drain bolt CHRYSLER VOYAGER 2004 Repair Manual

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)

SIDE VIEW MIRROR
REMOVAL
(1) Using a trim stick C-4755 or equivalent, lift up
the end of the instrument panel top pad enough to
gain access to the mirror electrical connector, if
equipped. (Refer to 23 - BODY/INSTRUMENT PAN-
EL/INSTRUMENT PANEL TOP COVER -
REMOVAL)
(2) Disconnect the electrical connector, if equipped.
(3) Using a trim stick or equivalent, remove the
trim cover (Fig. 21).
(4) Remove the bolts.
(5) Remove the mirror from the pillar.
INSTALLATION
(1) Route the mirror wire harness, if equipped,
through the a-pillar and place side view mirror in
position on vehicle (Fig. 21).
(2) Install the bolts and tighten to 10 N´m (85 in.
lbs.).
(3) Install the mirror trim cover.
(4) Connect the electrical connector, if equipped.
(5) Install the instrument panel top cover, if
equipped with the electric mirror. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
SIDE VIEW MIRROR GLASS
REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.
(1) Carefully pull/pry the broken glass holder from
the mirror assembly.
(2) Disconnect the heated mirror electrical connec-
tors from the terminals on the mirror glass holder, if
equipped.
INSTALLATION
CAUTION: It is important to make sure the motor is
square to the glass holder (attaching fingers) prior
to glass holder attachment, otherwise the glass
holder could be installed incorrectly causing poor
retention and possible repeat failure.
(1) Position the new mirror glass holder to the
mirror assembly.
NOTE: Position the mirror glass holder so that the
moisture drain hole on the mirror glass holder
assembly is facing downward.
(2) Align the mirror glass holder's attaching fin-
gers to the mirror motor housing.
NOTE: Ensure that the protective rubber cover of
the mirror motor housing is positioned correctly
around the bottom of the fingers area.
(3) Using one hand, firmly press the mirror glass
holder assembly into place while at the same time
supporting the housing assembly from the backside
with the other hand.
NOTE: Pressure must be applied equally over the
center portion of the mirror to engage the mirror
glass holder's attaching fingers to the correspond-
ing fingers on the housing assembly. One or more
clicks may be heard when finger engagement takes
place.
(4) Verify retention of the mirror glass holder
assembly by gently pulling outward on the mirror
glass holder.
Fig. 21 SIDE VIEW MIRROR
1 - MIRROR
2 - MIRROR TRIM COVER
3 - A-PILLAR
4 - BOLTS
RSEXTERIOR23-59

(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
REMOVAL
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) AND (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
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) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the windshield wiper module from the
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(5) Disconnect the liquid line and suction line from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(6) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(7) On LHD models, remove the one bolt that
secures the HVAC housing to the dash panel (Fig.
12).
(8) Remove the three nuts that secure the HVAC
housing to the dash panel.
(9) Remove the instrument panel from the passen-
ger compartment (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(10) Remove the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
REMOVAL).
(11) Remove the bolt or bolts (depending on appli-
cation) that secure the HVAC housing to the passen-
ger compartment side of the dash panel (Fig. 13) or
(Fig. 14).
(12) Pull the HVAC housing rearward far enough
for the mounting studs to clear the dash panel and
remove the housing from the passenger compart-
ment.
DISSASEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).
Fig. 11 Floor Distribution Ducts - LHD Shown, RHD
Typical
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-51
FLOOR DISTRIBUTION DUCTS (Continued)

