ors CHRYSLER CARAVAN 2005 Service Manual

DIAGNOSIS AND TESTING
REAR BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Integrated Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Turn the ignition switch to the On position. Be
certain that the rear A/C-heater control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, check the rear blower motor relay.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector
from the rear blower motor resistor block (Manual
Temperature Control) or the rear blower motor power
module (Automatic Temperature Control). Reconnect
the battery negative cable. Turn the ignition switch
to the On position. Be certain that the rear A/C-
heater control power is turned on. Check for battery
voltage at the fused rear blower motor relay output
circuit cavity of the rear HVAC wire harness connec-
tor for the rear blower motor resistor block (MTC) or
the rear blower motor power module (ATC). If OK, go
to Step 4. If not OK, repair the open fused front
blower motor relay output circuit to the IPM as
required.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.Disconnect the rear blower motor pigtail wire connec-
tor from the rear HVAC wire harness (MTC) or the
rear blower power module (ATC). Use jumper wires
to connect a battery and ground feeds to the blower
motor pigtail wire connector. The rear blower motor
should operate. If OK with MTC, proceed to diagno-
sis of the rear blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- REAR/BLOWER MOTOR RESISTOR - DIAGNOSIS
AND TESTING). If OK with ATC, use a DRBIII scan
tool to diagnose the rear blower motor power module.
Refer to the appropriate diagnostic information. If
not OK with MTC or ATC, replace the faulty rear
blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart for basic checks of the blower motor when a
vibration or noise is present (Fig. 3).
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 -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control sys-
tem, the blower motor pigtail wire is connected to a
take out and connector of the rear HVAC wire har-
ness. With the Automatic Temperature Control sys-
tem , the blower pigtail wire is connected to a
receptacle on the blower motor power module.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

A/C SYSTEM
WARNING: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE 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 PROP-
ERTY DAMAGE.
CAUTION - A/C SYSTEM
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
on the R-134a system. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible and damage
to the system will result.Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
pressure and can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
If equipped, do not remove the secondary retention
clip from any spring-lock coupler connection while
the refrigerant system is under pressure. Recover
the refrigerant before removing the secondary
retention clip. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Immediately after disconnecting a compo-
nent from the refrigerant system, seal the open fit-
tings with a cap or plug.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system must be
avoided.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging equipment and/or A/C systems.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approved
leak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
24 - 66 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

(4) Open both the suction and discharge valves,
then open the charge valve to allow the heated
refrigerant to flow into the system.
(5) When the transfer of refrigerant has stopped,
close both the suction and discharge valves.
(6) If all of the refrigerant charge did not transfer
from the dispensing device, open all of the windows
in the vehicle and set the heater-air conditioner con-
trols so that the compressor is engaged and the
blower motor is operating at its lowest speed setting.
Run the engine at a steady high idle (about 1400
rpm). If the compressor will not engage, test the com-
pressor clutch control circuit and repair as required.
(7) Open the suction valve to allow the remaining
refrigerant to transfer to the refrigerant system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH PRESSURE) VALVE AT THIS TIME.
(8) Close the suction valve and test the system
performance. (Refer to 24 - HEATING & AIR CON-
DITIONING - STANDARD PROCEDURE - A/C PER-
FORMANCE TEST).
(9) Disconnect the charging station and manifold
gauge set from the refrigerant system service ports.
(10) Reinstall the caps onto the refrigerant system
service ports.
(11) Run the HVAC Control Cooldown test to ver-
ify proper operation(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).
A/C COMPRESSOR
DESCRIPTION
A/C COMPRESSOR
Vehicles equipped with the 2.4L gasoline, 2.5L die-
sel, 2.8L diesel and 3.3L gasoline engines with the
front heating-A/C system only, use the Denso 10S17
A/C compressor. Vehicles equipped with the 3.3L and
the 3.8L gasoline engines with the optional rear heat-
ing-A/C system use the Denso 10S20 A/C compressor.
Both A/C compressors include an integral high pres-
sure relief valve. The A/C compressor is secured to a
mounting bracket on the 2.4L gasoline engine and
directly to the cylinder block on the 2.5L diesel, 2.8L
diesel, 3.3L gasoline and 3.8L gasoline engines.
HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the rear
of the A/C compressor. This mechanical valve is
designed to vent refrigerant from the A/C system to
protect against damage to the compressor and other
system components, caused by condenser air flow
restriction or an overcharge of refrigerant.
OPERATION
A/C COMPRESSOR
The A/C compressor is driven by the engine
through an electric clutch, drive pulley and belt
arrangement. The compressor is lubricated by refrig-
erant oil that is circulated throughout the refrigerant
system with the refrigerant.
The compressor draws in low-pressure refrigerant
vapor from the evaporator through its suction port. It
then compresses the refrigerant into a high-pressure,
high-temperature refrigerant vapor. The compressor
pumps the high-pressure refrigerant vapor to the
condenser through the compressor discharge port.
The compressor cannot be repaired. If faulty or
damaged, the entire compressor assembly must be
replaced. The compressor clutch, pulley and clutch
coil are available for service.
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents the system
when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes
when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING
A/C COMPRESSOR NOISE DIAGNOSIS
Excessive noise while the air conditioning compres-
sor is operating can be caused by loose compressor
mounts, a loose compressor clutch, or high operating
pressures in the refrigerant system. Verify compres-
sor drive belt condition, proper compressor mounting,
correct refrigerant charge level, and compressor head
pressure before compressor repair is performed.
With the close tolerances within the compressor, it
is possible to experience a temporary lockup. The
longer the compressor is inactive, the more likely the
condition is to occur. This condition is the result of
normal refrigerant migration within the refrigerant
system caused by ambient temperature changes. The
refrigerant migration may wash the refrigerant oil
out of the compressor.
24 - 72 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

