heater CHRYSLER VOYAGER 2004 Service Manual

(2) Remove the heater core tubes from the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inletopening and the expansion valve/evaporator tube
opening.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
EXPANSION VALVE - REMOVAL).
(5) Disconnect the HVAC wire harness connector
from the blower motor.
(6) Disengage the HVAC wire harness from the
routing clips molded into the outside of the HVAC
housing.
(7) Remove the four screws that secure the top of
the distribution housing to the HVAC housing (Fig.
15).
(8) Pull the top of the distribution housing away
from the HVAC housing far enough to disengage the
two hook retainers on the bottom of the distribution
housing from the two receptacles on the HVAC hous-
ing (Fig. 16).
(9) Remove the two screws that secure the upper
air inlet housing to the lower air inlet housing.
(10) Remove the three screws that secure the
upper air inlet housing to the top of the HVAC hous-
ing. Be certain to remove the screw located just
inside the inboard side of the fresh air intake open-
ing.
(11) Remove the upper air inlet housing from the
top of the HVAC housing to expose the recirculation
air door and the blower motor and wheel (Fig. 17).
Fig. 12 HVAC Housing Retainers - LHD Shown, RHD
Typical
1 - HVAC HOUSING
2 - DASH PANEL
3 - STUD (3)
4 - NUT (3)
5 - BOLT (LHD MODELS ONLY)
Fig. 13 HVAC Housing - LHD Models
1 - HVAC HOUSING
2 - BOLT
3 - BRACKET
4 - DASH PANEL
Fig. 14 HVAC Housing - RHD Models
1 - BOLT (2)
2 - RETAINER CLIP
3 - BOLT
4 - HVAC HOUSING
24 - 52 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

housing half to the lower half. Tighten the screws to
2 N´m (17 in. lbs.).
(3) Position the upper air inlet housing onto the
top of the HVAC housing over the recirculation air
door and the blower motor and wheel. Be certain
that the upper pivot of the recirculation air door is
captured in the pivot receptacle of the upper air inlet
housing.
(4) Install the three screws that secure the upper
air inlet housing to the top of the HVAC housing. Be
certain to install the screw located just inside the
inboard side of the fresh air intake opening. Tighten
the screws to 2 N´m (17 in. lbs.).
(5) Install the two screws that secure the upper air
inlet housing to the lower air inlet housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(6) Engage the two hook retainers on the bottom of
the distribution housing to the two receptacles on the
HVAC housing.
(7) Roll the top of the distribution housing up into
position against the HVAC housing.
(8) Install the three screws that secure the top of
the distribution housing to HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(9) Engage the HVAC wire harness in the routing
clips molded into the outside of the HVAC housing.
(10) Reconnect the HVAC wire harness connector
to the blower motor.
(11) Install the expansion valve onto the evapora-
tor inlet and outlet tube fittings (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
EXPANSION VALVE - INSTALLATION).
(12) Install a new foam seal onto the HVAC hous-
ing seal flange around the fresh air inlet opening and
the expansion valve/evaporator tube opening.
(13) Install the heater core tubes into the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
INSTALLATION - HEATER CORE TUBES).
(14) Install the HVAC housing into the vehicle
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - FRONT/HVAC HOUSING -
INSTALLATION).
INSTALLATION
(1) Position the HVAC housing into the passenger
compartment with the mounting studs located in
their proper mounting holes in the dash panel.(2) Install the bolt or bolts (depending on applica-
tion) that secure the HVAC housing to the passenger
compartment side of the dash panel. Tighten the
bolt(s) to 3 N´m (26 in. lbs.).
(3) Install the three nuts that secure the HVAC
housing to the engine compartment side of the dash
panel. Tighten the nuts to 7 N´m (62 in. lbs.).
(4) On LHD models, install the one bolt that
secures the HVAC housing to the engine compart-
ment side of the dash panel. Tighten the bolt to 4
N´m (35 in. lbs.).
(5) Reinstall the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
INSTALLATION).
(6) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(7) Reconnect the heater hoses to the heater core
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(8) Reconnect the suction line and liquid line to
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(9) Install the windshield wiper module (Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(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).
24 - 54 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION.........................56
REMOVAL.............................56
INSTALLATION.........................56
DISTRIBUTION DUCT
REMOVAL.............................57
INSTALLATION.........................57
BLOWER MOTOR
DESCRIPTION.........................57
OPERATION...........................57DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR .............................58
REMOVAL.............................58
INSTALLATION.........................58
HVAC HOUSING
REMOVAL.............................60
INSTALLATION.........................61
REAR FLOOR HEAT DUCT
REMOVAL.............................62
INSTALLATION.........................63
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear HVAC housing through one or a
combination of the two main housing outlets: air con-
ditioner, or heater. Once the conditioned air exits the
unit housing, it is directed through molded plastic
ducts to the various outlets in the vehicle interior.
These outlets and their locations are as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear floor heat duct to the intermediate and rear seat
occupants. The floor outlets are integral to the right
quarter trim panel and, if faulty or damaged, the
quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear distribution duct
and the headliner ducts to the intermediate and rear
seat occupants. The headliner ducts are integral to
the headliner panel. Each overhead outlet is housed
in a headliner bezel. The two forward headliner
bezels also feature a courtesy lamp, a fold-away coat
hook, and a fold-away assist handle. The overhead
outlets can be removed from the headliner bezels
individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel.
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
24 - 56 DISTRIBUTION - REARRS

DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillaR (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear distribution duct upwards far
enough to disengage it from the outlet at the top of
the rear HVAC housing (Fig. 2).
(3) While pulling the lower end of the rear distri-
bution duct away from the rear HVAC housing out-
let, disengage the upper end of the distribution duct
from the headliner duct.
(4) Remove the rea distribution duct from the
vehicle.
INSTALLATION
(1) Align the upper end of the rear distribution
duct to the headliner duct.
(2) Slide the upper end of the rear distribution
duct onto the headliner duct far enough to align the
lower end of the duct with the outlet at the top of the
rear HVAC housing.
(3) Slide the rear distribution duct downwards far
enough to engage it onto the outlet at the top of the
rear HVAC housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft. The blower motor
and wheel are located near the top of the rear HVAC
housing in the passenger compartment behind the
right rear wheel house. The rear HVAC housing must
be removed from the vehicle to access the blower
motor for service. The blower motor and blower
motor wheel are a factory balanced unit and cannot
be adjusted or repaired. If faulty or damaged, the
blower motor and blower wheel must be replaced as
a unit.
OPERATION
On models equipped with the Manual Temperature
Control (MTC) system, the rear blower motor will
operate only whenever the ignition switch is in the
On position, the front blower control switch is in any
position except Off and the rear blower control switch
on the front A/C-heater control is in any position
except Off. On models equipped with the Automatic
Temperature Control (ATC) system, the blower motor
will operate whenever the ignition switch is in the
On position, the A/C-heater control power is turned
on and the rear blower control switch on the front
A/C-heater control is in any position except Off. The
rear blower motor can only be turned off by turning
off the rear system at the front A/C-heater control.
The rear blower motor receives battery current
whenever the rear blower motor relay is energized.
The rear blower motor relay output circuit is pro-
tected by a fuse in the Integrated Power Module
(IPM) located in the engine compartment near the
battery. In the MTC system, the rear blower motor
speed is controlled by regulating the path to ground
through the blower control switch and the blower
motor resistor. In the ATC system, the rear blower
motor speed is controlled by an electronic blower
motor power module, which uses a pulse width mod-
ulated input from the ATC control module and feed-
back from the rear blower motor to regulate the
blower motor ground path it provides. The rear
blower motor and wheel are used to control the veloc-
ity of air moving through the rear HVAC housing.
The rear blower motor controls the velocity of the air
flowing through the rear HVAC housing by spinning
the blower wheel within the housing at the selected
speed or, in the ATC system, at the selected or pro-
grammed speed.
Fig. 2 Rear Distribution Duct
1 - HEADLINER DUCT
2 - REAR DISTRIBUTION DUCT
3 - REAR HVAC HOUSING OUTLET
RSDISTRIBUTION - REAR24-57

DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR
BLOWER MOTOR INOPERATIVE
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Integrated Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Turn the ignition switch to the On position. Be
certain that the rear A/C-heater control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, check the rear blower motor relay.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector
from the rear blower motor resistor block (Manual
Temperature Control) or the rear blower motor power
module (Automatic Temperature Control). Reconnect
the battery negative cable. Turn the ignition switch
to the On position. Be certain that the rear A/C-
heater control power is turned on. Check for battery
voltage at the fused rear blower motor relay output
circuit cavity of the rear HVAC wire harness connec-
tor for the rear blower motor resistor block (MTC) or
the rear blower motor power module (ATC). If OK, go
to Step 4. If not OK, repair the open fused front
blower motor relay output circuit to the IPM as
required.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear blower motor pigtail wire connec-
tor from the rear HVAC wire harness (MTC) or the
rear blower power module (ATC). Use jumper wires
to connect a battery and ground feeds to the blower
motor pigtail wire connector. The rear blower motor
should operate. If OK with MTC, proceed to diagno-
sis of the rear blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- REAR/BLOWER MOTOR RESISTOR - DIAGNOSIS
AND TESTING). If OK with ATC, use a DRBIII scan
tool to diagnose the rear blower motor power module.
Refer to the appropriate diagnostic information. If
not OK with MTC or ATC, replace the faulty rear
blower motor.BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart for basic checks of the blower motor when a
vibration or noise is present (Fig. 3).
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 -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control sys-
tem, the blower motor pigtail wire is connected to a
take out and connector of the rear HVAC wire har-
ness. With the Automatic Temperature Control sys-
tem , the blower pigtail wire is connected to a
receptacle on the blower motor power module.
(3) Remove the three screws that secure the rear
blower motor to the outboard side of the rear HVAC
housing (Fig. 4).
(4) Remove the rear blower motor from the rear
HVAC housing.
INSTALLATION
(1) Position the rear blower motor into the rear
HVAC housing.
(2) Install the three screws that secure the blower
motor to the rear HVAC housing. Tighten the screws
to 2 N´m (17 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control system
, the blower pigtail wire is connected to a take out
and connector of the rear HVAC wire harness. With
the Automatic Temperature Control system, the
blower pigtail wire is connected to a receptacle on
the blower motor power module.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

(9) Lower the vehicle.
(10) Remove the right quarter trim panel and
right D-pillar trim panel from the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - REMOVAL).
(11) Remove the rear distribution duct from the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear HVAC housing from the rear HVAC wire
harness connector located near the expansion valve
at the back of the housing.
(13) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(14) Remove the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing.
(15) Remove the rear floor heat duct from the
right quarter inner panel (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/REAR
FLOOR HEAT DUCT - REMOVAL).
(16) Take the proper precautions to protect the
carpeting below the rear heater core from spilled
engine coolant and have absorbent toweling readily
available to clean up any spills.
(17) Disconnect the heater hoses at the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).
(18) Install plugs in, or tape over the opened
heater core fittings and both heater hoses.
(19) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(20) Remove the screw that secures the back of the
rear HVAC housing to the right D-pillar (Fig. 7).
(21) Remove the screw that secures the front of
the rear HVAC housing to the right quarter inner
panel.
(22) Lift the rear HVAC housing up far enough for
the lower mounting studs and the evaporator exten-
sion lines to clear the mounting holes in the rear
floor panel.
(23) Remove the rear HVAC housing from the
vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-tings (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Position the rear HVAC housing into the vehi-
cle with the evaporator extension line sealing plate
inserted into the rectangular hole in the rear floor
panel behind the right rear wheel house.
(2) Align the rear HVAC housing lower mounting
studs with the mounting holes in the rear floor panel
and lower the unit to the floor.
(3) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(4) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N´m (97 in. lbs.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Reinstall the rear floor heat duct onto the right
quarter inner panel (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/REAR FLOOR
HEAT DUCT - INSTALLATION).
(8) Install the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel.
(10) Reconnect the body wire harness connector for
the rear HVAC housing to the rear HVAC wire har-
ness connector located near the expansion valve at
the back of the housing.
(11) Reinstall the rear distribution duct onto the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - 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 the three nuts that secure the rear
HVAC housing 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 evaporator extension line sealing plate that
extends through the rear floor panel behind the right
rear wheel housing.
RSDISTRIBUTION - REAR24-61
HVAC HOUSING (Continued)

