engine oil CHRYSLER VOYAGER 2002 Service Manual

(17) Remove the compressor from the engine com-
partment.
NOTE: If a replacement compressor is being
installed, be certain to drain and measure the refrig-
erant oil contained in the removed compressor.
This will determine how much oil the replacement
compressor must contain before it is installed.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
REMOVAL - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Remove the compressor from the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - REMOVAL).
(2) Remove the four screws that secure the com-
pressor mounting bracket to the engine (Fig. 3).
(3) Remove the compressor mounting bracket from
the engine.
INSTALLATION
INSTALLATION - COMPRESSOR
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
Use only refrigerant oil of the type recommended
for the compressor in the vehicle.(1) Position the compressor into the engine com-
partment.
(2) On models with the 2.4L engine, loosely install
the four screws that secure the compressor to the
mounting bracket on the engine. Tighten the screws
to 28 N´m (21 ft. lbs.).
(3) On models with the 3.3L and 3.8L engines,
loosely install the three screws and one nut that
secure the compressor to the engine. Tighten each of
the fasteners using the following sequence to 54 N´m
(40 ft. lbs.).
²The upper screw at the rear of the compressor.
²The lower screw at the rear of the compressor.
²The lower screw at the front of the compressor.
²The upper nut at the front of the compressor.
(4) On models with the 3.3L and 3.8L engines only,
engage the retainer on the engine wire harness com-
pressor clutch coil take out with the bracket on the
top of the compressor.
(5) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(6) Reinstall the serpentine accessory drive belt
onto the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTAL-
LATION).
(7) Lower the vehicle.
(8) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(10) Reconnect the discharge line fitting to the
compressor discharge port.
(11) Install and tighten the nut that secures the
discharge line fitting to the compressor. Tighten the
nut to 23 N´m (17 ft. lbs.).
(12) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(14) Reconnect the suction line fitting to the com-
pressor suction port.
(15) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N´m (17 ft. lbs.).
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(18) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
Fig. 3 Compressor Mounting Bracket - 2.4L Engine
1 - MOUNTING BRACKET
2 - SCREWS (4)
3 - ENGINE
24 - 64 PLUMBING - FRONTRS
COMPRESSOR (Continued)
ProCarManuals.com

FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install and tighten the four screws that secure
the compressor mounting bracket to the engine.
Tighten the screws to 54 N´m (40 ft. lbs.).
(3) Reinstall the compressor onto the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - INSTALLA-
TION).
CONDENSER
DESCRIPTION
The condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The condenser cannot be
repaired or adjusted and, if faulty or damaged, it
must be replaced. The condenser may be removed
from the cooling module for service without removing
the cooling module from the vehicle.
OPERATION
The condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
compressor to give up its heat to the air passing over
the condenser fins. When the refrigerant gas gives up
its heat, it condenses. When the refrigerant leaves
the condenser, it has become a high-pressure liquid
refrigerant. The volume of air flowing over the con-
denser fins is critical to the proper cooling perfor-
mance of the air conditioning system. Therefore, it is
important that there are no objects placed in front of
the radiator grille openings in the front of the vehicle
or foreign material on the condenser fins that might
obstruct air flow. Also, any factory-installed air seals
or shrouds must be properly reinstalled following
radiator or condenser 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)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).NOTE: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the 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. 4).
(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 screws that secure the hood
latch unit to the front of the radiator closure panel
crossmember and move the latch out of the way over
the top of the crossmember. Mark the location of
latch for reinstallation.
(6) Disconnect the hoses from the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - REMOVAL).
(7) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module.
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-65
COMPRESSOR (Continued)
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(8) Disconnect the discharge line fitting from the
condenser inlet port.
(9) Remove the seal from the discharge line fitting
and discard.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(11) Remove the nut that secures the liquid line
fitting to the condenser on the right side of the cool-
ing module.
(12) Disconnect the liquid line fitting from the con-
denser outlet port.
(13) Remove the seal from the liquid line fitting
and discard.
(14) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(15) Remove the screw that secures the top of the
mounting bracket on each side of the condenser to
the cooling module (Fig. 5).
(16) Lift the condenser, transmission oil cooler, and
mounting brackets as a unit far enough to disengage
the locating pin that secures the mounting brackets
in the lower mount rubber isolators on each side of
the cooling module.
(17) Remove the condenser, transmission oil cooler,
and mounting brackets from the vehicle as a unit.(18) Remove the two screws that secure each
mounting bracket to the sides of the condenser.
(19) Remove the one screw that secures the left
mounting bracket to the side of the transmission oil
cooler.
(20) Remove the left mounting bracket from the
side of the condenser and transmission oil cooler.
(21) Remove the condenser from the right mount-
ing bracket and transmission oil cooler unit.
INSTALLATION
NOTE: If the condenser is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
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 in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Position the condenser to the right mounting
bracket and transmission oil cooler unit.
(2) Position the left mounting bracket onto the side
of the condenser and transmission oil cooler.
(3) Install and tighten the one screw that secures
the left mounting bracket to the side of the transmis-
sion oil cooler. Tighten the screw to 5 N´m (45 in.
lbs.).
(4) Install and tighten the two screws that secure
each mounting bracket to the sides of the condenser.
Tighten the screws to 5 N´m (45 in. lbs.).
(5) Position the condenser, transmission oil cooler,
and mounting brackets into the vehicle as a unit. Be
certain that the locating pins that secure the mount-
ing brackets are engaged in the lower mount rubber
isolators on each side of the cooling module.
NOTE: Verify that the condensor isolators are all
installed and positioned correctly.
(6) Install and tighten the two screws that secure
the top of the mounting bracket on each side of the
condenser to the cooling module. Tighten the screws
to 5 N´m (45 in. lbs.).
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Reconnect the liquid line fitting to the con-
denser outlet port on the right side of the cooling
module.
Fig. 5 Condenser Mounting
1 - SCREW (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - CONDENSER
24 - 66 PLUMBING - FRONTRS
CONDENSER (Continued)
ProCarManuals.com