2.5L/2.8L DIESEL ENGINES
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).
NOTE: Before removing the A/C condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the A/C condenser and radiator. The air seals must
be reinstalled in their proper locations in order for
the A/C and engine cooling systems to perform as
designed.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
RECOVERY).
(2) 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. 8).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.(5) Remove the two bolts that secure the hood
latch to the front of the radiator closure panel cross-
member and move the latch out of the way over the
top of the crossmember. Mark the location of latch for
reinstallation.
(6) Disconnect the transmission oil cooler hoses
from the left side of the cooling module (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER
LINES - REMOVAL).
(7) Disconnect the A/C discharge line and the A/C
liquid line from the A/C condenser (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
LIQUID LINE - REMOVAL).
(8) Install plugs in, or tape over the opened refrig-
erant line fittings and the condenser ports.
(9) Remove the two screws that secure the top of
the mounting bracket on each side of the A/C con-
denser to the cooling module.
(10) Lift the A/C condenser, transmission oil cooler,
and mounting brackets as an assembly far enough to
disengage the lower mounting brackets from the rub-
ber isolators located on each side of the cooling mod-
ule.
(11) Remove the A/C condenser, transmission oil
cooler, and mounting brackets from the vehicle as an
assembly.
(12) Place the assembly on a workbench and
remove the two screws that secure each mounting
bracket to the A/C condenser.
(13) Remove the one screw that secures the left
mounting bracket to the side of the transmission oil
cooler.
(14) Remove the left mounting bracket from the
side of the A/C condenser and transmission oil cooler.
(15) Remove the A/C condenser from the right
mounting bracket and transmission oil cooler.
INSTALLATION
2.4L/3.3L/3.8L ENGINES
NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.7 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.
Fig. 10 Radiator Sight Shield ± Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-77
A/C CONDENSER (Continued)

