radiator CHRYSLER VOYAGER 2004 Manual PDF

Condition Possible Causes Correction
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid Line, Suction Line and Discharge
Line in this group. Inspect the refrigerant lines for
kinks, tight bends or improper routing. Correct
the routing or replace the refrigerant line, if
required.
2. Restricted refrigerant flow
through the A/C expansion
valve.2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Restricted refrigerant flow
through the A/C condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
WARNING: REVIEW SAFETY PRECAUTIONS AND
WARNINGS IN THIS GROUP BEFORE PERFORMING
THIS PROCEDURE (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING).
Check the coolant level, drive belt tension, radiator
air flow and fan operation. Start engine and allow to
warm up to normal operating temperature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing the radiator cap. Place a rag overthe cap and turn it to the first safety stop. Allow
pressure to escape through the overflow tube. When
the system pressure stabilizes, remove the cap com-
pletely.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two heater hoses. With the engine idling at normal
operating temperature, set the temperature control
to maximum heat, the mode control to the floor posi-
tion, and the blower in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged from the floor outlets. Com-
pare the test thermometer reading to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE
Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahrenheit Celsius Fahrenheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
If the floor outlet air temperature is insufficient,
check that the cooling system is operating to specifi-
cations (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Both heater hoses should be
HOT to the touch (the coolant return hose should be
slightly cooler than the supply hose). If the coolant
return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction
in heater system.OBSTRUCTED COOLANT FLOW Possible locations or causes
of obstructed coolant flow are as follows:
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at the cooling system connections.
²Plugged heater core.
If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is insuffi-
cient, a mechanical problem may exist.
24 - 10 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

erence signal and a sensor ground to the transducer,
then monitors the output voltage of the transducer
on a sensor return circuit to determine refrigerant
pressure. The PCM is programmed to respond to this
and other sensor inputs by controlling the operation
of the A/C compressor clutch and the radiator cooling
fan to help optimize air conditioning system perfor-
mance and to protect the system components from
damage. The A/C pressure transducer input to the
PCM will also prevent the A/C compressor clutch
from engaging when ambient temperatures are below
about 4.5É C (40É F) due to the pressure/temperature
relationship of the refrigerant. The Schrader-type
valve in the liquid line fitting permits the A/C pres-
sure transducer to be removed or installed without
disturbing the refrigerant in the system. The A/C
pressure transducer is diagnosed using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
The A/C pressure transducer is tested using a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information. Before testing the A/C pressure
transducer, be certain that the transducer wire har-
ness connection is clean of corrosion and properly
connected. For the A/C to operate, an A/C pressure
transducer voltage reading between 0.451 and 4.519
volts is required. Voltages outside this range indicate
a low or high refrigerant system pressure condition
to the powertrain control module (PCM). The PCM is
programmed to respond to a low or high refrigerant
system pressure by suppressing operation of the A/C
compressor. Refer to the A/C Pressure Transducer
Voltage chart for the possible conditions indicated by
the transducer voltage reading.
A/C PRESSURE TRANSDUCER VOLTAGE
Voltage Possible Indication
0.0 1. No sensor supply voltage from
PCM.
2. Shorted sensor circuit.
3. Faulty transducer.
0.150 TO 0.450 1. Ambient temperature below 10É
C (50É F).
2. Low refrigerant system pressure.
0.451 TO 4.519 1. Normal refrigerant system
pressure.
4.520 TO 4.850 1. High refrigerant system pressure.
5.0 1. Open sensor circuit.
2. Faulty transducer.
REMOVAL
NOTE: Note: It is not necessary to discharge the
refrigerant system to replace the A/C pressure
transducer.
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 10).
(3) Remove the A/C pressure transducer from the
fitting on the liquid line.
(4) Remove the O-ring seal from the A/C pressure
transducer fitting and discard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C pressure transducer.
(1) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the A/C pressure
transducer fitting. Use only the specified O-rings as
they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
(2) Install and tighten the A/C pressure transducer
onto the fitting onto the liquid line fitting.
(3) Connect the wire harness connector to the A/C
pressure transducer.
(4) Reconnect the battery negative cable.
Fig. 10 A/C Pressure Transducer - Typical
1 - RIGHT FRONT STRUT TOWER
2 - WIRE HARNESS CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 22 CONTROLS - FRONTRS
A/C PRESSURE TRANSDUCER (Continued)

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

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)