(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Reconnect the discharge line fitting to the
condenser inlet port on the right side of the cooling
module.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N´m (17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install and tighten the two screws that secure
the hood latch unit to the front of the radiator clo-
sure panel crossmember. Check and adjust the hood
latch as needed. Tighten the screws to 14 N´m (123
in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) 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.).
(20) 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.).
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
DISCHARGE LINE
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the 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. 6).
(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 nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 7).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the seal from the discharge line fitting
and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(9) Remove the nut that secures the discharge line
fitting to the top of the compressor (Fig. 8).
(10) Disconnect the discharge line fitting from the
compressor discharge port.
(11) Remove the seal from the discharge line fit-
ting and discard.
(12) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(13) Remove the discharge line from the engine
compartment.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-67
CONDENSER (Continued)
ProCarManuals.com

INSTALLATION
(1) Position the discharge line into the engine com-
partment.
(2) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(4) Reconnect the discharge line fitting to the com-
pressor discharge port on the top of the compressor.(5) Install and tighten the nut that secures the
discharge line fitting to the compressor. Tighten the
nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(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.
(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/
vapor mixture. As air flows over the fins of the evap-
orator, the humidity in the air condenses on the fins,
Fig. 7 Condenser Connections
1 - CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
Fig. 8 Discharge Line
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
24 - 68 PLUMBING - FRONTRS
DISCHARGE LINE (Continued)
ProCarManuals.com

(14) Remove the two screws that secure the expan-
sion valve to the evaporator tube tapping plate.
(15) Disconnect the HVAC wire harness connector
for the evaporator temperature sensor from the sen-
sor on the top of the expansion valve.
(16) Remove the expansion valve from the evapo-
rator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the expansion valve.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(3) Position the expansion valve onto the evapora-
tor inlet and outlet tube fittings.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube tapping
plate plate. Tighten the screws to 11 N´m (97 in.
lbs.).
(5) Reconnect the HVAC wire harness connector
for the evaporator temperature sensor to the sensor
connector receptacle on the top of the expansion
valve.
(6) 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.
(7) 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.
(8) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(9) 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.).
(10) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(11) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(12) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(13) 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.).(14) 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.
(15) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(16) Reinstall the air cleaner housing into the
right side of the engine compartment.
(17) Reconnect the battery negative cable.
(18) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(19) 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 the
heater 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.
RSPLUMBING - FRONT24-73
EXPANSION VALVE (Continued)
ProCarManuals.com

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.
Fig. 22 Heater Plumbing - 3.3/3.8L Engine w/o Rear
Heater
1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE & HOSE (TYPICAL)
Fig. 23 Heater Plumbing - 3.3/3.8L Engine w/Rear
Heater
1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE
Fig. 21 Heater Plumbing - 2.4L Engine
1 - ENGINE OUTLET NIPPLE
2 - HEATER SUPPLY
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE & HOSE UNIT
7 - HEATER RETURN
8 - ENGINE INLET NIPPLE
24 - 78 PLUMBING - FRONTRS
ProCarManuals.com