(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 the screw that secures the underbody
refrigerant line sealing plate to the evaporator exten-
sion 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 FLOOR HEAT 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
floor heat duct to the right quarter inner panel (Fig.
8).
(3) Slide the rear floor heat duct forward far
enough to disengage it from the outlet on the front of
the rear HVAC housing.
(4) Remove the rear floor heat duct from the vehi-
cle.
Fig. 7 Rear HVAC Housing
1 - U-NUT (3)
2 - REAR HVAC HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
24 - 62 DISTRIBUTION - REARRS
HVAC HOUSING (Continued)

PLUMBING - FRONT
TABLE OF CONTENTS
page page
PLUMBING - FRONT
DESCRIPTION - REFRIGERANT LINE.......65
OPERATION- REFRIGERANT LINES........65
WARNING
ENGINE COOLING SYSTEM.............65
A/C SYSTEM.........................65
CAUTION
A/C SYSTEM.........................66
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS......................66
DIAGNOSIS AND TESTING - SYSTEM
CHARGE LEVEL TEST - GASOLINE
ENGINES............................67
DIAGNOSIS AND TESTING - SYSTEM
CHARGE LEVEL TEST - 2.5L DIESEL......68
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
TUBING AND FITTINGS.................70
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........70
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................71
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................72
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................72
A/C COMPRESSOR
DESCRIPTION
DESCRIPTION - A/C COMPRESSOR.......73
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE..............................73
OPERATION
OPERATION - A/C COMPRESSOR........73
OPERATION - HIGH PRESSURE RELIEF
VALVE..............................73
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS....................74
REMOVAL
REMOVAL - COMPRESSOR.............74
REMOVAL - A/C COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE...............75
INSTALLATION
INSTALLATION.......................76
INSTALLATION - A/C COMPRESSOR
MOUNTING BRACKET - 2.4L ENGINE......76
A/C CONDENSER
DESCRIPTION.........................76
OPERATION...........................76REMOVAL.............................77
INSTALLATION.........................78
A/C DISCHARGE LINE
REMOVAL.............................79
INSTALLATION.........................80
A/C EVAPORATOR
DESCRIPTION.........................80
OPERATION...........................80
REMOVAL.............................80
INSTALLATION.........................80
EXPANSION VALVE
DESCRIPTION.........................81
OPERATION...........................81
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE ..............................81
REMOVAL.............................82
INSTALLATION.........................82
HEATER CORE
DESCRIPTION.........................83
OPERATION...........................83
REMOVAL
REMOVAL - HEATER CORE TUBES.......83
REMOVAL - HEATER CORE.............84
INSTALLATION
INSTALLATION - HEATER CORE TUBES....85
INSTALLATION - HEATER CORE..........85
HEATER INLET HOSE
REMOVAL.............................85
INSTALLATION.........................86
HEATER RETURN HOSE
REMOVAL.............................86
INSTALLATION.........................87
LIQUID LINE
REMOVAL.............................88
INSTALLATION.........................90
RECEIVER / DRIER
DESCRIPTION.........................91
OPERATION...........................91
REMOVAL.............................91
INSTALLATION.........................92
REFRIGERANT
DESCRIPTION.........................92
OPERATION...........................92
REFRIGERANT OIL
DESCRIPTION.........................92
OPERATION...........................92
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................93
24 - 64 PLUMBING - FRONTRS

