100 CHRYSLER VOYAGER 2003 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2003Pages: 2177, PDF Size: 59.81 MB
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INSTALLATION
(1) Place riser in position on seat.
(2) Install bolts attaching seat riser to seat cush-
ion frame (Fig. 35). Tighten bolts to 48 N´m (35 ft.
lbs.) torque.
(3) Install seat into vehicle.
BENCH SEAT RISER - THIRD
ROW
REMOVAL
(1) Remove seat track. (Refer to 23 - BODY/
SEATS/BENCH SEAT TRACK - REMOVAL)
(2) Remove bolts attaching riser to seat cushion
frame and remove the riser. (Fig. 40).
INSTALLATION
(1) Place riser in position on seat.
(2) Install bolts attaching riser to seat cushion
frame (Fig. 40). Tighten nuts to 48 N´m (35 ft. lbs.)
torque.
(3) Install seat track. (Refer to 23 - BODY/SEATS/
BENCH SEAT TRACK - INSTALLATION)
SEAT BACK HINGE COVERS -
QUAD BUCKET, 50/50 SPLIT,
BENCH
REMOVAL
(1) Remove seat from vehicle. Refer to Owner's
Manual for proper procedures.
(2) Remove screws attaching upper hinge cover to
seat back hinge (Fig. 36).
(3) Remove upper cover from seat back hinge.
(4) Remove screws attaching lower cover to seat
back hinge.
(5) Remove lower cover from hinge.
INSTALLATION
(1) Place lower cover in position on hinge.
(2) Install screws attaching lower cover to seat
back hinge (Fig. 36). Tighten screws to 2.3 N´m (20
in. lbs.) torque.
(3) Place upper cover in position on seat back
hinge.
(4) Install screws attaching upper hinge cover to
seat back hinge. Tighten screws to 2.3 N´m (20 in.
lbs.) torque.
(5) Install seat in vehicle.
BENCH SEAT BACK HINGE
REMOVAL
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
(1) Remove the bench seat back upper and lower
hinge covers. (Refer to 23 - BODY/SEATS/SEAT
BACK HINGE COVERS - 50/50 SPLIT, BENCH -
REMOVAL)
(2) Remove the seat back. (Refer to 23 - BODY/
SEATS/BENCH SEAT BACK - REMOVAL)
(3) Remove bolts attaching seat back hinge to seat
cushion frame (Fig. 37).
(4) Remove seat back hinge from seat.
INSTALLATION
INSTALLATION
NOTE: Bench seats equipped with child restraint
seats have an interlock feature that will not allow
the seat back to fold forward with the child seat
open.
(1) Place hinge in position on seat.
(2) Engage synchronizing cable end into (clip on
left side) hinge latch release arm.
(3) Engage synchronizing cable housing into seat
back hinge.
Fig. 36 BENCH SEAT BACK HINGE COVERS -
TYPICAL
1 - UPPER COVER SCREWS
2 - LOWER COVER
3 - LOWER COVER SCREWS
4 - UPPER COVER
23 - 100 SEATSRS
BENCH SEAT RISER - SECOND ROW (Continued)
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DESCRIPTION FIGURE
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 98
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 99
WHEELHOUSES - SHORT WHEEL BASE ONLY 100
FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 101
FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 102
INNER BODY SIDE SILL REINFORCEMENTS 103
TOE BOARD CROSS MEMBER 104
FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 105
DASH PANEL REINFORCEMENT 106
LOWER COWL PLENUM 107
UPPER COWL PLENUM SUPPORT 108
UPPER DASH PANEL 109
COWL SIDE PANELS 110
INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 111
INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 112
STRUT TOWER BRACKET AND COWL PLENUM 113
FRONT SIDE RAILS TO LOWER DASH PANEL 114
INNER BODY SIDE SILL TO LOWER DASH PANEL 115
FRONT HINGE TAPPING PLATE 116
FRONT HINGE PILLAR 117
INNER WINDSHIELD FRAME 118
WINDSHIELD FRAME 119
FENDER BRACKET 120
INNER B-PILLAR 121
STRIKER LATCH AND TAPPING PLATES 122
RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 123
RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE
ONLY124
RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 125
STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 126
BELT TAPPING PLATE - LONG WHEEL BASE ONLY 127
C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 128
OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 129
C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 130
LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 131
OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 132
TAIL LAMP - LONG WHEEL BASE ONLY 133
SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 134
ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 135
RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 136
LATCH REINFORCEMENT AND OUTER WHEELHOUSE - SHORT WHEEL BASE ONLY 137
D-PILLAR REINFORCEMENT - SHORT WHEEL BASE ONLY 138
23 - 162 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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Fig. 100 WHEELHOUSES - SHORT WHEEL BASE ONLY
Fig. 101 FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY
RSBODY STRUCTURE23 - 199
WELD LOCATIONS (Continued)