CAUTION:
When removing the heater hose from the heater
core or supply and return tube nipples, DO NOT
apply excessive pressure. Excessive pressure may
damage or deform the nipples and/or the heater
core causing an engine coolant leak.(3) After the clamp has been moved, grasp the end
of the hose firmly and carefully twist the hose back
and forth while pulling it away from the barbed end
of the nipple. Repeat this procedure at the opposite
end of the hose being removed. If this procedure is
not successful in removing the hose from the nipple,
carefully make a parallel cut through the hose where
it is engaged on the nipple and peel the hose off of
the nipple. This method of removal will require
heater hose replacement.
INSTALLATION
There are several heater core plumbing configura-
tions used on this model, depending upon the engine
size and other optional equipment. One plumbing
configuration is used for all 2.4L engines, while the
3.3L and 3.8L engines have unique heater return
plumbing on the engine for models with or without
an optional engine oil cooler. There are also unique
plumbing configurations at the heater core for mod-
els with or without the optional rear heater and air
conditioner. All models use a combination of formed
steel tubing and rubber hoses. In most cases, the
rubber hose is secured to the steel tubing with a
spring tension clamp.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose toward the center of the hose being
installed. Release the clamp when it is near the cen-
ter of the hose.
(2) Grasp one end of the heater hose being
installed firmly and carefully twist the hose back and
forth while pushing it over from the barbed end of
the nipple. Repeat this procedure at the opposite end
of the hose being installed.
(3) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose over the tube or nipple. Release the
clamp when it is over the tube or nipple.
(4) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
Fig. 24 Heater Return - 3.3/3.8L Engine w/o Oil
Cooler
1 - WATER PUMP RETURN NIPPLE
2 - HEATER RETURN TUBE & HOSE
3 - SCREW
4 - SCREW
Fig. 25 Heater Return - 3.3/3.8L Engine w/Oil Cooler
1 - ENGINE INLET NIPPLE
2 - HEATER RETURN TUBE & HOSE
3 - SCREW
4 - SCREW
5 - OIL COOLER
6 - HEATER RETURN HOSE
RSPLUMBING - FRONT24-79
HEATER HOSE (Continued)
ProCarManuals.com

(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(12) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(13) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(14) Remove the seals from the suction line and
liquid line fittings and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 31).
(19) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(20) Remove the seal from the underbody liquid
line fitting and discard.
(21) Install plugs in, or tape over the opened liquid
line fittings.
(22) Lower the vehicle.
(23) Remove the front liquid line rear section from
the engine compartment.INSTALLATION
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the filter/drier and includes the high
side service port on the fitting for the filter/drier. The
rear section connects between the filter/drier and the
expansion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
optional rear air conditioner, the rear section of the
front air conditioner liquid line also includes a liquid
line hose and tube extension that connects the front
liquid line to the liquid line for the rear air condi-
tioner.
FRONT SECTION
(1) Position the front section of the front liquid
line into the engine compartment.
(2) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Reconnect the liquid line fitting to the filter-
drier inlet port on the top of the filter-drier.
(5) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (16 in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Reconnect the liquid line fitting to the con-
denser outlet port on the right side of the cooling
module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (16 in. lbs.).
(13) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
Fig. 31 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
24 - 84 PLUMBING - FRONTRS
LIQUID LINE (Continued)
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FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the front liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(9) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (16 in. lbs.).
(10) Reinstall the A/C ground strap eyelet terminal
connector onto the weld stud on the top of the right
front strut tower.
(11) Install and tighten the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.).
(12) Reinstall the A/C pressure transducer onto
the fitting on the front liquid line rear section. (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/A/C PRESSURE TRANSDUCER -
INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
(21) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(22) Lower the vehicle.
(23) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(24) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
RECEIVER/DRIER
DESCRIPTION
The filter-drier is mounted in a bracket secured to
the right front strut tower in the engine compart-
ment. The filter-drier is connected between the front
and rear sections of the liquid line between the con-
denser outlet and the evaporator inlet. The filter-
drier cannot be repaired. If the filter-drier is faulty
or damaged, or if the refrigerant system has been
contaminated or left open to the atmosphere for an
indeterminable period, it must be replaced.
OPERATION
The filter-drier performs a filtering action to pre-
vent foreign material in the refrigerant from contam-
inating the expansion valve. A desiccant bag is
mounted inside the filter-drier canister to absorb any
moisture which may have entered and become
trapped within the refrigerant system. In addition,
during periods of high demand air conditioner opera-
tion, the filter-drier acts as a reservoir to store sur-
plus refrigerant. Refrigerant enters the filter-drier as
a high-pressure, low temperature liquid.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
RSPLUMBING - FRONT24-85
LIQUID LINE (Continued)
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