(1) Position the A/C condenser into the engine
compartment.
(2) Carefully lower the A/C condenser straight
down to engage the lower mounting brackets to the
radiator.
(3) Engage the upper A/C condenser mounting
brackets to the radiator. Be sure that the upper
retaining clips are fully engaged to the upper mount-
ing brackets.
(4) Remove the tape or plugs from the opened
refrigerant line fittings and the condenser ports.
(5) Connect the A/C discharge line and the A/C liq-
uid line to the A/C condenser (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C LIQUID LINE - INSTALLATION).
(6) Connect the transmission oil cooler lines to the
A/C Condenser. Be sure that the quick-connect fit-
tings are fully engaged to the cooler tapping block
(Refer to 7 - COOLING/TRANSMISSION - STAN-
DARD PROCEDURE - TRANSMISSION COOLING).
(7) Position the hood latch onto the front of the
radiator closure panel crossmember.
(8) Install the two screws that secure the hood
latch to the crossmember. Check and adjust the hoodlatch as required. Tighten the bolts to 14 N´m (123
in. lbs.).
(9) Position the radiator sight shield onto the radi-
ator closure panel crossmember.
(10) Install the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
Tighten the screws to 2 N´m (17 in. lbs.).
(11) Install 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. Tighten the screws to 6 N´m (53 in. lbs.).
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
2.5L/2.8L DIESEL ENGINES
NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.7 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.
(1) Position the A/C condenser onto the right
mounting bracket and transmission oil cooler unit.
(2) Position the left mounting bracket onto the side
of the A/C condenser and transmission oil cooler.
(3) Install the screw that secures the left mounting
bracket to the side of the transmission oil cooler.
Tighten the screw to 5 N´m (45 in. lbs.).
(4) Install the two screws that secure each mount-
ing bracket to the sides of the A/C condenser. Tighten
the screws to 5 N´m (45 in. lbs.).
NOTE: Verify that the A/C condenser isolators are
all installed and positioned correctly.
(5) Position the A/C condenser, transmission oil
cooler, and mounting brackets into the vehicle as an
assembly. Be certain that the lower mounting brack-
ets are engaged into the rubber isolators located on
each side of the cooling module.
(6) Install the two screws that secure the top of
the mounting bracket on each side of the A/C con-
denser to the cooling module. Tighten the screws to 5
N´m (45 in. lbs.).
Fig. 11 A/C Condenser ± 2.5L/2.8L Diesel Engines
1 - BOLT (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - A/C CONDENSER
24 - 78 PLUMBING - FRONTRS
A/C CONDENSER (Continued)

REMOVAL
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) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).
(3) Carefully lift the evaporator and its foam wrap
out of the lower half of the HVAC housing as a unit
(Fig. 15). Be certain not to lose the clam shell type
rubber seal that is fitted to the evaporator inlet and
outlet tubes where they exit the HVAC housing.
INSTALLATION
NOTE: If the evaporator is being replaced, add 50
milliliters (1.7 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Carefully lower the evaporator and its foam
wrap into the lower half of the HVAC housing as a
unit. Be certain that the clam shell type rubber seal
is fitted to the evaporator inlet and outlet tubes
where they exit the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
EXPANSION VALVE
DESCRIPTION
The front ªHº valve-type thermal expansion valve
(TXV) is located at the dash panel between the liquid
and suction lines, and the A/C evaporator. The
assembly consists of an aluminum H-valve body and
a thermal sensor. On RG models, the evaporator tem-
perature sensor is installed on the top of the expan-
sion valve.
OPERATION
High-pressure, low temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the evaporator coil. A mechanical sensor in the
expansion valve control head monitors the tempera-
ture and pressure of the refrigerant leaving the evap-
orator coil through the suction line, and adjusts the
orifice size at the liquid line to let the proper amount
of refrigerant into the evaporator coil to meet the
vehicle cooling requirements. Controlling the refriger-
ant flow through the A/C evaporator ensures that
none of the refrigerant leaving the evaporator is still
in a liquid state, which could damage the compressor.
The A/C expansion valve is a factory calibrated
unit and cannot be adjusted or repaired and, if faulty
or damaged, it must be replaced.
Fig. 15 HVAC Housing - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR AND WHEEL
4 - A/C EVAPORATOR
RSPLUMBING - FRONT24-81
A/C EVAPORATOR (Continued)

