recommended oil CHRYSLER VOYAGER 2004 Owner's Guide

STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) should be used. A
filter change should be made at the time of the
transmission oil change. The magnet (on the inside
of the oil pan) should also be cleaned with a clean,
dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 211).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
(7) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 212).
(8) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure.
(9) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent).
(3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
(5) Remove the suction line from the dipstick tube.
Fig. 211 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 212 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
RS41TE AUTOMATIC TRANSAXLE21 - 203
FLUID (Continued)

TORQUE CONVERTER CLUTCH (TCC)
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine's piston to the front
cover's friction material, a total converter engage-
ment can be obtained. The result of this engagement
is a direct 1:1 mechanical link between the engine
and the transmission.
The engagement and disengagement of the TCC
are automatic and controlled by the Powertrain Con-
trol Module (PCM). The engagement cannot be acti-
vated in the lower gears because it eliminates the
torque multiplication effect of the torque converter
necessary for acceleration. Inputs that determine
clutch engagement are: coolant temperature, vehicle
speed and throttle position. The torque converter
clutch is engaged by the clutch solenoid on the valve
body. The clutch will engage at approximately 56
km/h (35 mph) with light throttle, after the shift to
third gear.
REMOVAL
(1) Remove transmission and torque converter
from vehicle. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - 41TE - REMOVAL)
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate converter hub and oil pump seal lip
with transmission fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 326). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE - INSTALLATION)
(9) Fill the transmission with the recommended
fluid. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 41TE/FLUID - STANDARD PROCE-
DURE)TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 327) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between the battery and left fender.
Fig. 326 Checking Torque Converter Seating
1 - SCALE
2 - STRAIGHTEDGE
RS41TE AUTOMATIC TRANSAXLE21 - 247
TORQUE CONVERTER (Continued)

STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
should be used. A filter change should be made at
the time of the transmission oil change. The magnet
(on the inside of the oil pan) should also be cleaned
with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan. (2) Remove both engine mount-to-engine cross-
member cradle nuts. Using suitable screw jack and
wood block, raise engine and transmission slightly to
facilitate transaxle oil pan removal and installation. (3) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan. (4) Install a new filter and o-ring on bottom of the
valve body (Fig. 189). (5) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.). (6) Pour four quarts of Mopar tATF+4 through the
dipstick opening. (7) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position. (8) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level
to 3mm (1/8 in.) below the lowest mark on the dip-
stick (Fig. 190).
(9) Recheck the fluid level after the transaxle has
reached normal operating temperature (180ÉF.). Refer
to Fluid Level and Condition Check for the proper
fluid fill procedure. (10) To prevent dirt from entering transaxle, make
certain that dipstick is fully seated into the dipstick
opening.
DIPSTICK TUBE FLUID SUCTION METHOD
(ALTERNATIVE)
(1) When performing the fluid suction method,
make sure the transaxle is at full operating temper-
ature. (2) To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (VaculaŸ
or equivalent). (3) Insert the fluid suction line into the dipstick
tube.
NOTE: Verify that the suction line is inserted to the
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Follow the manufacturers recommended proce-
dure and evacuate the fluid from the transaxle.
Fig. 189 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
Fig. 190 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21s - 104 40TE AUTOMATIC TRANSAXLERS
FLUID (Continued)

white letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 28). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 29).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.
The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
All aluminum wheels have wheel mounting (lug)
nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load
carrying capacity. The diameter, width, offset, pilot
hole and bolt circle of the wheel should be the same
as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Fig. 28 Safety Rim
1 - TIRE
2 - WELL
3 - SAFETY HUMPS
4 - FLANGE
Fig. 29 Styled Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - STYLED WHEEL WEIGHT
22 - 18 TIRES/WHEELSRS
TIRES (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING
SYSTEM REQUIREMENTS...............1
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - SINGLE ZONE...........2
DESCRIPTION - DUAL ZONE.............2
DESCRIPTION - MANUAL THREE ZONE.....2
DESCRIPTION - AUTOMATIC THREE ZONE . . 3
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................4
OPERATION - SINGLE ZONE.............4
OPERATION - DUAL ZONE...............5
OPERATION - MANUAL THREE ZONE......5
OPERATION - THREE ZONE ATC..........5DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL
DOWN TEST..........................6
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST..................7
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST.................10
SPECIFICATIONS
A/C SYSTEM.........................11
CONTROLS - FRONT.....................14
CONTROLS - REAR......................34
DISTRIBUTION - FRONT...................43
DISTRIBUTION - REAR....................56
PLUMBING - FRONT.....................64
PLUMBING - REAR......................97
CABIN HEATER........................112
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser will
reduce the performance of the air conditioning and
engine cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manually controlled single zone type heating-air
conditioning system, manually controlled dual zone
type heating-air conditioning system, manually con-
trolled three zone type heating-air conditioning sys-
tem or an automatic controlled three zone typeheating-air conditioning system is available on this
model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing
mounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block or power module
(depending on application)
²Heater core
²Evaporator coil
²Blend door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
a combination of the three main housing outlets:
defrost, panel or floor. The defrost and panel outlets
are located on the top of the housing and the floor
outlet is located on the bottom of the housing. Once
the conditioned air exits the unit housing, it is fur-
ther directed through molded plastic ducts to the var-
ious outlets in the vehicle interior. These outlets and
their locations are as follows:
²Defroster Outlet- A single large defroster out-
let is located in the center of the instrument panel
top cover, near the base of the windshield.
²Side Window Demister Outlets- There are
two side window demister outlets, one is located at
RSHEATING & AIR CONDITIONING24-1

