warning CHRYSLER VOYAGER 2004 Service Manual

TIONING/PLUMBING - REAR/EXPANSION VALVE
- REMOVAL).
(4) Remove the rubber grommet that seals the
evaporator inlet and outlet tubes to the rear HVAC
housing near the expansion valve.
(5) Remove the three screws that secure the upper
half of the rear HVAC housing to the lower half (Fig.
1).
(6) Remove the three metal spring clips that
secure the upper half of the rear HVAC housing to
the lower half.
(7) Carefully separate and remove the upper half
of the rear HVAC housing from the lower half.
(8) Remove the A/C evaporator from the lower half
of the rear HVAC housing.
REMOVAL - A/C EVAPORATOR LINE
EXTENSION
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING), and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - HEATER PLUMBING).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Remove the screw that secures the plate that
captures and seals the evaporator line extension
within the base of the rear HVAC housing (Fig. 2).(3) Remove the capture plate from the rear HVAC
housing base.
(4) Carefully peel back the expansion valve foam
insulator wrap far enough to access the evaporator
line extension sealing plate on the bottom of the
expansion valve (Fig. 3).
(5) Remove the two screws that secure the expan-
sion valve bracket to the lower rear HVAC housing.
(6) Remove the nut that secures the expansion
valve bracket to the expansion valve stud.
(7) Remove the expansion valve bracket from the
expansion valve stud.
Fig. 1 Rear A/C Evaporator
1 - UPPER REAR HVAC HOUSING
2 - REAR A/C EVAPORATOR
3 - LOWER REAR HVAC HOUSING
Fig. 2 Evaporator Line Extension Plate
1 - REAR HVAC HOUSING BASE
2 - PLATE
3 - EVAPORATOR LINE EXTENSION
Fig. 3 Rear A/C Evaporator Line Extension
1 - UPPER REAR HVAC HOUSING
2 - LOWER REAR HVAC HOUSING
3 - EXPANSION VALVE BRACKET
4 - EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - INSULATOR WRAP
24 - 98 PLUMBING - REARRS
A/C EVAPORATOR (Continued)

The rear A/C expansion valve cannot be adjusted
or repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING - EXPANSION VALVE
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 expansion valve should only be tested
following testing of the compressor.
NOTE: Liquid CO
2is 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 sprayR-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), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING), and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - HEATER PLUMBING).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Carefully remove the foam insulator wrap from
the rear expansion valve.
(3) Remove the rear evaporator line extension from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(4) Remove the two screws that secure the expan-
sion valve to the evaporator tube sealing plate.
(5) Remove the expansion valve from the evapora-
tor tubes.
(6) Remove the seals from the evaporator tube fit-
tings and discard.
(7) Install plugs in, or tape over the opened evap-
orator tube fittings and both expansion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the rear A/C
evaporator tube fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the rear evapora-
tor tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
24 - 100 PLUMBING - REARRS
A/C EXPANSION VALVE (Continued)

(4) Install the two screws that secure the rear A/C
expansion valve to the evaporator tube sealing plate.
Tighten the screws to 11 N´m (97 in. lbs.).
(5) Install the rear evaporator line extension onto
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear HVAC housing, behind the right rear wheel
house. 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 nipples. The rear heater core can be ser-
viced without removing the rear HVAC housing from
the vehicle.
OPERATION
Engine coolant is circulated through underbody
heater hoses to the rear heater core at all times. As
the coolant flows through the rear 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
rear blend door allows control of the rear heater out-
put air temperature by controlling how much of the
air flowing through the rear HVAC housing is
directed through the heater core.
The rear heater core cannot be repaired and, if
faulty or damaged, it must be replaced.
STANDARD PROCEDURE - REAR HEATER
CORE FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-
fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.2.Thermal cycling of the engine cooling system. Fol-
lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
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 PLUMBING).
PRE-FILLING
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 reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
HVAC housing, and the rear HVAC housing should
be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
(4) Carefully pour the proper pre-mixed engine
coolant solution into the rear heater core through a
funnel until coolant begins to appear at the lower
hose fitting of the heater core.
(5) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(6) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
RSPLUMBING - REAR24 - 101
A/C EXPANSION VALVE (Continued)