DIAGNOSIS AND TESTING
FRONT A/C EXPANSION VALVE
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).
NOTE: The A/C expansion valve should only be
tested following testing of the A/C compressor.
NOTE: Liquid CO
2is required to test the A/C expan-
sion valve. This material is available from most
welding supply facilities. Liquid CO
2is also avail-
able from companies which service and sell fire
extinguishers.
When testing the A/C expansion valve, the work
area and the vehicle temperature must be 21É to 27É
C (70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the A/C-heater controls so that the A/C
compressor is operating, the temperature control is
in the highest temperature position, the mode door is
directing the output to the floor outlets, and the
blower motor is operating at the highest speed set-
ting.
(4) Start the engine and allow it to idle. After the
engine has reached normal operating temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the A/C evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 kPa to
1655 kPa (140 psi to 240 psi). The suction (low pres-
sure) gauge should read 138 kPa to 207 kPa (20 psi
to 30 psi). If OK, go to Step 6. If not OK, replace the
faulty A/C expansion valve.
WARNING:
PROTECT THE SKIN AND EYES FROM EXPOSURE
TO LIQUID CO
2OR PERSONAL INJURY CAN
RESULT.
(6) If the suction (low pressure) gauge reads
within the specified range, freeze the A/C expansion
valve for 30 seconds using liquid CO
2or another suit-able super-cold material.Do not spray R-134a or
R-12 refrigerant on the A/C expansion valve for
this test.The suction (low pressure) gauge reading
should drop by 69 kPa (10 psi). If OK, go to Step 7 If
not OK, replace the faulty A/C expansion valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 138 kPa to 207 kPa (20 psi to 30 psi). If not
OK, replace the faulty A/C expansion valve.
(8) When expansion valve testing is complete, test
the overall A/C system performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD 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) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 16).
(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the receiver/
drier.
(7) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.
(9) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the A/C expansion valve and move the
lines out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
24 - 82 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)

(9) Remove the evaporator line extension seal
plate from the expansion valve stud.
(10) Remove the evaporator line extension from
the expansion valve and the rear HVAC housing
base.
(11) Remove the seals from the evaporator line
extension fittings and discard.
(12) Install plugs in, or tape over the opened evap-
orator line extension fittings and both expansion
valve ports.
INSTALLATION
REAR A/C EVAPORATOR
NOTE: If the rear A/C evaporator is being replaced,
add 50 milliliters (1.7 fluid ounces) of refrigerant oil
to the refrigerant system. Use only refrigerant oil of
the type recommended for the A/C compressor in
the vehicle.
(1) Carefully lower the rear A/C evaporator and its
foam wrap into the lower half of the rear HVAC
housing.
(2) Position the upper half of the rear HVAC hous-
ing onto the lower half.
(3) Install the three metal spring clips that secure
the upper half of the rear HVAC housing to the lower
half.
(4) Install the three screws that secure the upper
half of the rear HVAC housing to the lower half.
Tighten the screws to 2 N´m (17 in. lbs.).
(5) Install the rubber grommet that seals the evap-
orator inlet and outlet tubes to the rear HVAC hous-
ing near the expansion valve.
(6) Reinstall the rear expansion valve onto the
rear A/C evaporator (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EXPANSION
VALVE - INSTALLATION).
(7) Reinstall the rear evaporator extension line
onto the expansion valve (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - REAR/EVAPO-
RATOR - INSTALLATION - EVAPORATOR EXTEN-
SION LINE).
(8) Reinstall the rear HVAC housing into the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/REAR HEATER-A/C
HOUSING - INSTALLATION).
REAR A/C EVAPORATOR LINE EXTENSION
(1) Remove the tape or plugs from the evaporator
line extension fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
line extension fittings.(3) Position the evaporator line extension to the
expansion valve and the rear HVAC housing base.
(4) Position the evaporator line extension seal
plate over the expansion valve stud.
(5) Install the nut that secures the evaporator line
extension seal plate to the expansion valve stud.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Position the expansion valve bracket over the
expansion valve stud.
(7) Install the two screws that secure the expan-
sion valve bracket to the lower rear HVAC housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(8) Install the nut that secures the expansion
valve bracket to the expansion valve stud. Tighten
the nut to 23 N´m (17 ft. lbs.).
(9) Carefully restore the expansion valve foam
insulator wrap back around the expansion valve.
(10) Position the plate that captures and seals the
evaporator line extension onto the rear HVAC hous-
ing base.
(11) Install the screw that secures the capture
plate to the base of the rear HVAC housing. Tighten
the screw to 2 N´m (17 in. lbs.).
(12) Install the rear HVAC housing into the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING -
INSTALLATION).
A/C EXPANSION VALVE
DESCRIPTION
The rear ªHº valve-type thermal expansion valve
(TXV) is located at the rear of the rear HVAC hous-
ing between the evaporator line extension and the
evaporator coil. High-pressure, low temperature liq-
uid refrigerant from the liquid line passes through
the expansion valve orifice, converting it into a low-
pressure, low-temperature mixture of liquid and gas
before it enters the evaporator coil.
OPERATION
A mechanical sensor in the expansion valve control
head monitors the temperature and pressure of the
refrigerant leaving the evaporator coil through the
suction line, and adjusts the orifice size at the liquid
line to let the proper amount of refrigerant into the
evaporator coil to meet the vehicle cooling require-
ments. Controlling the refrigerant flow through the
evaporator ensures that none of the refrigerant leav-
ing the evaporator is still in a liquid state, which
could damage the compressor.
The rear A/C expansion valve cannot be adjusted
or repaired and, if faulty or damaged, it must be
replaced.
24 - 100 PLUMBING - REARRS
A/C EVAPORATOR (Continued)

