air condition CHRYSLER VOYAGER 2003 Service Manual
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Page 2056 of 2177
(10) Reconnect the body wire harness connector for
the rear heater-A/C unit housing to the rear HVAC
wire harness connector located near the expansion
valve at the back of the unit.
(11) Reinstall the auxiliary A/C distribution duct
onto the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - INSTALLATION).
(12) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(13) Raise and support the vehicle.
(14) Install and tighten the three nuts that secure
the rear heater-A/C unit mounting studs to the rear
floor panel behind the right rear wheel housing.
Tighten the nuts to 9 N´m (80 in. lbs.).
(15) Remove the tape or plugs from the underbody
liquid line and suction line fittings and both ports in
the rear heater-A/C unit evaporator extension line
sealing plate that extends through the rear floor
panel behind the right rear wheel housing.
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line and
suction line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line sealing
plate.
(18) Install and tighten the screw that secures the
underbody refrigerant line sealing plate to the evap-
orator extension line sealing plate. Tighten the screw
to 23 N´m (17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
(21) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(24) Run the HVAC Cooldown test to verify proper
operation(Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).REAR HEATER DISTRIBUTION
DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel. (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
heater distribution duct to the right quarter inner
panel (Fig. 9).
(3) Slide the rear heater distribution duct forward
far enough to disengage it from the outlet on the
front of the rear heater-air conditioner unit housing.
(4) Remove the rear heater distribution duct from
the vehicle.
INSTALLATION
(1) Align the inlet end of rear heater distribution
duct with the outlet on the front of the rear heater-
air conditioner unit housing.
(2) Slide the rear heater distribution duct rear-
ward far enough to fully engage the inlet end of the
duct with the outlet on the front of the rear heater-
air conditioner unit housing.
(3) Install and tighten the two screws that secure
the rear heater distribution duct to the right quarter
inner panel. Tighten the screws to 1.6 N´m (14 in.
lbs.).
(4) Reinstall the trim onto the right quarter inner
panel. (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - INSTALLATION).
Fig. 9 Rear Heater Distribution Duct
1 - REAR HEATER DISTRIBUTION DUCT
2 - REAR HEATER-A/C UNIT OUTLET
3 - SCREW (2)
RSDISTRIBUTION - REAR24-59
REAR HEATER-A/C HOUSING (Continued)
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Page 2058 of 2177
PLUMBING - FRONT
WARNING
WARNING
WARNING:: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE SYSTEM IS HOT AND UNDER
PRESSURE. FAILURE TO OBSERVE THIS WARNING
CAN RESULT IN SERIOUS BURNS FROM THE
HEATED ENGINE COOLANT. ALLOW THE VEHICLE
TO COOL FOR A MINIMUM OF 15 MINUTES
BEFORE OPENING THE COOLING SYSTEM FOR
SERVICE.
WARNING: THE ENGINE COOLING SYSTEM CON-
TAINS ANTIFREEZE. ANTIFREEZE IS AN ETHYLENE
GLYCOL BASED COOLANT AND IS HARMFUL IF
SWALLOWED OR IF THE VAPORS ARE INHALED. IF
SWALLOWED, DRINK TWO GLASSES OF WATER
AND INDUCE VOMITING. IF VAPORS ARE INHALED,
MOVE TO AN AREA FOR FRESH AIR. SEEK MEDI-
CAL ATTENTION IMMEDIATELY. DO NOT STORE IN
OPEN OR UNMARKED CONTAINERS. WASH SKIN
AND CLOTHING THOROUGHLY AFTER COMING IN
CONTACT WITH ETHYLENE GLYCOL. KEEP OUT
OF REACH OF CHILDREN.
WARNING: DISPOSE OF ETHYLENE GLYCOL
BASED COOLANT PROPERLY. CONTACT YOUR
DEALER OR A LOCAL GOVERNMENT AGENCY FOR
THE LOCATION OF AN APPROVED ETHYLENE GLY-
COL COLLECTION AND/OR RECYCLING CENTER IN
YOUR AREA.
