ABS CHRYSLER VOYAGER 1996 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 1996, Model line: VOYAGER, Model: CHRYSLER VOYAGER 1996Pages: 1938, PDF Size: 55.84 MB
Page 1448 of 1938

REMOTE POWER STEERING FLUID RESERVOIR
REMOVE
(1) Remove the filler cap from remote power steer-
ing fluid reservoir (Fig. 31).
(2) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(3) Remove at power steering pump, the power
steering fluid hose coming from the power steering
fluid reservoir. Let the power steering fluid drain out
of the reservoir and hose.
(4) Lower vehicle.
(5) Remove the fluid supply hose (Fig. 31) from the
remote power steering fluid reservoir.
(6) Remove the 2 mounting screws (Fig. 31)
attaching the remote fluid reservoir to the inner
fender.
(7) Remove remote reservoir from inner fender.
INSTALL
(1) Install remote power steering fluid reservoir on
inner fender, by first inserting tab on reservoir into
hole in inner fender. Then rotate reservoir so mount-
ing tabs are against inner fender.
(2) Install and securely tighten the 2 reservoir
mounting screws (Fig. 31).
CAUTION: The power steering fluid reservoir to
power steering pump supply hose must be routed
tightly against the strut tower and parallel to the
dash panel. It must also be routed under the wiring
harness and below the drip tube. This will prevent
the hose from coming in contact with the accessory
drive belt. The power steering fluid supply hose
must be located in its correct position by clipping it
to the stud in the strut tower (Fig. 32).(3) Install the fluid supply hose onto the power
steering fluid reservoir fitting (Fig. 31). Install the
hose clamp on the fluid supply hose at the fluid res-
ervoir.Be sure hose clamp in installed past bead
on fluid reservoir fitting.
(4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for
this vehicle.
(5) Install power steering fluid supply hose on
power steering pump. Install the hose clamp on the
fluid supply hose at the power steering pump.Be
sure hose clamp in installed past bead on pump
fitting.
(6) Lower vehicle.
(7) Install routing clip for power steering fluid sup-
ply hose on stud in strut tower (Fig. 32).
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.
(12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(13) Add power steering fluid if necessary.
(14) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(15) Stop the engine. Check the fluid level and
refill as required.
(16) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 31 Remote Power Steering Fluid Reservoir
Fig. 32 Power Steering Fluid Hose Routing Clip
19 - 22 STEERINGNS
REMOVAL AND INSTALLATION (Continued)
Page 1547 of 1938