DIAGNOSIS AND TESTING
REAR A/C EXPANSION VALVE
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).
NOTE: The expansion valve should only be tested
following testing of the compressor.
NOTE: Liquid CO
2is required to test the expansion
valve. This material is available from most welding
supply facilities. Liquid CO
2is also available from
companies which service and sell fire extinguish-
ers.
When testing the expansion valve, the work area
and the vehicle temperature must be 21É to 27É C
(70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the heater-air conditioner controls so that
the compressor is operating, the temperature control
is in the highest temperature position, the mode door
is directing the output to the floor outlets, and the
blower is operating at the highest speed setting.
(4) Start the engine and allow it to idle at 1000
rpm. After the engine has reached normal operating
temperature, allow the passenger compartment to
heat up. This will create the need for maximum
refrigerant flow into the evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). The suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30
psi). If OK, go to Step 6. If not OK, replace the faulty
expansion valve.
WARNING: PROTECT THE SKIN AND EYES FROM
EXPOSURE TO LIQUID CO
2. PERSONAL INJURY
CAN RESULT.
(6)
If the suction (low pressure) gauge reads within
the specified range, freeze the expansion valve control
head for 30 seconds using liquid CO
2or another suit-
able super-cold material.Do not spray R-134a or
R-12 refrigerant on the expansion valve controlhead for this test.
The suction (low pressure) gauge
reading should drop by 10 psi. If OK, go to Step 7 If
not OK, replace the faulty expansion valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not
OK, replace the faulty expansion valve.
(8) When expansion valve testing is complete, test
the overall air conditioner performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
Remove all test equipment before returning the vehi-
cle to service.
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), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING), and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - HEATER PLUMBING).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Carefully remove the foam insulator wrap from
the rear expansion valve.
(3) Remove the rear evaporator line extension from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(4) Remove the two screws that secure the expan-
sion valve to the evaporator tube sealing plate.
(5) Remove the expansion valve from the evapora-
tor tubes.
(6) Remove the seals from the evaporator tube fit-
tings and discard.
(7) Install plugs in, or tape over the opened evap-
orator tube fittings and both expansion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the rear A/C
evaporator tube fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the rear evapora-
tor tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install the two screws that secure the rear A/C
expansion valve to the evaporator tube sealing plate.
Tighten the screws to 11 N´m (97 in. lbs.).
RSPLUMBING - REAR24 - 101
A/C EXPANSION VALVE (Continued)

(5) Using spring tension clamp pliers, compress
and slide the clamps off of the rubber hoses at the
front of the underbody heater tubes (Fig. 15).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(6) Disconnect the heater hoses by carefully twist-
ing the hoses back and forth on the rear heater
extension tubes, while gently pulling them away
from the end of the tubes.
(7) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
(8) Remove the screws that secure the underbody
line retaining straps to the vehicle underbody.
(9) Remove the underbody heater tubes from the
retaining straps.
(10) Remove the underbody heater tubes from the
vehicle.
UNDERBODY REFRIGERANT LINES
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 CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT RECOVERY).
(2) Raise and support vehicle.
(3) Disconnect the exhaust system from the
exhaust hanger rubber isolators and position the
exhaust system out of the way (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(4) Disconnect the underbody refrigerant lines
from the front liquid and suction line extension tubes
and remove and discard the O-ring seals. (Fig. 16).
Fig. 15 Underbody Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 16 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 14 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
24 - 110 PLUMBING - REARRS
UNDERBODY LINES (Continued)