WARNING - A/C PLUMBING
WARNING:: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
WARNING: AVOID BREATHING THE REFRIGERANT
AND REFRIGERANT OIL VAPOR OR MIST. EXPO-
SURE MAY IRRITATE THE EYES, NOSE, AND/ORTHROAT. WEAR EYE PROTECTION WHEN SERVIC-
ING THE AIR CONDITIONING REFRIGERANT SYS-
TEM. SERIOUS EYE INJURY CAN RESULT FROM
DIRECT CONTACT WITH THE REFRIGERANT. IF
EYE CONTACT OCCURS, SEEK MEDICAL ATTEN-
TION IMMEDIATELY.
WARNING: DO NOT EXPOSE THE REFRIGERANT
TO OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
WARNING: IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
WARNING: THE EVAPORATION RATE OF R-134a
REFRIGERANT AT AVERAGE TEMPERATURE AND
ALTITUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
WARNING: THE R-134a SERVICE EQUIPMENT OR
THE VEHICLE REFRIGERANT SYSTEM SHOULD
NOT BE PRESSURE TESTED OR LEAK TESTED
WITH COMPRESSED AIR. SOME MIXTURES OF AIR
AND R-134a HAVE BEEN SHOWN TO BE COMBUS-
TIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS, AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
CAUTION - A/C PLUMBING
CAUTION:: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
CAUTION: R-12 refrigerant oil must not be mixed
with R-134a refrigerant oil. They are not compatible.
RSPLUMBING - FRONT24-61
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Page 2059 of 2177
CAUTION: Do not use R-12 equipment or parts on
the R-134a system. Damage to the system will
result. All parts, tools, and equipment must be
designed for R-134a refrigerant.
CAUTION: Do not discharge refrigerant into the
atmosphere. Use an R-134a refrigerant recovery/re-
cycling device that meets SAE Standard J2210.
CAUTION: The refrigerant must be recovered com-
pletely from the system before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. If any pres-
sure is noticed as a fitting is loosened, tighten the
fitting and recover the refrigerant from the system
again.
CAUTION: The refrigerant system must always be
evacuated before charging.
CAUTION: Do not overcharge the refrigerant sys-
tem. This will cause excessive compressor head
pressure and can cause noise and system failure.
CAUTION: Do not open the refrigerant system or
remove the sealing caps from a replacement com-
ponent until it is to be installed. This will prevent
contamination in the system.
CAUTION: Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.
CAUTION: When it is necessary to open the refrig-
erant system, have everything needed to service
the system ready. Immediately after disconnecting a
component from the refrigerant system, seal the
open fittings with a cap or plug to prevent the
entrance of dirt and moisture. The refrigerant sys-
tem should not be left open to the atmosphere any
longer than necessary.
CAUTION: Before connecting an open refrigerant
fitting, always install a new seal and or gasket. All
fittings with O-rings need to be coated with refrig-
erant oil before installation. Use only O-rings that
are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak. Coat the fitting and seal with clean refrigerant
oil before connecting. Unified plumbing connec-tions with gaskets cannot be serviced with O-rings.
The gaskets are not reusable and new gaskets do
not require lubrication before installing.
CAUTION: When installing a refrigerant line, avoid
sharp bends that may restrict refrigerant flow. A
good rule for the flexible hose refrigerant lines is to
keep the radius of all bends at least ten times the
diameter of the hose. Sharp bends will reduce the
flow of refrigerant.
CAUTION: Position the refrigerant lines away from
exhaust system components or any sharp edges,
which may damage the line. The flexible hose lines
should be routed so they are at least 80 millimeters
(3 inches) from the exhaust manifold. Inspect all
flexible refrigerant system hose lines at least once
a year to make sure they are in good condition and
properly routed.
CAUTION: High pressures are produced in the
refrigerant system when it is operating. Extreme
care must be exercised to make sure that all refrig-
erant system connections are pressure tight.
CAUTION: Tighten refrigerant fittings only to the
specified torque. The aluminum fittings used in the
refrigerant system will not tolerate overtightening.