material on the condenser fins that might obstruct
air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radia-
tor or condenser service.
The A/C condenser cannot be repaired or adjusted,
and if faulty or damaged, it must be replaced.
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: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove 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 (Fig. 8).(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the two screws that secure the hood
latch unit to the front of the radiator closure panel
crossmember and move the latch out of the way over
the top of the crossmember. Mark the location of
latch for reinstallation.
(6) Disconnect the hoses from the transmission oil
cooler fittings on the left side of the cooling module
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - REMOVAL).
(7) Remove the nut that secures the discharge line
fitting to the A/C condenser on the right side of the
cooling module.
(8) Disconnect the discharge line fitting from the
condenser inlet port.
(9) Remove the O-ring seal and gasket from the
discharge line fitting and discard.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(11) Remove the nut that secures the liquid line
fitting to the condenser on the right side of the cool-
ing module.
(12) Disconnect the liquid line fitting from the con-
denser outlet port.
(13) Remove the O-ring seal and gasket from the
liquid line fitting and discard.
(14) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(15) Remove the screw that secures the top of the
mounting bracket on each side of the condenser to
the cooling module (Fig. 9).
(16) Lift the condenser, transmission oil cooler, and
mounting brackets as a unit far enough to disengage
the locating pin that secures the mounting brackets
in the lower mount rubber isolators on each side of
the cooling module.
(17) Remove the condenser, transmission oil cooler,
and mounting brackets from the vehicle as a unit.
(18) Remove the two screws that secure each
mounting bracket to the sides of the A/C condenser.
(19) Remove the one screw that secures the left
mounting bracket to the side of the transmission oil
cooler.
(20) Remove the left mounting bracket from the
side of the condenser and transmission oil cooler.
(21) Remove the condenser from the right mount-
ing bracket and transmission oil cooler unit.
Fig. 8 Radiator Air Seals
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-77
A/C CONDENSER (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)

A/C DISCHARGE 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).
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove 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 (Fig. 10).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 11).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the O-ring seal and gasket from the
discharge line fitting and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.(9) Remove the nut that secures the discharge line
fitting to the top of the compressor (Fig. 12).
(10) Disconnect the discharge line fitting from the
compressor discharge port.
(11) Remove the O-ring seal and gasket from the
discharge line fitting and discard.
(12) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(13) Remove the discharge line from the engine
compartment.
Fig. 10 Radiator Sight Shield - Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
Fig. 11 A/C Discharge Line to Condenser
1 - A/C CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
Fig. 12 A/C Discharge Line to Compressor - Typical
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
RSPLUMBING - FRONT24-79

INSTALLATION
(1) Position the discharge line into the engine com-
partment.
(2) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(4) Install a new dual plane seal and reconnect the
discharge line fitting to the compressor discharge
port on the top of the compressor.
(5) Install the nut that secures the discharge line
fitting to the compressor. Tighten the nut to 23 N´m
(17 ft. lbs.).
(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(8) Install a new dual plane seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(9) Install the nut that secures the discharge line
fitting to the condenser. Tighten the nut to 23 N´m
(17 ft. lbs.).
(10) Position the radiator sight shield onto the
radiator closure panel crossmember.
(11) 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.).
(12) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
A/C EVAPORATOR
DESCRIPTION
The A/C evaporator is located in the HVAC hous-
ing, behind the instrument panel. The evaporator is
positioned in the housing so that all air that enters
the housing must pass over the fins of the evaporator
coils before it is distributed through the system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the compressor isengaged and circulating refrigerant through the
evaporator tubes.
OPERATION
Refrigerant enters the A/C evaporator from the
expansion valve as a low-temperature, low-pressure
liquid. As air flows over the fins of the evaporator,
the humidity in the air condenses on the fins, and
the heat from the air is absorbed by the refrigerant.
Heat absorption causes the refrigerant to boil and
vaporize. The refrigerant becomes a low-pressure gas
when it leaves the evaporator.
The A/C evaporator cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
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) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).
(3) Carefully lift the evaporator and its foam wrap
out of the lower half of the HVAC housing as a unit.
Be certain not to lose the clam shell type rubber seal
that is fitted to the evaporator inlet and outlet tubes
where they exit the HVAC housing.
INSTALLATION
NOTE: If the evaporator is being replaced, add 50
milliliters (1.8 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Carefully lower the evaporator and its foam
wrap into the lower half of the HVAC housing as a
unit. Be certain that the clam shell type rubber seal
24 - 80 PLUMBING - FRONTRS
A/C DISCHARGE LINE (Continued)

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: The front A/C liquid line is serviced in two
sections. The front section connects between the
A/C condenser and the receiver/drier and includes
the high side service port. The rear section con-
nects between the receiver/drier and the expansion
valve and includes the fitting for the A/C pressure
transducer. On models equipped with the optional
rear air conditioner, the rear section of the front air
conditioner liquid line also includes a liquid line
hose and tube extension that connects the front liq-
uid line to the liquid line for the rear air conditioner.
FRONT 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) Remove 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 (Fig. 23).
(5) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(6) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(7) Remove the nut that secures the liquid line fit-
ting to the condenser on the right side of the cooling
module (Fig. 24).
(8) Disconnect the liquid line fitting from the A/C
condenser outlet port.
(9) Remove the O-ring seal and gasket from the
liquid line fitting and discard.
(10) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(11) Disengage 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 compart-
ment (Fig. 25).(12) Remove the screw that secures the liquid line
front section fitting to the top of the receiver/drier.
(13) Disconnect the liquid line fitting from the
receiver/drier inlet port.
(14) Remove the seals from the liquid line fitting
and discard.
(15) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
(16) Remove the front section of the front liquid
line from the engine compartment.
Fig. 23 Radiator Sight Shield - Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
Fig. 24 A/C Condenser Connections
1 - A/C CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
24 - 88 PLUMBING - FRONTRS

(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)