SERVICE PORT VALVE CORE
DESCRIPTION.........................94
REMOVAL.............................94
INSTALLATION.........................94SUCTION LINE
REMOVAL.............................94
INSTALLATION.........................95
PLUMBING - FRONT
DESCRIPTION - REFRIGERANT LINE
The refrigerant lines and hoses are used to carry
the refrigerant between the various air conditioning
system components. A barrier hose design with a
nylon tube, which is sandwiched between rubber lay-
ers, is used for the R-134a air conditioning system on
this vehicle. This nylon tube helps to further contain
the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
refrigerant hoses are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. 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.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from an exhaust manifold.
OPERATION- REFRIGERANT LINES
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
The refrigerant lines and hoses are coupled with
other components of the HVAC system with either
O-rings or dual plane seals.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNING
ENGINE COOLING SYSTEM
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 ENGINE COOLING SYSTEM ISHOT AND UNDER PRESSURE. FAILURE TO
OBSERVE THIS WARNING CAN RESULT IN SERI-
OUS BURNS FROM THE HEATED ENGINE COOL-
ANT. ALLOW THE VEHICLE TO COOL FOR A
MINIMUM OF 15 MINUTES BEFORE OPENING THE
COOLING SYSTEM FOR SERVICE.
A/C SYSTEM
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.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO OPEN
FLAME. POISONOUS GAS IS CREATED WHEN
REFRIGERANT IS BURNED. AN ELECTRONIC LEAK
DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE THE WORK AREA BEFORE RESUMING
SERVICE. LARGE AMOUNTS OF REFRIGERANT
RELEASED IN A CLOSED WORK AREA WILL DIS-
PLACE THE OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIGER-
ANT AT AVERAGE TEMPERATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER-
ANT WILL FREEZE. ALWAYS PROTECT THE SKIN
OR DELICATE OBJECTS FROM DIRECT CONTACT
WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE VEHI-
CLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
RSPLUMBING - FRONT24-65

the engine to run at idle under the following condi-
tions for five minutes.
(a) Front windows are open.
(b) Transaxle in Park.
(c) Front heater-A/C controls set to outside air,
full cool, panel mode, blower high, and compressor
engaged.
(d) If the vehicle is so equipped, the rear heater-
A/C controls must be set to full cool and blower
high.
(4) Raise the liquid line (discharge) pressure to
about 1793 kPa (260 psi) by placing a piece of card-
board over part of the front side of the condenser. To
place the cardboard properly, remove the upper radi-
ator sight shield from the front fascia. Cover only
enough of the condenser to raise and maintain the
liquid line pressure at the specified level.
(5) Observe the liquid line (discharge) pressure
and liquid line temperature. Using the Charge Deter-
mination Chart (Fig. 1), determine whether the
refrigerant system is operating within the Proper
Charge Range.
(a) If the refrigerant system is operating in the
Undercharged area of the chart, add 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant to
the system.(b) If the refrigerant system is operating in the
Overcharged area of the chart, reclaim 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant from
the system.
(6) Recheck the system charge level following each
refrigerant adjustment. Continue this process until
the system readings are in the Proper Charge Range
area on the Charge Determination Chart.
DIAGNOSIS AND TESTING - SYSTEM CHARGE
LEVEL TEST - 2.5L DIESEL
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).
Fig. 1 Charge Determination Chart, Ambient Test Condition 85ÉF
24 - 68 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)