compressor clutch coil take out from the bracket on
the top of the compressor.(15) On models with the 3.3L and 3.8L engines,
remove the two bolts and two nuts that secure the
compressor to the engine.
(16) On models with the 2.4L and 2.5L engine,
remove the four bolts that secure the compressor to
the mounting bracket on the engine (2.4L), or the cyl-
inder block (2.5L).
(17) Remove the A/C compressor from the engine
compartment.
NOTE: If a replacement compressor is being
installed, be certain to drain and measure the refrig-
erant oil contained in the removed compressor.
This will determine how much oil the replacement
compressor must contain before it is installed
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: The filter/drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
REMOVAL - A/C COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Remove the A/C compressor from the mounting
bracket (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - REMOVAL).
(2) Remove the four bolts that secure the compres-
sor mounting bracket to the engine (Fig. 7).
(3) Remove the compressor mounting bracket from
the engine.
Fig. 5 A/C Compressor - 2.4L Shown, 2.5L Typical
1 - CLUTCH COIL CONNECTOR
2 - DISCHARGE PORT
3 - A/C COMPRESSOR
4 - SUCTION PORT
5 - BOLT (4)
6 - A/C COMPRESSOR MOUNTING BRACKET
Fig. 6 A/C Compressor - 3.3L/3.8L Engine
1 - STUD
2 - CLUTCH COIL CONNECTOR
3 - DISCHARGE PORT
4 - BOLT (2)
5 - SUCTION PORT
6 - A/C COMPRESSOR
7 - STUD
8 - NUTS (2)
Fig. 7 Compressor Mounting Bracket - 2.4L Engine
1 - MOUNTING BRACKET
2 - BOLTS (4)
3 - ENGINE
RSPLUMBING - FRONT24-75
A/C COMPRESSOR (Continued)

REAR SECTION
(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. 25).
(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) On RHD models, remove the liquid line from
the retaining bracket located at the top of the dash
panel
(17) If the vehicle is equipped with the optional
rear air conditioner, go to Step 18. If the vehicle does
not have the optional rear air conditioner, go to Step
24.
(18) Raise and support the vehicle.
(19) 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. 26).
(20) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(21) Remove the O-ring seal from the underbody
liquid line fitting and discard.
Fig. 25 Liquid Line - LHD Shown, RHD Typical
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
Fig. 26 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 - FRONT24-89
LIQUID LINE (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)

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)

(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
er-A/C system (Fig. 8).
(18) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(19) Remove the O-ring seal from the underbody
liquid line fitting and discard.
(20) Install plugs in, or tape over the opened liquid
line fittings.
(21) Lower the vehicle.
(22) Remove the liquid line from the engine com-
partment.
INSTALLATION
(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/
A/C PRESSURE TRANSDUCER - INSTALLATION).
(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) Raise and support the vehicle.
(16) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(18) 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.).
(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-
A/C system.
(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).
Fig. 8 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 - REAR24 - 105
LIQUID LINE (Continued)

(9) Loosen the two fasteners at the rail. Take care
to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the flexible section of the cabin
heater exhaust tube from the exhaust tube by loos-
ening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to crossmember.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable support device under the
cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the
crossmembers.
(14) Remove the loosened fasteners that support
the cabin heater while supporting the weight of the
heater.
(15) Swing the cabin heater mounting bracket
from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.
(16) Remove the cabin heater from the vehicle.
INSTALLATION
(1) Install the cabin heater mounting bracket
between the exhaust bracket and the rail mounting
location.
(2) Support the cabin heater and install the fasten-
ers that secure the cabin heater to the mounting
bracket.
(3) Install the three fasteners to the crossmem-
bers. Tighten the M6 fasteners to 7 N´m (62 in. lbs.).
(4) Position the two spacer washers between the
body and the rubber grommets for the two mounting
points on the rail.
(5) Tighten the remaining M6 fasteners to 7 N´m
(62 in. lbs.) and the M8 fasteners to 23 N´m (17 ft.
lbs.) which mount the exhaust tube assembly to the
vehicle.
(6) Install the seat hex nut at the heater mounting
flange to the crossmembers. Tighten the nut to 60
N´m (44 ft. lbs.)
(7) Install the flexible section of the cabin heater
exhaust tube to the exhaust tube. Tighten the M6
bolt of the clamp securley. Install the hose to the
exhaust tube.
(8) Tighten the two M8 fasteners at the rail to 23
N´m (17 ft. lbs.). Taking care so that the exhaust
tube bracket tab is on the top of the heater bracket.(9) Install the wiring harness (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
(10) Tighten the hose and tube assembly to the
toe-board crossmember at two locations.
(11) Install the second hose to the underbody hose
and tube assembly.
(12) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(13) Remove the cabin heater support device from
under the vehicle.
(14) Lower the vehicle.
(15) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(16) Verify function of the cabin heater.
SUPPLEMENTAL DIESEL
HEATER WIRING
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Unplug connector from vehicle wiring harness
to cabin heater harness.
(3) Unplug connector from cabin heater harness to
dosing pump connector.
(4) Unplug two connectors from cabin heater har-
ness to cabin heater controller connectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.
(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
RSCABIN HEATER24 - 119
HEATER UNIT (Continued)