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diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
MANUAL TEMPERATURE CONTROL
The front blower speed and rear blower speed (if
equipped with rear HVAC) must be set to High and
the evaporator temperature sensor must be greater
than 55É F or the test will fail immediately. The test
is activated by depressing the A/C and PWR buttons
simultaneously and holding them depressed for no
less than five seconds. The PWR and A/C LEDs will
blink on and off until the test is complete. If the
LEDs stop blinking before two minutes, then the cool
down test has been completed successfully. If the two
minutes expire without the expansion valve temper-
ature reaching 20É F less than the outside air tem-
perature, then the cool down test has been failed and
further A/C system diagnosis is required. If the test
is failed, the LEDs will continue to blink until the
vehicle has been driven for greater than (8 miles).
AUTOMATIC TEMPERATURE CONTROL
The ambient air temperature in the room where
the vehicle will be tested must be a minimum of 21É
C (70ÉF) for this test. The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking before two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-
perature reaching 20É F less than the evaporator ini-
tial temperature, then the cool down test has been
failed and further A/C system diagnosis is required.
If the test is failed, the snowflake icon and the
DELAY text will continue to blink across ignition
cycles until the vehicle has been driven for greater
than (8 miles).
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
An air conditioning performance test is the best
way to determine whether the system is performing
up to standard. This test also provides valuable clues
as to the possible cause of trouble with the air con-
ditioning system. The ambient air temperature in the
location where the vehicle will be tested must be a
minimum of 21É C (70ÉF) for this test.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFOREPERFORMING 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: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer to monitor the engine
speed.
(2) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set to
monitor the refrigerant system pressures.
(3) Set the heater-air conditioner controls so that
the compressor is engaged, the air within the vehicle
is being recirculated, the output air is directed
through the panel outlets, the temperature control is
in the full cool position, and the blower motor is oper-
ating at its highest speed.
(4) Start the engine and allow the engine to oper-
ate for about five minutes or until it reaches normal
operating temperature. Then hold the engine speed
at 1000 rpm with the compressor clutch engaged. If
the compressor clutch does not engage, proceed with
diagnosis of the compressor clutch coil. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH COIL - DIAGNO-
SIS AND TESTING).
(5) Close all the vehicle windows and doors.
(6) Insert a thermometer in the left center panel
outlet and operate the engine for five minutes.
(7) With the compressor clutch engaged, record the
left center panel outlet discharge air temperature,
the discharge pressure (high side service port), and
the suction pressure (low side service port). The com-
pressor clutch may cycle, depending upon the ambi-
ent temperature and humidity. If the clutch cycles,
use the readings obtained before the clutch disen-
gaged.
(8) Compare the discharge air temperature read-
ing to the Performance Temperature and Pressure
chart. If the temperature reading is high, check the
refrigerant system for leaks and proper refrigerant
charge level. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/REFRIGER-
ANT - DIAGNOSIS AND TESTING - REFRIGER-
ANT SYSTEM CHARGE LEVEL).
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)
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Page 2003 of 2177
Performance Temperature and Pressure
Ambient Temperature 21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Left Center Panel
Outlet Discharge Air
Temperature1to8ÉC
(34 to 46É F)3to9ÉC
(37 to 49É F)4 to 10ÉC
(39 to 50É F)6to11ÉC
(43 to 52É F)7 to 18É C
(45 to 65É F)
Discharge Pressure
(High Side Service
Port)1034 to 1724
kPa
(150 to 250
psi)1517 to 2275
kPa
(220 to 330
psi)1999 to 2620
kPa
(290 to 380
psi)2068 to 2965
kPa
(300 to 430
psi)2275 to 3421
kPa
(330 to 450 psi)
Suction Pressure (Low
Side Service Port)103 to 207 kPa
(15 to 30 psi)117 to 221 kPa
(17 to 32 psi)138 to 241 kPa
(20 to 35 psi)172 to 269 kPa
(25 to 39 psi)207 to 345 kPa
(30 to 50 psi)
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
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).
