the engine compart-
ment ends of the tubes from the dash panel seal.
(14) Remove the heater core tubes and sealing
plate as a unit from beneath the instrument panel.
(15) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
REMOVAL - HEATER CORE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(4) Remove the brake lamp switch from its mount-
ing bracket. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(5) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm.
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER - REMOV-
AL).
(6) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 17).(7) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.
(8) Remove the heater core shield from the distri-
bution housing.
(9) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-
ant and have absorbent toweling readily available to
mop up any spills.
(10) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 18).
(11) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(12) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
(13) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(14) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(15) While pulling the accelerator pedal upward
(Fig. 19) and pushing the brake pedal downward
(Fig. 20) far enough for clearance, pull the heater
core out of the distribution housing.
(16) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation. Also, if
the heater core was leaking, use absorbent toweling
and reach into the heater core opening to mop up
any residual engine coolant within the distribution
housing.
Fig. 17 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
24 - 76 PLUMBING - FRONTRS
HEATER CORE (Continued)
ProCarManuals.com

WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).(2) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose to the tube or nipple toward the center of
the hose to be removed. Release the clamp when it is
off of the tube or nipple.
Fig. 21 Heater Plumbing - 2.4L Engine
1 - ENGINE OUTLET NIPPLE
2 - HEATER SUPPLY
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE & HOSE UNIT
7 - HEATER RETURN
8 - ENGINE INLET NIPPLE
Fig. 22 Heater Plumbing - 3.3/3.8L Engine w/o Rear
Heater
1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE & HOSE (TYPICAL)
Fig. 23 Heater Plumbing - 3.3/3.8L Engine w/Rear
Heater
1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE
Fig. 24 Heater Return - 3.3/3.8L Engine w/o Oil
Cooler
1 - WATER PUMP RETURN NIPPLE
2 - HEATER RETURN TUBE & HOSE
3 - SCREW
4 - SCREW
RSPLUMBING - FRONT24-79
HEATER HOSE (Continued)
ProCarManuals.com

CAUTION:
When removing the heater hose from the heater
core or supply and return tube nipples, DO NOT
apply excessive pressure. Excessive pressure may
damage or deform the nipples and/or the heater
core causing an engine coolant leak.
(3) After the clamp has been moved, grasp the end
of the hose firmly and carefully twist the hose back
and forth while pulling it away from the barbed end
of the nipple. Repeat this procedure at the opposite
end of the hose being removed. If this procedure is
not successful in removing the hose from the nipple,
carefully make a parallel cut through the hose where
it is engaged on the nipple and peel the hose off of
the nipple. This method of removal will require
heater hose replacement.
INSTALLATION
There are several heater core plumbing configura-
tions used on this model, depending upon the engine
size and other optional equipment. One plumbing
configuration is used for all 2.4L engines, while the
3.3L and 3.8L engines have unique heater return
plumbing on the engine for models with or without
an optional engine oil cooler. There are also unique
plumbing configurations at the heater core for mod-
els with or without the optional rear heater and air
conditioner. All models use a combination of formed
steel tubing and rubber hoses. In most cases, the
rubber hose is secured to the steel tubing with a
spring tension clamp.WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose toward the center of the hose being
installed. Release the clamp when it is near the cen-
ter of the hose.
(2) Grasp one end of the heater hose being
installed firmly and carefully twist the hose back and
forth while pushing it over from the barbed end of
the nipple. Repeat this procedure at the opposite end
of the hose being installed.
(3) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose over the tube or nipple. Release the
clamp when it is over the tube or nipple.
(4) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
LIQUID LINE
REMOVAL
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the filter/drier and includes the high
side service port on the fitting for the filter/drier. The
rear section connects between the filter/drier and the
expansion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
optional rear air conditioner, the rear section of the
front air conditioner liquid line also includes a liquid
line hose and tube extension that connects the front
liquid line to the liquid line for the rear air condi-
tioner.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
FRONT SECTION
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
Fig. 25 Heater Return - 3.3/3.8L Engine w/Oil Cooler
1 - ENGINE INLET NIPPLE
2 - HEATER RETURN TUBE & HOSE
3 - SCREW
4 - SCREW
5 - OIL COOLER
6 - HEATER RETURN HOSE
24 - 80 PLUMBING - FRONTRS
HEATER HOSE (Continued)
ProCarManuals.com

