engine oil CHRYSLER VOYAGER 2004 Service Manual

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 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) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 13).
(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the receiver/
drier.
(7) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.(9) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the A/C expansion valve and move the
lines out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate.
(15) On ATC equipped models, disconnect the
HVAC wire harness connector from the evaporator
temperature sensor.
(16) Remove the A/C expansion valve from the
evaporator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
(19) On ATC equipped models, remove the evapo-
rator temperature sensor retainer and evaporator
temperature sensor from the A/C expansion valve, if
required.
INSTALLATION
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) On ATC equipped models, install the evapora-
tor temperature sensor and retainer onto the A/C
expansion valve, if removed.
(2) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the A/C expansion valve.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(4) Position the A/C expansion valve onto the evap-
orator inlet and outlet tube fittings.
(5) Install the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(6) On ATC equipped models, connect the HVAC
wire harness connector to the evaporator tempera-
ture sensor.
(7) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
Fig. 13 A/C Expansion Valve - LHD Shown, RHD
Typical
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR (ATC ONLY)
3 - A/C EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 82 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)

(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(9) Connect the liquid line and suction line fittings
to the expansion valve.
(10) Install the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the liquid line
rear section fitting and the receiver/drier outlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(13) Connect the liquid line fitting to the receiver/
drier outlet port.
(14) Install the screw that secures the liquid line
fitting to the receiver/drier. Tighten the screw to 11
N´m (97 in. lbs.).
(15) Connect the wire harness connector to the A/C
pressure transducer.
(16) Connect the drain tube to the wiper module
drain on the right side of the engine compartment.
(17) Install the air cleaner housing.
(18) Reconnect the battery negative cable.
(19) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(20) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing, which is attached to the HVAC housing, behind
the instrument panel. It is a heat exchanger made of
rows of tubes and fins. One end of the core is fitted
with a molded plastic tank, which includes integral
heater core inlet and outlet ports. Removable heater
core tubes attach to the ports by use of a sealing
plate secured with a screw to the heater core tank.
This removable heater core tube arrangement allows
the heater core to be serviced without removing the
HVAC housing from the vehicle.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend doorallows control of the heater output air temperature
by regulating the amount of air that is flowing
through the heater core within the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
REMOVAL - HEATER CORE TUBES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/HEATER INLET HOSE -
REMOVAL) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER RETURN
HOSE - REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel.
NOTE: Take the proper precautions to protect the
carpeting below the heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to clean up any spills.
(5) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 14).
(6) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(7) Install plugs in, or tape over the opened heater
core tube fittings and both heater core ports.
(8) Pull both heater core tubes simultaneously
slightly away from the distribution housing and rear-
ward far enough to disengage the engine compart-
ment ends of the tubes from the dash panel seal.
RSPLUMBING - FRONT24-83
EXPANSION VALVE (Continued)

INSTALLATION
INSTALLATION - HEATER CORE TUBES
(1) Remove the plugs or tape from both heater core
tube fittings and both heater core ports.
(2) Position the heater core tubes and sealing plate
as a unit beneath the instrument panel.
(3) Align the engine compartment ends of both
heater core tubes with the openings in the dash
panel seal and push them simultaneously forward
through the seal far enough to engage the heater
core ends of the tubes with the heater core supply
and return ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
NOTE: The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes
as required so that the sealing plate fits flush
against the heater core supply and return ports,
which indicates that the tubes are properly indexed.
(5) Index both heater core tubes to the heater core
ports.
(6) Install the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports. Tighten the screw to 3 N´m (27 in. lbs.).
(7) Install the silencer under the driver side end of
the instrument panel.
(8) Connect the heater hoses to the heater hose
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/HEATER INLET HOSE - INSTAL-
LATION) and(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER RETURN
HOSE - INSTALLATION).
(9) Reconnect the battery negative cable.
(10) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
INSTALLATION - HEATER CORE
(1) While pushing the brake pedal downward and
pulling the accelerator pedal upward far enough for
clearance, slide the heater core into the distribution
housing.
(2) Install the two screws that secure the heater
core mounting plate to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Install the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - INSTALLATION).
(4) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm (Referto 5 - BRAKES/HYDRAULIC/MECHANICAL/
POWER BRAKE BOOSTER - INSTALLATION).
(5) Reinstall the brake lamp switch into its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION).
(6) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(7) Reconnect the battery negative cable.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(9) Operate system for two thermostat cycles to
assure the elimination of any air that may be
trapped within the cooling system.
HEATER INLET HOSE
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).
NOTE: The heater inlet hose is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.
(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 (Fig. 17), (Fig. 18) or (Fig. 19).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes/heater core, causing an engine coolant leak.
(3) Disconnect each hose end by carefully twisting
the hose back and forth on the tube or nipple, while
gently pulling it away from the end of the tube or
nipple.
NOTE:
Replacement of the heater inlet hoses will be
required if the hose ends are cut for removal.
(4) If necessary, carefully cut the hose end and
peel the hose off of the tube or nipple.
RSPLUMBING - FRONT24-85
HEATER CORE (Continued)