CAUTION: Some clutch packs appear similar, but
they are not the same. Do not interchange clutch
components, as they might fail.
HYDRAULICS
The hydraulics of the transaxle provide:
²Manual shift lever select function
²Main line pressure regulation
²Torque converter and cooler flow control
Oil flow to the friction elements is controlled
directly by four solenoid valves. The hydraulics also
include a unique logic- controlled solenoid torque con-
verter clutch control valve. This valve locks out the
1st gear reaction element with the application of 2nd,
direct, or overdrive gear elements. It also redirects
the 1st gear solenoid output so that it can control
torque converter clutch operation. To regain access to
1st gear, a sequence of commands must be used to
move the solenoid TCC control valve. This precludes
any application of the 1st gear reaction element with
other elements applied. It also allows one solenoid to
control two friction elements.
Small, high-rate accumulators are provided in each
controlled friction element circuit. These serve to
absorb the pressure responses, and allow the controls
to read and respond to changes that are occurring.
SOLENOIDS
The solenoid valves perform most control functions,
these valves must be extremely durable and tolerant
of dirt. For that reason hardened-steel poppet and
ball valves are used. These are free from any close
operating clearances. The solenoids operate the
valves directly without any intermediate element.
Direct operation means that these units must have
very high output. They must close against the size-
able flow areas and high line pressures. Fast
response is also required to meet the control require-
ments.
Two of the solenoids are normally-venting and two
are normally-applying; this was done to provide a
default mode of operation. With no electrical power,
the transmission provides 2nd gear in (OD), (3), or
(L) shift lever positions. All other transmission lever
positions will operate normally. The choice of 2nd
gear was made to provide adequate breakaway per-
formance while still accommodating highway speeds.
SENSORS
There are three pressure switches to identify sole-
noid application. There are two speed sensors to read
input (torque converter turbine) and output (parking
sprag) speeds. There is also a transmission range
sensor to indicate the manual shift lever position.
The pressure switches are incorporated in an assem-
bly with the solenoids. Engine speed, throttle posi-tion, temperature, etc., are also observed. Some of
these signals are read directly from the engine con-
trol sensors; others are read from a multiplex circuit
with the powertrain control module.
ELECTRONICS
The 41TE Transmission Control Module (TCM) is
located underhood in a potted, die-cast aluminum
housing. The module used is a new controller called
EATX III. The TCM has a sealed, 60-way connector.
ADAPTIVE CONTROLS
These controls function by reading the input and
output speeds over 140 times a second and respond-
ing to each new reading. This provides the precise
and sophisticated friction element control needed to
make smooth clutch-to-clutch shifts for all gear
changes. The use of overrunning clutches or other
shift quality aids are not required. As with most
automatic transaxles, all shifts involve releasing one
element and applying a different element. In simpli-
fied terms, the upshift logic allows the releasing ele-
ment to slip backwards slightly. This ensures that it
does not have excess capacity. The apply element is
filled until it begins to make the speed change to the
higher gear. The apply pressure is then controlled to
maintain the desired rate of speed change. This con-
tinues until the shift is made. The key to providing
excellent shift quality is precision. For example, the
release element for upshifts is allowed to slip back-
wards slightly. The amount of that slip is typically
less than a total of 20 degrees. To achieve that pre-
cision, the TCM learns the traits of the transaxle
that it is controlling. It learns the release rate of the
releasing element and the apply time of the applying
element. It also learns the rate at which the apply
element builds pressure sufficient to begin making
the speed change. This method achieves more preci-
sion than would be possible with exacting tolerances.
It can also adapt to any changes that occur with age
or environment.
For kickdown shifts, the control logic allows the
releasing element to slip. Then controls the rate at
which the input (and engine) accelerate. When the
lower gear speed is achieved, the releasing element
reapplies to maintain that speed until the apply ele-
ment is filled. This provides quick response since the
engine begins to accelerate immediately. This also
provides a smooth torque exchange since the release
element can control the rate of torque increase. This
control can make any powertrain feel more respon-
sive without increasing harshness.
Adaptive controls respond to input speed changes.
They compensate for changes in engine or friction
element torque and provide good, consistent shift
quality for the life of the transaxle.
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 73
DESCRIPTION AND OPERATION (Continued)
Page 1602 of 1938

Fig. 231 Install Strap Bolts
Fig. 232 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
Fig. 233 Tighten Stirrup Strap Bolts To 23 N´m
(200 in. lbs.)
Fig. 234 Bend Tabs On Strap Up Against Flats Of
Bolts
Fig. 235 Install Transfer Shaft Bearing Cone
Fig. 236 Install Bearing Cup To Shaft
21 - 128 TRANSAXLE AND POWER TRANSFER UNITNS
DISASSEMBLY AND ASSEMBLY (Continued)
Page 1750 of 1938

POWER SEAT SWITCH
Diagnostic information for power seat switch is
located in Group 8R, Power Seats.
REMOVAL
(1) Remove seat cushion side cover.
(2) Disconnect wire connector from power seat
switch.
(3) Pry power seat switch knobs straight off switch
(Fig. 35).
(4) Remove screws holding power seat switch to
side cover (Fig. 36).
(5) Remove power seat switch from side cover.
INSTALLATION
(1) Place power seat switch in position on side
cover.
(2) Install screws to hold power seat switch to side
cover (Fig. 36).
(3) Push power seat switch knobs straight on
switch (Fig. 35).
(4) Connect wire connector into power seat switch.
(5) Install seat cushion side cover.
RECLINER HANDLE ± MANUAL
REMOVAL
(1) Remove screw holding recliner handle to
recliner spline shaft (Fig. 37).
(2) Remove recliner handle from spline shaft.
INSTALLATION
(1) Place recliner handle in position on spline
shaft.
(2) Install screw to hold recliner handle to recliner
spline shaft (Fig. 37).
UNDER SEAT STORAGE BIN
REMOVAL
(1) Release under seat storage bin latch and open
bin.
(2) Depress lock tabs at the rear/top edge of the
storage bin (Fig. 38).
(3) Pull storage bin from bucket seat riser.
INSTALLATION
(1) Engage storage bin tracks into guides on each
side of seat riser.
(2) Push storage bin inward until lock tabs snap
past retaining ridge on tracks
(3) Verify storage bin latch operation.
Fig. 35 Power Seat Switch Knobs
Fig. 36 Power Seat Switch
Fig. 37 Recliner Handle ± Manual
23 - 20 BODYNS
REMOVAL AND INSTALLATION (Continued)
Page 1771 of 1938