Check the coolant level, drive belt tension, radiator
air flow, and cooling fan operation. Start the engine
and allow it to warm up to normal temperature.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With the engine idling at normal running tempera-
ture, set the heater-A/C controls as follows. Temper-
ature control to full Heat, Mode control to Floor,
Blower control to the highest speed setting. Using a
test thermometer, check the air temperature coming
from the center floor outlets and compare this read-
ing to the Temperature Reference table.
TEMPERATURE REFERENCE
AMBIENT
TEMPERATUREMINIMUM FLOOR
OUTLET
TEMPERATURE
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153ÉIf the floor outlet air temperature is insufficient,
check that the cooling system is operating to specifi-
cations. (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Both heater hoses should be
HOT to the touch (the coolant return hose should be
slightly cooler than the supply hose). If the coolant
return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction
in heater system.
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED
COOLANT FLOW
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at cooling system connections.
²Plugged heater core.
²Air locked heater core.
²Restrictor in backwards.
If coolant flow is verified and the heater floor out-
let temperature is insufficient, a mechanical problem
may exist.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend-air door not functioning properly.
TEMPERATURE CONTROL
If heater floor outlet temperature cannot be
adjusted with the heater-A/C control temperature
control lever, one of the following could require ser-
vice:
²Blend-air door binding.
²Faulty blend-air door motor.
²Improper engine coolant temperature.
²Faulty heater-A/C control.
24 - 6 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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NOTE: Liquid CO2is required to test the expansion
valve. This material is available from most welding
supply facilities. Liquid CO
2is also available from
companies which service and sell fire extinguish-
ers.
When testing the expansion valve, the work area
and the vehicle temperature must be 21É to 27É C
(70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the heater-air conditioner controls so that
the compressor is operating, the temperature control
is in the highest temperature position, the mode door
is directing the output to the floor outlets, and the
blower is operating at the highest speed setting.
(4) Start the engine and allow it to idle at 1000
rpm. After the engine has reached normal operating
temperature, allow the passenger compartment to
heat up. This will create the need for maximum
refrigerant flow into the evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). The suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30
psi). If OK, go to Step 6. If not OK, replace the faulty
expansion valve.
WARNING:
PROTECT THE SKIN AND EYES FROM EXPOSURE
TO LIQUID CO
2. PERSONAL INJURY CAN RESULT.
(6) If the suction (low pressure) gauge reads
within the specified range, freeze the expansion valve
control head for 30 seconds using liquid CO
2or
another suitable super-cold material.Do not spray
R-134a or R-12 refrigerant on the expansion
valve control head for this test.The suction (low
pressure) gauge reading should drop by 10 psi. If OK,
go to Step 7 If not OK, replace the faulty expansion
valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not
OK, replace the faulty expansion valve.
(8) When expansion valve testing is complete, test
the overall air conditioner performance. (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
Remove all test equipment before returning the vehi-
cle to service.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
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) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer from
the transducer on the front liquid line rear section
(Fig. 14).
(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the filter-drier.
(7) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.
Fig. 14 Expansion Valve
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - FRONT LIQUID LINE REAR SECTION
RSPLUMBING - FRONT24-73
EXPANSION VALVE (Continued)
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Page 2071 of 2177
(9) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve and move the lines
out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) 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 theexpansion 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 11 N´m (100 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
24 - 74 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)
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Page 2079 of 2177
REAR SECTION
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the A/C pressure transducer from the
fitting on the front liquid line rear section. (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(6) Remove the nut that secures the A/C ground
strap to the weld stud on the top of the right front
strut tower (Fig. 28).(If equipped)
(7) Remove the A/C ground strap eyelet terminal
connector from the weld stud. (If equipped)
(8) Remove the screw that secures the liquid line
rear section fitting to the top of the filter-drier.
(9) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(12) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(13) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(14) Remove the seals from the suction line and
liquid line fittings and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 29).