INSTALLATION
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) Using spring tension clamp pliers, compress
and slide each clamp away from the end of the hose
being installed.
(2) Install each hose by carefully twisting the hose
back and forth while gently pushing it onto the tube
or nipple end.
(3) Using spring tension clamp pliers, compress
and slide the clamps onto each end of the hose being
installed.
(4) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
HEATER RETURN HOSE
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).
NOTE: The heater return tube is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.
Fig. 17 Heater Inlet Hose - 2.4L Shown, 2.5L Typical
1 - ENGINE OUTLET NIPPLE
2 - HEATER INLET HOSE
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE
7 - HEATER RETURN HOSE
8 - ENGINE INLET NIPPLE
Fig. 18 Heater Inlet Hose - 3.3L/3.8L W/O Rear
Heater
1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE (TYPICAL)
Fig. 19 Heater Inlet Hose - 3.3L/3.8L With Rear
Heater
1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE
24 - 86 PLUMBING - FRONTRS
HEATER INLET HOSE (Continued)

(22) Install plugs in, or tape over the opened liquid
line fittings.
(23) Lower the vehicle.
(24) Remove the front liquid line rear section from
the engine compartment.
INSTALLATION
FRONT SECTION
(1) Position the front section of the front liquid
line into the engine compartment.
(2) Remove the tape or plugs from the liquid line
front section fitting for the receiver/drier and the
receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Reconnect the liquid line fitting to the receiver/
drier inlet port on the top of the receiver/drier.
(5) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
(7) Remove the tape or plugs from the A/C con-
denser outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plane seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install the nut that secures the liquid line fit-
ting to the condenser. Tighten the nut to 23 N´m (17
ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) Install the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
Tighten the screws to 2 N´m (17 in. lbs.).
(13) Install 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. Tighten the screws to 6 N´m (53 in. lbs.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).REAR SECTION
(1) Position the rear section of the front liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the receiver/drier and the
receiver/drier outlet port.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the receiver/
drier outlet port on the top of the receiver/drier.
(9) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(10) If equipped, reinstall the A/C ground strap
eyelet terminal connector onto the weld stud on the
top of the right front strut tower (if equipped).
(11) If equipped, install the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.)
(12) Install the A/C pressure transducer (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - INSTAL-
LATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) On RHD models, install the liquid line into
the retaining bracket located at the top of the dash
panel.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
24 - 90 PLUMBING - FRONTRS
LIQUID LINE (Continued)