to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 45).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(5) Install hood.
(6) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 46).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 47).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net-
pierced tabs. If alignment is required, flatten tabs.
(5) Install bolts attaching hood latch to radiator
closure panel crossmember.
(6) Verify hood operation and alignment. Adjust as
necessary.
Fig. 44 HoodFig. 45 Hood Hinge
Fig. 46 Hood Latch
NSBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)
Page 1782 of 1938

INSTALLATION
(1) Place crossbar in position on roof.
(2) Engage crossbar into notch in front riser.
(3) Slide crossbar rearward into desired position.
(4) Install luggage rack front riser covers.
LUGGAGE RACK RISER COVER
REMOVAL
(1) Disengage lock tabs holding luggage rack front
riser cover to riser.
(2) Remove cover from riser (Fig. 69).
INSTALLATION
(1) Place cover in position on luggage rack riser.
(2) Engage lock tabs to holding luggage rack front
riser cover to riser.
LUGGAGE RACK SIDE RAIL
REMOVAL
(1) Remove luggage rack front riser covers.
(2) Remove crossbars.
(3) Remove screws attaching side rail to front riser
and roof panel (Fig. 70).
(4) Remove screws attaching side rail to center
riser and roof panel.
(5) Remove screws attaching side rail to rear riser
and roof panel (Fig. 71).
(6) Remove side rail from vehicle.
INSTALLATION
(1) Place side rail in position on vehicle.
(2) Install screws to attach side rail to rear riser
and roof panel.
(3) Install screws to attach side rail to center riser
and roof panel.
(4) Install screws to attach side rail to front riser
and roof panel.
(5) Install crossbars.
(6) Install luggage rack front riser covers.
OVERHEAD GRAB-HANDLES
REMOVAL
(1) Using a trim stick (C-4755), remove screw
access covers from grab-handle.
(2) Remove screws holding grab-handle to roof rail.
(3) Remove grab-handle from vehicle.
INSTALLATION
(1) Place grab-handle in position on vehicle.
(2) Install screws to hold grab-handle to roof rail.
(3) Install screw access covers into grab-handle.
QUARTER GLASS
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Remove screw attaching quarter window
retainer to vent motor arm.
(4) Disengage quarter window retainer from vent
motor arm.
Fig. 69 Luggage Rack Riser Cover
Fig. 70 Luggage Rack Front Riser
Fig. 71 Luggage Rack Rear Riser
23 - 52 BODYNS
REMOVAL AND INSTALLATION (Continued)
Page 1784 of 1938

(3) Install bolts to hold ends of crossmember to
radiator closure panel (Fig. 75).
(4) Install bolts to hold radiator isolators to cross-
member.
(5) Install screw to hold coolant recovery bottle to
crossmember.
(6) Install bolt to hold air cleaner housing to cross-
member.
(7) Install engine air inlet resonator.
(8) Install radiator sight shield.
(9) Align hood latch by placing latch over netpierce
tabs. If alignment is required, flatten tabs.
(10) Install bolts to hold hood latch to crossmem-
ber.
(11) Verify hood latch operation and hood align-
ment.
RAIL LAMP MODULE
WITHOUT REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail.
(3) Remove rail lamp module from headlining (Fig.
76).
(4) Disconnect wire connector from body wiring
harness.
(5) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module in vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screw attaching module to roof rail
inside coat hook.
WITH REAR HVAC
REMOVAL
(1) Pull coat hook open.
(2) Remove screw attaching rail lamp module to
roof rail inside coat hook (Fig. 77).
(3) Remove screws attaching rail lamp module to
roof rail from behind grab handle.
(4) Remove rail lamp module from headlining.
(5) Disconnect wire connector from body wiring
harness.
(6) Remove rail lamp module from vehicle.
INSTALLATION
(1) Position rail lamp module to vehicle.
(2) Connect wire connector to body wiring harness.
(3) Position rail lamp module to headlining.
(4) Install screws to attach rail lamp module to
roof rail behind grab handle.
(5) Install screw to attach rail lamp module to roof
rail inside coat hook.
Fig. 75 Radiator Closure Panel CrossmemberFig. 76 Rail Lamp Module ± w/o Rear HVAC
Fig. 77 Rail Lamp Module ± w/Rear HVAC
23 - 54 BODYNS
REMOVAL AND INSTALLATION (Continued)
Page 1800 of 1938

