instrument panel CHRYSLER VOYAGER 2001 Service Manual

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 PLUMB-
ING).
(1) Gently flex the recirculation air door far
enough to position the blower motor and blower
wheel into the blower housing in the lower half of the
evaporator housing (Fig. 9).
(2) Relocate the recirculation air door as necessary
to install and tighten the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing (Fig. 11). Tighten the
screws to 2 N´m (18 in. lbs.).
(3) Reach through the fresh air intake opening to
access and engage the upper pivot receptacle of the
recirculation air door with the pivot post of the upper
intake air housing.
(4) Feed the blower motor pigtail wires and har-
ness connector through the grommet hole in the
lower intake air housing and seat the rubber grom-
met (Fig. 10).
(5) Position the lower intake air housing onto the
evaporator housing and upper intake air housing. Be
certain that the splined output shaft of the recircula-
tion air door actuator is properly engaged with the
splined receptacle on the bottom of the recirculation
air door.(6) Install and tighten the three screws that secure
the lower air intake housing to the lower half of the
evaporator housing. Tighten the screws to 2 N´m (18
in. lbs.).
(7) Install and tighten the two screws that secure
the upper intake air housing to the lower intake air
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(8) Engage the HVAC wire harness take out for
the recirculation air door actuator with the routing
clips molded into the bottom of the lower intake air
housing.
(9) Reconnect the blower motor pigtail wire har-
ness connector to the connector receptacle of either
the blower motor resistor or power module, as the
vehicle is equipped.
(10) Reinstall the instrument panel into the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION - FRONT/HVAC HOUSING -
INSTALLATION).
DEFROSTER DUCT
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) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the defroster
duct to the instrument panel armature.
(5) Remove the defroster duct from the instrument
panel.
Fig. 11 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-49
BLOWER MOTOR (Continued)

INSTALLATION
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) Position the defroster duct to the instrument
panel.
(2) Install the fasteners that secure the defroster
duct to the instrument panel armature.
(3) Reinstall the instrument panel in the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Reconnect the battery negative cable.
DEMISTER DUCTS
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) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.(4) Remove the fasteners that secure the demister
ducts to the instrument panel armature.
(5) Disengage the demister ducts from the demis-
ter outlets.
(6) Remove the demister ducts from the instru-
ment panel.
INSTALLATION
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) Position the demister ducts to the instrument
panel.
(2) Engage the demister ducts to the demister out-
lets.
(3) Install the fasteners that secure the demister
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 12).
(3) Pull the floor distribution duct assembly rear-
ward far enough to disengage the center floor distri-
bution duct from the outlet on the bottom of the
heater-A/C housing unit.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
24 - 50 DISTRIBUTION - FRONTRS
DEFROSTER DUCT (Continued)

INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required (Fig. 12).
(2) Slide the floor distribution duct assembly
under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.
(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
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 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) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Disconnect the liquid line and suction line from
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(5) Disconnect the heater hoses from the heater
core tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(6) Remove the four nuts that secure the heater-
A/C unit housing studs to the engine compartment
side of the dash panel (Fig. 13).
(7) Remove the instrument panel from the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(8) Remove the floor distribution duct from the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - REMOVAL).
(9) Remove the one screw that secures the heater-
A/C unit housing bracket to the passenger compart-
ment side of the dash panel (Fig. 14).
(10) Pull the heater-A/C unit housing rearward far
enough for the mounting studs to clear the dash
panel and remove the unit from the passenger com-
partment.
Fig. 12 Floor Distribution Ducts
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-51
FLOOR DISTRIBUTION DUCTS (Continued)

INSTALLATION
(1) Position the heater-A/C unit housing against
the dash panel in the passenger compartment with
the four mounting studs located in their proper
mounting holes in the dash panel (Fig. 14).
(2) Install and tighten the one screw that secures
the heater-A/C unit housing bracket to the passenger
compartment side of the dash panel. Tighten the
screw to 3 N´m (26 in. lbs.).
(3) Install and tighten the four nuts that secure
the heater-A/C unit housing studs to the engine com-partment side of the dash panel (Fig. 13). Tighten
the nuts to 7 N´m (62 in. lbs.).
(4) Reinstall the floor distribution duct onto the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - INSTALLATION).
(5) Reinstall the instrument panel into the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
INSTALLATION).
(6) Reconnect the heater hoses to the heater core
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(7) Reconnect the suction line and liquid line to
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(8) Reconnect the battery negative cable.
(9) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(10) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
PANEL DUCTS
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) Disconnect and isolate the battery negative
cable.
Fig. 13 Heater-A/C Unit Housing Studs
1 - HEATER-A/C UNIT HOUSING
2 - DASH PANEL
3 - NUT (4)
4 - STUD (4)
Fig. 14 Heater-A/C Unit Housing
1 - HEATER-A/C UNIT HOUSING
2 - SCREW
3 - BRACKET
4 - DASH PANEL
24 - 52 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the panel
ducts to the instrument panel armature.
(5) Disengage the panel ducts from the panel out-
lets.
(6) Remove the panel ducts from the instrument
panel.INSTALLATION
(1) Position the panel ducts to the instrument
panel.
(2) Engage the panel ducts to the panel outlets.
(3) Install the fasteners that secure the panel
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
RSDISTRIBUTION - FRONT24-53
PANEL DUCTS (Continued)