(19) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(20) Remove the seal from the underbody liquid
line fitting and discard.
(21) Install plugs in, or tape over the opened liquid
line fittings.(22) Lower the vehicle.
(23) Remove the front liquid line rear section from
the engine compartment.
INSTALLATION
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the filter/drier and includes the high
side service port on the fitting for the filter/drier. The
rear section connects between the filter/drier and the
expansion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
optional rear air conditioner, the rear section of the
front air conditioner liquid line also includes a liquid
line hose and tube extension that connects the front
liquid line to the liquid line for the rear air condi-
tioner.
FRONT SECTION
(1) Position the front section of the front liquid
line into the engine compartment.
(2) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Reconnect the liquid line fitting to the filter-
drier inlet port on the top of the filter-drier.
(5) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
Fig. 29 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
24 - 82 PLUMBING - FRONTRS
LIQUID LINE (Continued)
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Page 2080 of 2177
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plane seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (16 in. lbs.).
(13) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the front liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(9) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).(10) Reinstall the A/C ground strap eyelet terminal
connector onto the weld stud on the top of the right
front strut tower. (If equipped)
(11) Install and tighten the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.) (If equipped).
(12) Reinstall the A/C pressure transducer onto
the fitting on the front liquid line rear section. (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/A/C PRESSURE TRANSDUCER -
INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
(21) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(22) Lower the vehicle.
(23) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(24) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
RECEIVER/DRIER
DESCRIPTION
The filter-drier is mounted in a bracket secured to
the right front strut tower in the engine compart-
ment. The filter-drier is connected between the front
and rear sections of the liquid line between the con-
denser outlet and the evaporator inlet. The filter-
drier cannot be repaired. If the filter-drier is faulty
or damaged, or if the refrigerant system has been
contaminated or left open to the atmosphere for an
RSPLUMBING - FRONT24-83
LIQUID LINE (Continued)
ProCarManuals.com
Page 2082 of 2177
(6) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(7) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(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 filter-
drier inlet port on the top of the filter-drier.
(10) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(11) Reinstall the air cleaner housing into the
right side of the engine compartment.
(12) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas. Even though
R-134a does not contain chlorine, it must be
reclaimed and recycled just like CFC-type refriger-
ants. This is because R-134a is a greenhouse gas and
can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system. R-134a
refrigerant system service ports, service tool couplers
and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an
R-134a system is not accidentally contaminated with
the wrong refrigerant (R-12). There are also labels
posted in the engine compartment of the vehicle and
on the compressor identifying to service techniciansthat the air conditioning system is equipped with
R-134a.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: The proper amount of R-134a refrigerant for
the refrigerant system in this model is:
²Single or Dual Zone (Front Unit Only) - 0.96
kilograms (2.13 pounds or 34 ounces)
²Three Zone (Front and Rear Units) - 1.31 kilo-
grams (2.88 pounds or 46 ounces)
The procedure that follows should be used to deter-
mine whether the refrigerant system contains the
proper refrigerant charge. Symptoms of an improper
refrigerant charge (low) include: poor air conditioner
performance, fog emitted from the air conditioner
outlets, a hissing sound from the expansion valve/
evaporator area. There are two different methods
with which the refrigerant charge level may be
tested:
1. Using a DRBIIItscan tool, a thermocouple and
the Charge Determination Chart (Fig. 31). Refer to
the appropriate diagnostic information.
2. Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 31).
A temperature probe is required to measure liquid
line temperature. The clamp-on, Type K thermocou-
ple temperature probe used in this procedure is
available through the DaimlerChrysler Professional
Service Equipment (PSE) program. This probe (PSE
#66-324-0014 or #80PK-1A) is compatible with tem-
perature-measuring instruments that accept Type K
thermocouples, and have a miniature connector
input. Other temperature probes are available
through aftermarket sources; however, all references
in this procedure will reflect the use of the probe
made available through the PSE program.
In order to use the temperature probe, a digital
thermometer will also be required. If a digital ther-
mometer is not available, an adapter is available
through the PSE program that will convert any stan-
dard digital multimeter into a digital thermometer.
This adapter is designed to accept any standard Type
RSPLUMBING - FRONT24-85
RECEIVER/DRIER (Continued)
ProCarManuals.com