(12) Remove the receiver/drier and mounting
bracket unit from the studs.
INSTALLATION
NOTE: If the receiver/drier is being replaced, add 25
milliliters (0.9 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Position the receiver/drier and mounting
bracket unit onto the weld studs on the side of the
right front strut tower.
(2) Install the two nuts that secure the receiver/
drier mounting bracket to the studs. Tighten the
nuts to 10 N´m (89 in. lbs.).
(3) Remove the tape or plugs from the liquid line
rear section fitting for the receiver/drier and the
receiver/drier outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(5) Reconnect the liquid line fitting to the receiver/
drier outlet port on the top of the receiver/drier.
(6) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(7) Remove the tape or plugs from the liquid line
front section fitting for the receiver/drier and the
receiver/drier inlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Reconnect the liquid line fitting to the receiver/
drier inlet port on the top of the receiver/drier.
(10) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(11) Reinstall the air cleaner housing into the
right side of the engine compartment.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-mable, clear, and colorless liquefied gas. Even though
R-134a does not contain chlorine, it must be
reclaimed and recycled just like CFC-type refriger-
ants. This is because R-134a is a greenhouse gas and
can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system. R-134a
refrigerant system service ports, service tool couplers
and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an
R-134a system is not accidentally contaminated with
the wrong refrigerant (R-12). There are also labels
posted in the engine compartment of the vehicle and
on the compressor identifying to service technicians
that the air conditioning system is equipped with
R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each con-
tains a different additive package. The compressor
used in this vehicle is designed to use an ND-8 PAG
refrigerant oil. Use only refrigerant oil of this same
type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance. PAG
refrigerant oil is much more hygroscopic than min-
eral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil
container should always be kept tightly capped until
it is ready to be used. After use, recap the oil con-
tainer immediately to prevent moisture contamina-
tion.
24 - 92 PLUMBING - FRONTRS
RECEIVER / DRIER (Continued)

from the system back into the new A/C compressor.
Refer to the reclaim/recycling equipment manufactur-
ers instructions.
SERVICE PORT VALVE CORE
DESCRIPTION
A/C SERVICE PORT VALVE CORES
The low side valve is located on the suction line
near the A/C compressor. The low side A/C service
port valve core is a serviceable item. The high side
A/C service port valve core is located on the liquid
line fitting attached to the top of the receiver/drier.
The high side A/C service port valve core is not a sep-
arate serviceable item. If the high side service port
valve core is faulty or damaged, the front section of
the liquid line will require replacement.
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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Using a standard Schrader-type valve core tool,
remove the valve core from the low side A/C service
port located on the suction line.
(3) Install a plug in or tape over the opened low
side A/C service port.
INSTALLATION
(1) Lubricate the low side A/C service port valve
core with clean refrigerant oil prior to installation.
Use only refrigerant oil of the type recommended for
the compressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port located on the suction line near the A/C com-
pressor.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the low side A/C service port.
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-tem refrigerant while uncoupling the charge adapt-
ers.
(4) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(5) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(6) Reinstall the protective cap onto the A/C ser-
vice port.
SUCTION 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: The front suction line includes the low side
service port on a section of tubing located near the
A/C compressor. On models equipped with the
optional rear A/C system, the front suction line also
includes a suction line hose and tube extension
that connects the front suction line to the suction
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 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 A/C compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the O-ring 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.
24 - 94 PLUMBING - FRONTRS
REFRIGERANT OIL (Continued)

(9) Remove 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. 28).
(10) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the suction line from the retaining
bracket located at the top of the dash panel.
(15) If the vehicle is equipped with the optional
rear air conditioner, go to Step 16. If the vehicle does
not have the optional rear air conditioner, go to Step
22.
(16) Raise and support the vehicle.
(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 29).
(18) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.(19) Remove the O-ring seal from the underbody
suction line fitting and discard.
(20) Install plugs in, or tape over the opened suc-
tion line fittings.
(21) Lower the vehicle.
(22) Remove the suction line from the engine com-
partment.
INSTALLATION
(1) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Install 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.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Install a new dual plan seal and reconnect the
suction line fitting to the compressor suction port.
Fig. 28 Suction Line - LHD Shown, RHD Typical
1 - A/C EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - RETAINING CLIP
5 - SUCTION LINE
Fig. 29 Underbody A/C Line Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY REFRIGERANT LINES
RSPLUMBING - FRONT24-95
SUCTION LINE (Continued)

(10) Install the nut that secures the suction line
fitting to the A/C compressor. Tighten the nut to 23
N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Install the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) On RHD models, install the suction line into
the retaining bracket located at the top of the dash
panel.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(20) Lower the vehicle.
(21) Reconnect the battery negative cable.
(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 - 96 PLUMBING - FRONTRS
SUCTION LINE (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)