(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 26).
(5) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(6) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(7) Remove the nut that secures the liquid line fit-
ting to the condenser on the right side of the cooling
module (Fig. 27).
(8) Disconnect the liquid line fitting from the con-
denser outlet port.
(9) Remove the seals from the liquid line fitting
and discard.
(10) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(11) Disengage the retainer that secures the liquid
line routing clip to the top of the right frame rail
ahead of the front strut tower in the engine compart-
ment (Fig. 28).
(12) Remove the screw that secures the liquid line
front section fitting to the top of the filter-drier.
(13) Disconnect the liquid line fitting from the fil-
ter-drier inlet port.
(14) Remove the seals from the liquid line fitting
and discard.
(15) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier inlet port.
(16) Remove the front section of the front liquid
line from the engine compartment.
Fig. 26 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
Fig. 27 Condenser Connections
1 - CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
Fig. 28 Front Liquid Lines
1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - EXPANSION VALVE
7 - FRONT LIQUID LINE REAR SECTION
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - FILTER-DRIER
11 - ROUTING CLIP
12 - FRONT LIQUID LINE FRONT SECTION
RSPLUMBING - FRONT24-81
LIQUID LINE (Continued)
ProCarManuals.com

REAR SECTION
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the A/C pressure transducer from the
fitting on the front liquid line rear section. (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(6) Remove the nut that secures the A/C ground
strap to the weld stud on the top of the right front
strut tower (Fig. 28).(If equipped)
(7) Remove the A/C ground strap eyelet terminal
connector from the weld stud. (If equipped)
(8) Remove the screw that secures the liquid line
rear section fitting to the top of the filter-drier.
(9) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(12) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(13) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(14) Remove the seals from the suction line and
liquid line fittings and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 29).
(19) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(20) Remove the seal from the underbody liquid
line fitting and discard.
(21) Install plugs in, or tape over the opened liquid
line fittings.(22) Lower the vehicle.
(23) Remove the front liquid line rear section from
the engine compartment.
INSTALLATION
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the filter/drier and includes the high
side service port on the fitting for the filter/drier. The
rear section connects between the filter/drier and the
expansion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
optional rear air conditioner, the rear section of the
front air conditioner liquid line also includes a liquid
line hose and tube extension that connects the front
liquid line to the liquid line for the rear air condi-
tioner.
FRONT SECTION
(1) Position the front section of the front liquid
line into the engine compartment.
(2) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Reconnect the liquid line fitting to the filter-
drier inlet port on the top of the filter-drier.
(5) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
Fig. 29 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
24 - 82 PLUMBING - FRONTRS
LIQUID LINE (Continued)
ProCarManuals.com

(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plane seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (16 in. lbs.).
(13) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the front liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(9) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).(10) Reinstall the A/C ground strap eyelet terminal
connector onto the weld stud on the top of the right
front strut tower. (If equipped)
(11) Install and tighten the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.) (If equipped).
(12) Reinstall the A/C pressure transducer onto
the fitting on the front liquid line rear section. (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/A/C PRESSURE TRANSDUCER -
INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
(21) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(22) Lower the vehicle.
(23) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(24) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
RECEIVER/DRIER
DESCRIPTION
The filter-drier is mounted in a bracket secured to
the right front strut tower in the engine compart-
ment. The filter-drier is connected between the front
and rear sections of the liquid line between the con-
denser outlet and the evaporator inlet. The filter-
drier cannot be repaired. If the filter-drier is faulty
or damaged, or if the refrigerant system has been
contaminated or left open to the atmosphere for an
RSPLUMBING - FRONT24-83
LIQUID LINE (Continued)
ProCarManuals.com