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

CAUTION
A/C SYSTEM
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
on the R-134a system. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible and damage
to the system will result.
Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
pressure and can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
If equipped, do not remove the secondary retention
clip from any spring-lock coupler connection while
the refrigerant system is under pressure. Recover
the refrigerant before removing the secondary
retention clip. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Immediately after disconnecting a compo-
nent from the refrigerant system, seal the open fit-
tings with a cap or plug.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system must be
avoided.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging equipment and/or A/C systems.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approvedleak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with R-134a
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT - DIAGNO-
SIS AND TESTING - REFRIGERANT SYSTEM
CHARGE LEVEL). If while performing this test A/C
liquid line pressure is less than 345 kPa (50 psi) pro-
ceed to System Empty procedure. If liquid line pres-
sure is greater than 345 kPa (50 psi) proceed to
System Low procedure. If the refrigerant system is
empty or low in refrigerant charge, a leak at any line
fitting or component seal is likely. A review of the fit-
tings, lines and components for oily residue is an
indication of the leak location.
To detect a leak in the refrigerant system, perform
one of the following procedures as indicated by the
results of the refrigerant system charge level test.
SYSTEM EMPTY
(1) Evacuate the refrigerant system to the lowest
degree of vacuum possible (approx. 28 in Hg.) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - FRONT/REFRIGERANT - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
Determine if the system holds a vacuum for 15 min-
utes. If vacuum is held, a leak is probably not
24 - 66 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
If a compressor designed to use R-134a refrigerant
is left open to the atmosphere for an extended period
of time. It is recommended that the refrigerant oil be
drained and replaced with new oil or a new compres-
sor be used. This will eliminate the possibility of con-
taminating the refrigerant system.
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be filled. Moisture and air mixed with the refrig-
erant will raise the compressor head pressure above
acceptable operating levels. This will reduce the per-
formance of the air conditioner and damage the com-
pressor. Moisture will boil at near room temperature
when exposed to vacuum. A R-134a refrigerant recov-
ery/recycling/charging station that meets SAE Stan-
dard J2210 must be used to evacuate the refrigerant
system. See the operating instructions supplied by
the equipment manufacturer for proper care and use
of this equipment. To evacuate the refrigerant sys-
tem, use the following procedure:
NOTE: When connecting the service equipment
couplings to the refrigerant system service ports,
be certain that the valve of each coupling is fully
closed. This will reduce the amount of effort
required to make the connection.
(1) Recover the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(2) Connect a suitable charging station, refrigerant
recovery machine or a manifold gauge set with vac-
uum pump and refrigerant recovery equipment.
(3) Open the suction and discharge valves and
start the vacuum pump. The vacuum pump should
run a minimum of 45 minutes prior to charge to
eliminate all moisture in system. When the suction
gauge reads -88 kPa (-26 in. Hg) vacuum or greater
for 30 minutes, close all valves and turn off vacuum
pump. If the system fails to reach specified vacuum,
the refrigerant system likely has a leak that must be
corrected. If the refrigerant system maintains speci-fied vacuum for at least 30 minutes, start the vac-
uum pump, open the suction and discharge valves.
Then allow the system to evacuate an additional 10
minutes.
(4) Close all valves. Turn off and disconnect the
vacuum pump.
(5) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE
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).
After all refrigerant system leaks have been
repaired and the refrigerant system has been evacu-
ated, a refrigerant charge can be injected into the
system. For the proper amount of the refrigerant
charge, refer to REFRIGERANT CHARGE CAPAC-
ITY. A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. See the operating instructions supplied
by the equipment manufacturer for proper care and
use of this equipment.
REFRIGERANT CHARGE CAPACITY
The R-134a refrigerant system charge capacity for
this vehicle is:
²Single or Dual Zone (Front Unit Only - with
2.5L Turbo Diesel)0.79 kilograms (1.75 pounds or
28 ounces)
²Single or Dual Zone (Front Unit Only)- 0.88
kilograms (1.94 pounds or 31 ounces)
²Three Zone (Front and Rear Units)- 1.21
kilograms (2.69 pounds or 43 ounces)
NOTE: Always refer to the underhood HVAC Speci-
fication Tag for the latest fill specification for the
vehicle being serviced.
24 - 72 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