(7) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
THERMAL CYCLING
If the rear heater core was emptied and was not
pre-filled, it will be necessary to thermal cycle the
vehicle at least two times to ensure that the rear
heater core is properly filled.
(1) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(2) Start the engine and allow it to operate until
the thermostat opens.
(3) Turn the engine off and allow it to cool.
(4) With the engine cold and not running, check
and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(5) Start the engine and allow it to operate until
the thermostat opens again.
(6) Turn the engine off and allow it to cool down
again.
(7) With the engine cold and not running, check
and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(8) Check the performance of the rear heater.
Refer to REAR HEATER PERFORMANCE CHECK.
REAR HEATER PERFORMANCE CHECK
Successful completion of the rear heater perfor-
mance check will confirm that the rear heater core is
properly filled with engine coolant. If the check is not
successful, either there is still air trapped in the rear
heater core or the rear heater plumbing is restricted.
This check should be performed with the vehicle in a
shop where the ambient temperature is about 21É C
(70É F).
(1) Start the engine and allow it to idle until it
warms up to normal operating temperature.
(2) Adjust the heater-A/C controls so that the front
heater is turned Off, the rear heater is set for full
Heat, and the rear blower motor is at its highest
speed setting.
(3) Use an accurate test thermometer to measure
the temperature of the air being discharged from the
rear heater outlet located at the base of the right
C-pillar.
(4) Proper discharge air temperature readings
should be from 57É to 63É C (135É to 145É F).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 - HEATER PLUMBING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) 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).
(3) Remove the rear heater distribution duct from
the right quarter inner panel (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
REMOVAL).
(4) Remove the screw that secures the back of the
rear HVAC housing to the right D-pillar.
(5) Remove the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
(6) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(7) Disconnect the heater hoses at the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).
(8) Install plugs in, or tape over the opened heater
core fittings and both heater hoses (Fig. 5).
Fig. 5 Rear Heater Core
1 - REAR HVAC HOUSING OUTLET
2 - REAR HVAC UNIT HOUSING
3 - LATCH (4)
4 - REAR HEATER CORE
5 - RIGHT REAR WHEEL HOUSE
6 - REAR HEATER HOSES
24 - 102 PLUMBING - REARRS
HEATER CORE (Continued)

(9) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(10) Release the four latch tabs that secure the
heater core into the rear HVAC housing.
(11) Carefully pull the heater core straight out of
the rear HVAC housing.
(12) Use absorbent toweling to clean 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) Carefully slide the heater core into the rear
HVAC housing.
(2) Using hand pressure, press firmly and evenly
on the heater core end plate until the four latch tabs
that secure the heater core in the rear HVAC housing
are fully engaged.
(3) Remove the plugs or tape from the heater core
fittings and both heater hoses.
(4) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(5) 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.).
(6) 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.).
(7) Install the rear heater distribution duct (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION - REAR/REAR HEATER DISTRIBUTION
DUCT - INSTALLATION).
(8) Install the right quarter trim panel and right
D-pillar trim panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - INSTALLATION).
(9) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
HEATER HOSES
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).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Using spring tension clamp pliers, compress
and slide the clamps off of each end of the hose being
removed.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(3) Disconnect the front underbody heater inlet
and return hose by carefully twisting the hoses back
and forth on the underbody tubes, while gently pull-
ing them away from the end of the tubes (Fig. 6).
(4) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.
NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
Fig. 6 Underbody Heater Hose Connections - Front
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY LINES
RSPLUMBING - REAR24 - 103
HEATER CORE (Continued)

INSTALLATION
(1) Install the front underbody heater inlet and
return hoses by carefully twisting the hoses back and
forth on the underbody tubes, while gently pushing
them onto the end of the tubes.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(2) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose over the tubes. Release the clamp when
it is over the tube.
(3) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
LIQUID 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).
NOTE: On models equipped with the optional rear
A/C system, the rear section of the front air condi-
tioner liquid line also includes a liquid line hose
and tube extension that connects the front liquid
line to the underbody liquid line for the rear A/C
system.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD 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 (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER -
REMOVAL).(6) If equipped, remove the nut that secures the
A/C ground strap to the weld stud on the top of the
right front strut tower (Fig. 7).
(7) If equipped, remove the A/C ground strap eye-
let terminal connector from the weld stud.
(8) Remove the bolt that secures the liquid line
rear section fitting to the top of the receiver/drier.
(9) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(10) Remove the O-ring seal from the liquid line
fitting and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the receiver/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) Raise and support the vehicle.
Fig. 7 Liquid Line
1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - EXPANSION VALVE
7 - FRONT LIQUID LINE REAR SECTION
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - RECEIVER/DRIER
11 - ROUTING CLIP
12 - FRONT LIQUID LINE FRONT SECTION
24 - 104 PLUMBING - REARRS
HEATER HOSES (Continued)