SLIDING DOOR LATCH/LOCK CONTROL
REMOVAL
(1) Remove sliding door trim panel.
(2) Remove sliding door stop bumper.
(3) Remove sound pad, if equipped.
(4) Remove latch/lock control cover (Fig. 113).
(5) With sliding door ajar, disengage clip holding
rear latch link to latch/lock control (Fig. 114) (Fig.
115).
(6) Place a flat head screw driver between metal
clip ears and bottom of link.
NOTE: Rotate screw driver to remove link.
CAUTION: Replace the latch/lock control if any of
the metal clips on the latch/lock control are bent or
broken. DO NOT attempt to repair the clips to retain
the links.
(7) Remove rear latch link from latch/lock control.
(8) Disengage clip holding outside door handle link
to latch/lock control (Fig. 115).
(9) Remove outside door handle link from latch/
lock control.
(10) Disengage clip holding inside door handle
bellcrank link to latch/lock control (Fig. 115).
(11) Separate inside door handle bellcrank link
from latch/lock control.
(12) Disengage clip holding lock cylinder link to
latch/lock control.
(13) Remove lock cylinder link from control.
(14) Disengage clip holding inside lock link to
latch/lock control.
(15) Remove inside lock link from control.
(16) Disengage lock tabs holding hold open latch
cable case to latch/lock control.
(17) Remove hold open latch cable ball end from
latch/lock control.
(18) Loosen bolts holding latch/lock control to slid-
ing door.
(19) If equipped, disconnect wire connector from
power door lock motor.
(20) Remove latch/lock from vehicle.
INSTALLATION
(1) Position latch/lock locking lever in unlocked
position.
(2) Engage rigging cam (Fig. 114).
(3) Place latch/lock in position on vehicle.
(4) If equipped, engage wire connector into power
door lock motor.
(5) Insert bolt heads into slots in sliding door
inner panel.
(6) Tighten bolts to hold latch/lock control to slid-
ing door.(7) Engage hold open latch cable ball end into
latch/lock control.
(8) Engage lock tabs to hold the hold open latch
cable case to latch/lock control.
(9) Insert lock cylinder link into control.
(10) Engage clip to hold lock cylinder link to latch/
lock control.
(11) Insert inside lock link into control.
(12) Engage clip to hold inside lock link to latch/
lock control.
(13) Lift clip for inside door handle bellcrank link
to top of slot in mechanism (Fig. 114).
(14) Engage clip to hold bellcrank link to latch/lock
control.
(15) Lower clip for outside door handle link to bot-
tom of slot in mechanism and engage link to clip
(Fig. 114).
NOTE: Move link rearward until movement stops
before engaging link to clip.
(16) Place rear latch link in position on control by
moving link rearward until movement stops.
(17) Engage clip to hold rear latch release link to
latch/lock control.
(18) Push inside lock link button downward to dis-
engage rigging cam.
(19) Verify sliding door operation.
(20) Install latch/lock cover.
(21) Install sound pad, if equipped.
(22) Install sliding door stop bumper.
(23) Install sliding door trim panel.
Fig. 113 Latch/Lock Cover
23 - 70 BODYNS
REMOVAL AND INSTALLATION (Continued)
Page 1820 of 1938

absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep
the radius of all bends at least 10 times the diame-
ter of the hose. Sharper bends will reduce the flow
of refrigerant. The flexible hose lines should be
routed so they are at least 3 inches (80 mm) from
the exhaust manifold. Inspect all flexible hose lines
to make sure they are in good condition and prop-
erly routed.
The use of correct wrenches when making con-
nections is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain
stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used.
All tools, including the refrigerant dispensing
manifold, the manifold gauge set, and test hoses
should be kept clean and dry.
HVAC CONTROL MODULE
The HVAC control module regulates the operation
of the various actuator motors. The actuator motors
are used to move the mode, blend- air, and RECIRC.
doors (Fig. 3).
The control module is included in the A/C control
head located on the instrument panel. The control
head includes the blower speed switch, rear wiper
and washer operation, front & rear window defogger,
recirculation door operation, and A/C compressor
operation if equipped. Refer to Group 8E, Instrument
Panel and Systems for service procedures.
NOTE: The RECIRC. function on the HVAC control
module automatically defaults to the OFF position
after a ignition key cycle. To reactivate the RECIRC.
function, the RECIRC. button must be repressedThe rear blower speed switch is serviced separately
from the control head.
SIDE DOOR HEATER A/C OUTLETS
The driver's and passenger side doors have supple-
mental air outlets and duct work. The air is chan-
neled from the instrument panel to the door duct and
either to the lower floor or upper door outlets (Fig.
4). The air can be adjusted to blow on the first rear
passenger seat(s).
SIDE WINDOW DEMISTER
The side window demisters direct air from the
heater assembly. The outlets are located on the top
forward corners of the front door panels (Fig. 5). The
demisters operate when the control mode selector is
on FLOOR, MIX or DEFROST setting.
SYSTEM AIRFLOW
The system pulls outside (ambient) air through the
cowl opening at the base of the windshield. Then it
goes into the plenum chamber above the heaterÐA/C
Fig. 3 HVAC Control Module
Fig. 4 Door Outlets
24 - 4 HEATING AND AIR CONDITIONINGNS
DESCRIPTION AND OPERATION (Continued)
Page 1821 of 1938

unit housing. On air conditioned vehicles, the air
passes through the evaporator. At this point the air
flow can be directed either through or around the
heater core. This is done by adjusting the blend- air
door with the TEMP control on the control head. An
optional zone control HVAC control module is avail-
able. This unit has dual blend-air doors that can be
regulated independently of each other. The tempera-
ture setting can be different from driver's side to pas-
senger side. After the air passes the blend-air door(s),
the air flow can then be directed from the Panel,
Floor, and Defrost outlets. Air flow velocity can be
adjusted with the blower speed selector switch on the
control head.
Ambient air intake can be shut off by closing the
recirculating air door. This will recirculate the air
that is already inside the vehicle. This is done by
depressing the Recirc. button on the control head. On
air conditioned vehicles, moving the control to Mix or
Defrost depresses the A/C button and will engage the
compressor. This will send refrigerant through the
evaporator, and remove heat and humidity from the
air before it goes through the heater core.
CAUTION: In cold weather, use of the Recirculation
mode may lead to excessive window fogging. The
Recirculation mode is automatically deactivated in
Mix and Defrost modes to improve window clearing
operation.
SYSTEM OIL LEVEL
It is important to have the correct amount of oil in
the A/C system to ensure proper lubrication of the
compressor. Too little oil will result in damage to the
compressor. Too much oil will reduce the cooling
capacity of the system and consequently result in
higher discharge air temperatures.NOTE: The oil used in the compressor is ND8 PAG
R134a refrigerant oil. Only refrigerant oil of the
same type should be used to service the system.
Do not use any other oil. The oil container should
be kept tightly capped until it is ready for use.
Tightly cap afterwards to prevent contamination
from dirt and moisture. Refrigerant oil will quickly
absorb any moisture it comes in contact with. Spe-
cial effort must be used to keep all R-134a system
components moisture-free. Moisture in the oil is
very difficult to remove and will cause a reliability
problem with the compressor.
It will not be necessary to check oil level in the
compressor or to add oil unless there has been an oil
loss. Oil loss at a leak point will be evident by the
presence of a wet, shiny surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and
components. The evaporator, condenser, and filter-
drier will retain a significant amount of oil, refer to
the Refrigerant Oil Capacities chart. When a compo-
nent is replaced, the specified amount of refrigerant
oil must be added. When the compressor is replaced,
the amount of oil that is retained in the rest of the
system must be drained from the replacement com-
pressor. When a line or component has ruptured and
oil has escaped, the compressor should be removed
and drained. The filter-drier must be replaced along
with the ruptured part. The oil capacity of the sys-
tem, minus the amount of oil still in the remaining
components, can be measured and poured into the
suction port of the compressor.
Example: On a dual system the evaporator retains
60 ml (2 oz). The condenser retains 30 ml (1 oz) of
oil, and system capacity may be 220 ml (7.40 oz) of
oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
Fig. 5 Demister Inlet
NSHEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)