INSTALLATION
INSTALLATION
NOTE: If a replacement A/C compressor is being
installed, be certain to check the refrigerant oil level
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
Use only refrigerant oil of the type recommended
for the compressor in the vehicle.
NOTE: The filter/drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
(1) Position the A/C compressor into the engine
compartment.
(2) On models with the 2.4L and 2.5L engine,
loosely install the four bolts that secure the compres-
sor to the mounting bracket on the engine (2.4L), or
the cylinder block (2.5L). Tighten the bolts to 28 N´m
(21 ft. lbs.).
(3) On models with the 3.3L and 3.8L engines,
loosely install the two bolts and two nuts that secure
the compressor to the engine. Tighten each of the fas-
teners using the following sequence to 54 N´m (40 ft.
lbs.).
²The upper nut at the front of the compressor.
²The lower nut at the front of the compressor.
²The upper bolt at the rear of the compressor.
²The lower bolt at the rear of the compressor.
(4) On models with the 3.3L and 3.8L engines,
engage the retainer on the engine wire harness com-
pressor clutch coil take out to the bracket on the top
of the compressor.
(5) Connect the engine wire harness connector to
the compressor clutch coil pigtail wire connector on
the top of the compressor.
(6) Reinstall the serpentine accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS).
(7) Lower the vehicle.
(8) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(10) Install a new gasket and reconnect the dis-
charge line fitting to the compressor discharge port.
(11) Install the nut that secures the discharge line
fitting to the compressor. Tighten the nut to 23 N´m
(17 ft. lbs.).
(12) Remove the tape or plugs from the compressor
suction port and the suction line fitting.(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(14) Install a new gasket and reconnect the suc-
tion line fitting to the compressor suction port.
(15) Install the nut that secures the suction line
fitting to the compressor. Tighten the nut to 23 N´m
(17 ft. lbs.).
(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(18) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - A/C COMPRESSOR
MOUNTING BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install the four bolts that secure the compres-
sor mounting bracket to the engine. Tighten the bolts
to 54 N´m (40 ft. lbs.).
(3) Reinstall the A/C compressor onto the mount-
ing bracket (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR -
INSTALLATION).
A/C CONDENSER
DESCRIPTION
The A/C condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The A/C condenser is a
heat exchanger that allows the high-pressure refrig-
erant gas being discharged from the compressor to
give up its heat to the air passing over the condenser
fins. The A/C condenser may be removed from the
cooling module for service without removing the cool-
ing module from the vehicle.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning system. Therefore, it is important that
there are no objects placed in front of the radiator
grille openings in the front of the vehicle or foreign
24 - 76 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)

INSTALLATION
NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.8 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Position the A/C condenser to the right mount-
ing bracket and transmission oil cooler unit.
(2) Position the left mounting bracket onto the side
of the condenser and transmission oil cooler.
(3) Install the screw that secures the left mounting
bracket to the side of the transmission oil cooler.
Tighten the screw to 5 N´m (45 in. lbs.).
(4) Install the two screws that secure each mount-
ing bracket to the sides of the condenser. Tighten the
screws to 5 N´m (45 in. lbs.).
(5) Position the condenser, transmission oil cooler,
and mounting brackets into the vehicle as a unit. Be
certain that the locating pins that secure the mount-ing brackets are engaged in the lower mount rubber
isolators on each side of the cooling module.
NOTE: Verify that the condenser isolators are all
installed and positioned correctly.
(6) Install the two screws that secure the top of
the mounting bracket on each side of the condenser
to the cooling module. Tighten the screws to 5 N´m
(45 in. lbs.).
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plan seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10)
Install the nut that secures the liquid line fitting
to the condenser. Tighten the nut to 23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Install a new dual plan seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(14) Install the nut that secures the discharge line
fitting to the condenser. Tighten the nut to 23 N´m
(17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install the two screws that secure the hood
latch unit to the front of the radiator closure panel
crossmember. Check and adjust the hood latch as
needed. Tighten the screws to 14 N´m (123 in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) Install 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.).
(20) 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.).
(21) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
Fig. 9 A/C Condenser
1 - SCREW (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - A/C CONDENSER
24 - 78 PLUMBING - FRONTRS
A/C CONDENSER (Continued)