SUCTION LINE
REMOVAL
On models equipped with the optional rear A/C
system, the front air conditioner suction line also
includes a suction line hose and tube extension that
connects the front suction line to the underbody suc-
tion line for the rear A/C system.
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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner top cover and snorkel
from the air cleaner housing located on 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 nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment (Fig. 9).
(10) Remove the nut that secures the suction line
and liquid line fittings to the front expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the front expansion valve.
(12) Remove the O-ring 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) Raise and support the vehicle.
(15) 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. 10).(16) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.
(17) Remove the O-ring seal from the underbody
suction line fitting and discard.
Fig. 9 Suction Line
1 - A/C EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - RETAINING CLIP
5 - SUCTION LINE
Fig. 10 Underbody Line Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY REFRIGERANT LINES
24 - 106 PLUMBING - REARRS

REMOVAL
REMOVAL - UNDERBODY HEATER TUBES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Raise and support vehicle.
(3) Disconnect the underbody heater tubes at the
rear of the vehicle by releasing the insert in the rear
underbody heater tube quick connect fittings (Fig.17) and carefully pulling downward on the inlet and
return tubes.
(4) Remove the three retaining straps that secure
the rear heater underbody tubes to the vehicle under-
body (Fig. 18).
(5) Lower the rear of the underbody heater tubes
and drain any residual coolant from the tubes into a
suitable container.
(6) Using spring tension clamp pliers, compress
and slide the clamps off of the rubber hoses at the
front of the underbody heater tubes.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(7) Disconnect the front underbody heater inlet
and return hoses by carefully twisting the hoses back
and forth on the underbody tubes, while gently pull-
ing them away from the end of the tubes.
(8) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.
NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
(9) Remove the underbody heater tubes from the
vehicle.
Fig. 15 Rear heater hose quick connects
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
Fig. 16 Rear A/C Block Connection
1 - CLEAN AREA AROUND BLOCK BEFORE REMOVAL
Fig. 17 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
RSPLUMBING - REAR24 - 109
UNDERBODY LINES (Continued)

REMOVAL - UNDERBODY REFRIGERANT LINES
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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Hoist and support vehicle.
(3) Remove the underbody refrigerant lines from
the three retaining straps that secure the rear under-
body refrigerant lines to the vehicle underbody (Fig.
19).
(4) Remove the underbody refrigerant lines from
the two rear retaining clamps, behind rear wheel.
(5) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(6) Remove the O-ring seal from the underbody liq-
uid line fitting and discard.
(7) Install plugs in, or tape over the opened liquid
line fittings.
(8) Disconnect the front suction line extension fit-
ting from the underbody suction line fitting for the
rear air conditioner.
(9) Remove the O-ring seal from the underbody
suction line fitting and discard.(10) Install plugs in, or tape over the opened suc-
tion line fittings.
(11) Disconnect the underbody refrigerant line
sealing plate from the rear evaporator extension line
sealing plate that extends through the rear floor
panel behind the right rear wheel housing (Fig. 20).
(12) Remove the O-ring seal from the underbody
refrigerant line fittings and discard.
(13) Install plugs in, or tape over the opened
underbody refrigerant line fittings and the rear evap-
orator extension line sealing plate ports.
(14) Separate the ABS harness from the flex hose
clamps.
(15) Remove the underbody refrigerant lines from
the vehicle.
Fig. 18 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 19 Underbody Refrigerant Line Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 20 Underbody Refrigerant Line Sealing Plate
1 - REFRIGERANT LINE SEALING PLATE
24 - 110 PLUMBING - REARRS
UNDERBODY LINES (Continued)

(5) Remove the two retaining screws and remove
pipe assembly (Fig. 2).
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N´m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
clamp securely.
(4) Install the cabin heater tubes to the lower
heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(7) Verify function of the cabin heater.
EXHAUST TUBE
REMOVAL
WARNING: THERE IS A POTENTIAL DANGER OF
SKIN BURNS AS THE SUPPLEMENTAL CABIN
HEATER AND ITS COMPONENTS MAY BE VERY
HOT. MAKE SURE THE CABIN HEATER IS
ALLOWED TO COOL DOWN BEFORE ANY SERVICE
WORK ON THE CABIN HEATER SYSTEM IS
ATTEMPTED.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 3).
(3) Remove the clamp at the flexible pipe connec-
tion and the cabin heater housing (if required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
Fig. 1 Cabin Heater Flexible Air Intake Line
1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
Fig. 2 Cabin Heater Air Intake And Heater Pipe
Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24 - 114 CABIN HEATERRS
AIR INTAKE PIPE (Continued)