CAUTION: When disconnecting a refrigerant fitting,
use a wrench on both halves of the fitting. This will
prevent twisting of the refrigerant lines or tubes.
CAUTION: Refrigerant oil will absorb moisture from
the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to
use it. Replace the cap on the oil container immedi-
ately after using. Store refrigerant oil only in a
clean, airtight, and moisture-free container.
CAUTION: All tools, including the refrigerant recy-
cling equipment, the manifold gauge set, and test
hoses should be kept clean and dry. Keep the work
area clean. Contamination of the refrigerant system
through careless work habits must be avoided. The
refrigerant system will remain chemically stable as
long as pure, moisture-free R-134a refrigerant and
refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles
or serious damage can occur if foreign material is
introduced to the refrigerant system.
24 - 62 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)
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Page 2060 of 2177
A/C COMPRESSOR
DESCRIPTION
All vehicles use the Nippondenso 10S20 compres-
sor. This compressor use an aluminum swash plate,
teflon coated pistons and aluminum sleeveless cylin-
der walls. This compressor includes an integral high
pressure relief valve. The compressor is secured low
in the right front corner of the engine compartment
to a mounting bracket on the cylinder block (2.4L
engine), or directly to the cylinder block (3.3L and
3.8L engines) is integral to the compressor. This com-
pressor cannot be repaired. If faulty or damaged, the
entire compressor must be replaced. The compressor
clutch, pulley, and clutch coil are available for service
replacement.
OPERATION
The compressor is driven by the engine through an
electric clutch, drive pulley and belt arrangement.
The compressor is lubricated by refrigerant oil that is
circulated throughout the refrigerant system with the
refrigerant. The compressor draws in low-pressure
refrigerant vapor from the evaporator through its
suction port. It then compresses the refrigerant into
a high-pressure, high-temperature refrigerant vapor.
The compressor pumps high-pressure refrigerant
vapor to the condenser through the compressor dis-
charge port. The mechanical high pressure relief
valve is designed to vent refrigerant from the system
to protect against damage to the compressor or other
system components, caused by condenser air flow
restrictions or an overcharge of refrigerant. The valve
only vents enough refrigerant to reduce the system
pressure, then re-seats itself. The valve opens at a
discharge pressure of 3445 to 4135 kPA (500 to 600
psi) or above, and closes when a minimum discharge
pressure of 2756 kPa (400 psi) is reached.
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS
Excessive noise while the air conditioning compres-
sor is operating can be caused by loose compressor
mounts, a loose compressor clutch, or high operating
pressures in the refrigerant system. Verify compres-
sor drive belt condition, proper compressor mounting,
correct refrigerant charge level, and compressor head
pressure before compressor repair is performed.
With the close tolerances within the compressor, it
is possible to experience a temporary lockup. The
longer the compressor is inactive, the more likely the
condition is to occur. This condition is the result of
normal refrigerant migration within the refrigerant
system caused by ambient temperature changes. Therefrigerant migration may wash the refrigerant oil
out of the compressor.
NOTE: Prior to a vehicle being removed from ser-
vice or stored for more than two weeks, the com-
pressor should be operated to ensure adequate
refrigerant oil distribution throughout the system
components. Turn on the air conditioner for a min-
imum of five minutes with outside air and the high-
est blower speed selected.
BELT NOISE
If the compressor drive belt slips at initial start-up,
it does not necessarily mean the compressor has
failed. The following procedure can be used to iden-
tify a compressor drive belt noise problem.
A. Start the vehicle and run at idle.
B. Turn the air conditioner On and listen for belt
squeal.
C. If belt squeal is heard, turn the air conditioner
Off immediately.
If the belt squeal stops when the air conditioner is
turned Off, perform the following repair procedures.
(1) Using an appropriate sized oil filter wrench or
a strap wrench, grasp the outer diameter of the com-
pressor clutch hub. While facing the compressor,
rotate the hub clockwise, then counterclockwise. If
the hub rotates, proceed to the next step. If the hub
will not rotate, the compressor is internally damaged,
and must be replaced.
(2) Turn the hub clockwise five complete revolu-
tions and remove the tool.
