heating CHRYSLER VOYAGER 2004 Manual Online

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)

is fitted to the evaporator inlet and outlet tubes
where they exit the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
EXPANSION VALVE
DESCRIPTION
The front ªHº valve-type thermal expansion valve
(TXV) is located at the dash panel between the liquid
and suction lines, and the A/C evaporator. The
assembly consists of an aluminum H-valve body and
a thermal sensor. On vehicles equipped with the
automatic temperature control (ATC) heater- A/C sys-
tem, the evaporator temperature sensor is installed
on the top of the expansion valve.
OPERATION
High-pressure, low temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the evaporator coil. A mechanical sensor in the
expansion valve control head monitors the tempera-
ture and pressure of the refrigerant leaving the evap-
orator coil through the suction line, and adjusts the
orifice size at the liquid line to let the proper amount
of refrigerant into the evaporator coil to meet the
vehicle cooling requirements. Controlling the refriger-
ant flow through the A/C evaporator ensures that
none of the refrigerant leaving the evaporator is still
in a liquid state, which could damage the compressor.
The A/C expansion valve is a factory calibrated
unit and cannot be adjusted or repaired and, if faulty
or damaged, it must be replaced.
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
NOTE: The A/C expansion valve should only be
tested following testing of the A/C compressor.NOTE: Liquid CO
2is required to test the A/C expan-
sion valve. This material is available from most
welding supply facilities. Liquid CO
2is also avail-
able from companies which service and sell fire
extinguishers.
When testing the A/C expansion valve, the work
area and the vehicle temperature must be 21É to 27É
C (70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the A/C-heater controls so that the com-
pressor is operating, the temperature control is in
the highest temperature position, the mode door is
directing the output to the floor outlets, and the
blower is operating at the highest speed setting.
(4) Start the engine and allow it to idle. After the
engine has reached normal operating temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the A/C evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). The suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30
psi). If OK, go to Step 6. If not OK, replace the faulty
A/C expansion valve.
WARNING:
PROTECT THE SKIN AND EYES FROM EXPOSURE
TO LIQUID CO
2. PERSONAL INJURY CAN RESULT.
(6) If the suction (low pressure) gauge reads
within the specified range, freeze the expansion valve
control head for 30 seconds using liquid CO
2or
another suitable super-cold material.Do not spray
R-134a or R-12 refrigerant on the expansion
valve control head for this test.The suction (low
pressure) gauge reading should drop by 10 psi. If OK,
go to Step 7 If not OK, replace the faulty A/C expan-
sion valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not
OK, replace the faulty A/C expansion valve.
(8) When expansion valve testing is complete, test
the overall air conditioner performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
RSPLUMBING - FRONT24-81
A/C EVAPORATOR (Continued)

REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 13).
(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the receiver/
drier.
(7) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.(9) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the A/C expansion valve and move the
lines out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate.
(15) On ATC equipped models, disconnect the
HVAC wire harness connector from the evaporator
temperature sensor.
(16) Remove the A/C expansion valve from the
evaporator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
(19) On ATC equipped models, remove the evapo-
rator temperature sensor retainer and evaporator
temperature sensor from the A/C expansion valve, if
required.
INSTALLATION
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) On ATC equipped models, install the evapora-
tor temperature sensor and retainer onto the A/C
expansion valve, if removed.
(2) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the A/C expansion valve.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(4) Position the A/C expansion valve onto the evap-
orator inlet and outlet tube fittings.
(5) Install the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(6) On ATC equipped models, connect the HVAC
wire harness connector to the evaporator tempera-
ture sensor.
(7) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
Fig. 13 A/C Expansion Valve - LHD Shown, RHD
Typical
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR (ATC ONLY)
3 - A/C EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 82 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)

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

(9) Remove the heater core tubes and sealing plate
as a unit from beneath the instrument panel.
(10) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
REMOVAL - HEATER CORE
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 silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(2) Remove the brake lamp switch from its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(3) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-CHANICAL/POWER BRAKE BOOSTER -
REMOVAL).
(4) Remove the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
(5) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(6) While pulling the accelerator pedal upward
(Fig. 15) and pushing the brake pedal downward
(Fig. 16) far enough for clearance, pull the heater
core out of the distribution housing.
(7) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation. Also, if
the heater core was leaking, use absorbent toweling
and reach into the heater core opening to mop up
any residual engine coolant within the distribution
housing.
Fig. 14 Heater Core Tubes - LHD Shown, RHD
Typical
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
Fig. 15 Accelerator Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
Fig. 16 Brake Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
2 - BRAKE PEDAL
24 - 84 PLUMBING - FRONTRS
HEATER CORE (Continued)

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

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

(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Using spring tension clamp pliers, compress
and slide the clamps off of each end of the hose being
removed (Fig. 20), (Fig. 21) or (Fig. 22).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes/heater core, causing an engine coolant leak.
(3) Disconnect each hose end by carefully twisting
the hose back and forth on the tube or nipple, while
gently pulling it away from the end of the tube or
nipple.
NOTE:
Replacement of the heater return hoses will be
required if the hose ends are cut for removal.
(4) If necessary, carefully cut the hose end and
peel the hose off of the tube or nipple.
INSTALLATION
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING).(1) Using spring tension clamp pliers, compress
and slide the clamp away from the end of the heater
return hose.
(2) Install each hose end by carefully twisting the
hose back and forth while gently pushing it onto the
tube.
(3) Using spring tension clamp pliers, compress
and slide the clamps onto each end of the heater
return hose.
(4) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
Fig. 20 Heater Return Hose - 2.4L Shown, 2.5L
Typical
1 - ENGINE OUTLET NIPPLE
2 - HEATER INLET HOSE
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE
7 - HEATER RETURN HOSE
8 - ENGINE INLET NIPPLE
Fig. 21 Heater Return Hose - 3.3L/3.8L W/O Rear
Heater
1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE (TYPICAL)
Fig. 22 HEATER HOSES - 3.3/3.8L With Rear Heater
1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE
RSPLUMBING - FRONT24-87
HEATER RETURN HOSE (Continued)