(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting (Fig. 7).
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(8) Reconnect the discharge line fitting to the con-
denser inlet port on the right side of the cooling mod-
ule.
(9) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N´m (17 ft. lbs.).
(10) Position the radiator sight shield onto the
radiator closure panel crossmember (Fig. 6).
(11) 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 (18 in. lbs.).
(12) 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.).
(13) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(14) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
EVAPORATOR
DESCRIPTION
The evaporator is located in the heater-A/C unit
housing, behind the instrument panel. The evapora-
tor is positioned in the heater-A/C housing so that all
air that enters the housing must pass over the fins of
the evaporator before it is distributed through the
system ducts and outlets. However, air passing over
the evaporator fins will only be conditioned when the
compressor is engaged and circulating refrigerant
through the evaporator tubes. The heater-A/C unit
housing must be removed from the vehicle to access
the evaporator for service. The evaporator cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
Refrigerant enters the evaporator from the expan-
sion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas when
it leaves the evaporator.
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 PLUMB-
ING).
(1) Remove the HVAC unit housing from the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION - FRONT/HVAC HOUSING -
REMOVAL).
(2) Remove the heater core tubes from the heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inlet
opening and the expansion valve/evaporator tube
opening on the dash panel side of the unit.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/EXPANSION VALVE - REMOVAL).
Fig. 8 Discharge Line
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
RSPLUMBING - FRONT24-71
DISCHARGE LINE (Continued)

connector receptacle on the top of the expansion
valve.
(7) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(9) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(10) Install and tighten the nut that secures the
suction line and liquid line fittings to the stud on the
expansion valve. Tighten the nut to 23 N´m (17 ft.
lbs.).
(11) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(13) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(14) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (18 in. lbs.).
(15) Reconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer to the
transducer on the front liquid line rear section.
(16) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(17) Reinstall the air cleaner housing into the
right side of the engine compartment.
(18) Reconnect the battery negative cable.
(19) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(20) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing of the heater-A/C unit, under the instrument
panel. 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 ports. The removable heater core tubes
are held in place these ports by a sealing plate
secured with a screw to the heater core tank. This
removable heater core tube arrangement allows theheater core to be serviced without removing the heat-
er-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 heater-A/C unit housing is directed through the
heater core.
REMOVAL- HEATER CORE EXTENSION TUBES
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) Disconnect the heater hoses from the heater
hose tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
24 - 76 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)

(5) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 15).
(6) 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.
(7) Remove the heater core shield from the distri-
bution housing.
(8) 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
clean up any spills.
(9) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 16).
(10) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(11) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
(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.
Fig. 15 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 16 Heater Core Tubes
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
RSPLUMBING - FRONT24-77
HEATER CORE (Continued)

(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.
INSTALLATION- HEATER CORE EXTENSION
TUBES
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) Remove the plugs or tape from both heater core
tube fittings and both heater core ports.
(2) Position the heater core tubes and sealing plate
as a unit beneath the instrument panel.
(3) Align the engine compartment ends of both
heater core tubes with the openings in the dash
panel seal and push them simultaneously forward
through the seal far enough to engage the heater
core ends of the tubes with the heater core supply
and return ports (Fig. 16).
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing (Fig. 15). Be certain that the two
location tabs on the front of the shield are engaged in
the receptacles in the two lower finger formations of
the evaporator housing near the dash panel.
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(10) Reconnect the heater hoses to the heater hose
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(11) Reconnect the battery negative cable.
(12) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
Fig. 20 Brake Pedal
1 - SLIDE HEATER CORE PAST BRAKE PEDAL
2 - DEPRESS BRAKE PEDAL
RSPLUMBING - FRONT24-79
HEATER CORE (Continued)

INSTALLATION - 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) While pushing the brake pedal downward (Fig.
20) and pulling the accelerator pedal upward (Fig.
19) far enough for clearance, slide the heater core
into the distribution housing.
(2) Install and tighten the two screws that secure
the heater core mounting plate to the distribution
housing (Fig. 18). Tighten the screws to 2 N´m (17 in.
lbs.).
(3) Remove the plugs or tape from the heater core
tube fittings and both heater core ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel (Fig. 17).
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).(9) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm. (Refer
to 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
POWER BRAKE BOOSTER - INSTALLATION).
(10) Reinstall the brake lamp switch into its
mounting bracket. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION).
(11) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(12) Reconnect the battery negative cable.
(13) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(14) Operate sustem for two thermostat cycles to
assure elimination of air in the system.
HEATER HOSE
REMOVAL
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 (Fig. 21),
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 (Fig. 24) or (Fig.
25). There are also unique plumbing configurations
at the heater core for models with or without the
optional rear heater and air conditioner (Fig. 22) or
(Fig. 23). 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) 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.
24 - 80 PLUMBING - FRONTRS
HEATER CORE (Continued)