(3) Start the vehicle and run at idle.
(4) Turn the air conditioner On. Observe the com-
pressor and the system for normal operation, noting
cooling performance and noise levels. Operate for five
minutes before turning the air conditioner Off. If
acceptable cooling performance is observed during
compressor operation, the compressor does not need
to be replaced.
(5) Inspect the drive belt for wear, damage, and
proper tension. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND TEST-
ING).
RSPLUMBING - FRONT24-63
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Page 2061 of 2177
REMOVAL
REMOVAL - COMPRESSOR - 2.4/3.3/3.8L
ENGINES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(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 nut that secures the suction line
fitting to the top of the compressor.
(4) Disconnect the suction line fitting from the
compressor suction port.
(5) Remove the seals from the suction line fitting
and discard.
(6) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(7) Remove the nut that secures the discharge line
fitting to the top of the compressor.
(8) Disconnect the discharge line fitting from the
compressor discharge port.
(9) Remove the seals from the discharge line fit-
ting and discard.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(11) Raise and support the vehicle.
(12) Remove the serpentine accessory drive belt
from the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
REMOVAL) or (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - 3.3L/3.8L - REMOVAL).
(13) Disconnect the engine wire harness connector
for the compressor clutch coil from the coil pigtail
wire connector on the top of the compressor (Fig. 1)
or (Fig. 2).
(14) On models with the 3.3L and 3.8L engines,
disengage the retainer on the engine wire harness
compressor clutch coil take out from the bracket on
the top of the compressor.
(15) On models with the 2.4L engine, remove the
four screws that secure the compressor to the mount-
ing bracket on the engine.
(16) On models with the 3.3L and 3.8L engines,
remove the two screws and two nuts that secure the
compressor to the engine.(17) Remove the compressor from the engine com-
partment.
Fig. 1 Compressor - 2.4L Engine
1 - CLUTCH COIL CONNECTOR
2 - DISCHARGE PORT
3 - COMPRESSOR
4 - SUCTION PORT
5 - SCREW (4)
6 - COMPRESSOR MOUNTING BRACKET
Fig. 2 Compressor - 3.3L/3.8L Engine
1 - STUDS (2)
2 - CLUTCH COIL CONNECTOR
3 - DISCHARGE PORT
4 - SCREW (2)
5 - SUCTION PORT
6 - COMPRESSOR
7 - SCREW (IF EQUIPPED)
8 - NUTS (2)
24 - 64 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
ProCarManuals.com
Page 2062 of 2177
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).
NOTE: The filter drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
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.
NOTE: The filter drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
(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 two screws and two nuts 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 nut at the front of the compressor.
²The lower nut at the front of the compressor.
²The upper screw at the rear of the compressor.
²The lower screw at the rear 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) Install a new gasket and reconnect the dis-
charge 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) Install a new gasket and reconnect the suc-
tion line fitting to the compressor 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.).
Fig. 3 Compressor Mounting Bracket - 2.4L Engine
1 - MOUNTING BRACKET
2 - SCREWS (4)
3 - ENGINE
RSPLUMBING - FRONT24-65
A/C COMPRESSOR (Continued)
ProCarManuals.com
Page 2063 of 2177
(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 -
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
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 66 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
ProCarManuals.com
Page 2064 of 2177
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.
(8) Disconnect the discharge line fitting from the
condenser inlet port.
(9) Remove the seals from the discharge line fit-
ting 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 seals 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 theair 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.).
Fig. 5 Condenser Mounting
1 - SCREW (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - CONDENSER
RSPLUMBING - FRONT24-67
CONDENSER (Continued)
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Page 2065 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 plan 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) 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) Install a new dual plan seal and 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.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 68 PLUMBING - FRONTRS
CONDENSER (Continued)
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Page 2066 of 2177
(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 seals 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.
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) Install a new dual plane seal and reconnect the
discharge line fitting to the compressor 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) Install a new dual plane seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(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
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
RSPLUMBING - FRONT24-69
DISCHARGE LINE (Continued)
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