indeterminable period or if the compressor has failed,
it must be replaced.
OPERATION
The filter-drier performs a filtering action to pre-
vent foreign material in the refrigerant from contam-
inating the expansion valve. A desiccant bag is
mounted inside the filter-drier canister to absorb any
moisture which may have entered and become
trapped within the refrigerant system. In addition,
during periods of high demand air conditioner opera-
tion, the filter-drier acts as a reservoir to store sur-
plus refrigerant. Refrigerant enters the filter-drier as
a high-pressure, low temperature liquid.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the screw that secures the liquid line
front section fitting to the top of the filter-drier (Fig.
30).
(4) Disconnect the liquid line fitting from the fil-
ter-drier inlet port.
(5) Remove the seal from the liquid line fitting and
discard.
(6) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier inlet port.
(7) Remove the screw that secures the liquid line
rear section fitting to the top of the filter-drier.
(8) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(9) Remove the seal from the liquid line fitting and
discard.
(10) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(11) Remove the two nuts that secure the filter-
drier mounting bracket to the weld studs on the side
of the right front strut tower.
(12) Remove the filter-drier and mounting bracket
unit from the studs.
INSTALLATION
NOTE: If the filter-drier is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Position the filter-drier and mounting bracket
unit onto the weld studs on the side of the right front
strut tower.
(2) Install and tighten the two nuts that secure
the filter-drier mounting bracket to the studs.
Tighten the nuts to 10 N´m (89 in. lbs.).
(3) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(5) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
Fig. 30 Front Liquid Lines
1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - EXPANSION VALVE
7 - FRONT LIQUID LINE REAR SECTION
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - FILTER-DRIER
11 - ROUTING CLIP
12 - FRONT LIQUID LINE FRONT SECTION
24 - 84 PLUMBING - FRONTRS
RECEIVER/DRIER (Continued)
ProCarManuals.com

TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner top cover and snorkel
from the air cleaner housing located on the right side
of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage the retainer that secures the suction
line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment (Fig. 34).( If Equipped).
(10) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve.(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 35).
(17) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.
(18) Remove the seal from the underbody suction
line fitting and discard.
(19) Install plugs in, or tape over the opened suc-
tion line fittings.
(20) Lower the vehicle.
(21) Remove the suction line from the engine com-
partment.
INSTALLATION
The front air conditioner suction line includes the
low side service port on a section of tubing located
near the compressor. On models equipped with the
optional rear air conditioner, the front air conditioner
suction line also includes a suction line hose and
tube extension that connects the front suction line to
the suction line for the rear air conditioner.
Fig. 34 Suction Line
1 - EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - ROUTING CLIP (If Equipped)
5 - SUCTION LINE
Fig. 35 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
RSPLUMBING - FRONT24-91
SUCTION LINE (Continued)
ProCarManuals.com

WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment. (If Equipped).
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Install a new dual plan seal and reconnect the
suction line fitting to the compressor suction port.
(10) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.
(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and theengine compartment plumbing for the rear heater
and air conditioner.
(20) Lower the vehicle.
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
SERVICE PORTS
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Remove the protective cap from the A/C service
port (Fig. 36).
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(3) Using a standard Schrader-type valve core tool,
remove the valve core from the A/C service port (Low
Fig. 36 A/C Service Port - Typical
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 92 PLUMBING - FRONTRS
SUCTION LINE (Continued)
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INSTALLATION
(1) Remove the tape or plugs from the evaporator
tube fittings and both expansion valve ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube sealing
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(5) Reinstall the rear evaporator line extension
onto the expansion valve. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - REAR/EVAPO-
RATOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear heater-A/C unit housing, behind the right
rear wheel house. It is a heat exchanger made of
rows of tubes and fins. One end of the core is fitted
with a molded plastic tank that includes integral
heater core inlet and outlet nipples. The heater core
can be serviced without removing the rear heater-A/C
unit housing from the vehicle. The heater core cannot
be repaired and, if faulty or damaged, it must be
replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the rear heater-A/C unit housing is directed through
the heater core.
STANDARD PROCEDURE - HEATER CORE
FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.
2.Thermal cycling of the engine cooling system. Fol-
lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
PRE-FILLING
If the rear heater core or the rear heater-A/C hous-
ing have been removed from the vehicle for service,
the rear heater core may be pre-filled with the proper
engine coolant mixture prior to reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
heater-A/C unit housing, and the rear heater-A/C
unit housing should be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
24 - 98 PLUMBING - REARRS
EXPANSION VALVE (Continued)
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