wheel CHRYSLER VOYAGER 2005 Service Manual

MANIFOLD GAUGE SET
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
²LOW PRESSURE GAUGE HOSE- The low
pressure hose (Blue with Black stripe) attaches to
the low side service port. This service port is located
on the suction line near the A/C compressor.
²HIGH PRESSURE GAUGE HOSE- The high
pressure hose (Red with Black stripe) attaches to the
high side service port. This service port is located on
the liquid line fitting at the reciever/drier.
²RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE- The center manifold hose (Yel-
low, or White, with Black stripe) is used to recover,
evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold
gauge set are opened, the refrigerant in the system
will escape through this hose.
REFRIGERANT SYSTEM RECOVERY
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).
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
REFRIGERANT SYSTEM EVACUATE
NOTE: Special effort must be used to prevent mois-
ture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a
reliability problem with the compressor.
Fig. 2 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134a REFRIGERANT STATION
Fig. 3 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
24 - 70 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

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
(Fig. 15). 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 (1.7 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(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
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 RG models, the evaporator tem-
perature sensor is installed on the top of the expan-
sion 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.
Fig. 15 HVAC Housing - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR AND WHEEL
4 - A/C EVAPORATOR
RSPLUMBING - FRONT24-81
A/C EVAPORATOR (Continued)

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 door
allows 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
FRONT 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. 17).
(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.
(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.
Fig. 17 Heater Core Tubes - LHD Shown, RHD
Typical
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
24 - 84 PLUMBING - FRONTRS
HEATER CORE (Continued)

FRONT 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. 18) and pushing the brake pedal downward
(Fig. 19) 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.
INSTALLATION
FRONT 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.
Fig. 18 Accelerator Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
Fig. 19 Brake Pedal - LHD Shown, RHD Typical
1 - HEATER CORE
2 - BRAKE PEDAL
RSPLUMBING - FRONT24-85
HEATER CORE (Continued)

PLUMBING - REAR
TABLE OF CONTENTS
page page
A/C EVAPORATOR
DESCRIPTION.........................98
OPERATION...........................98
REMOVAL
REAR A/C EVAPORATOR...............98
REAR A/C EVAPORATOR LINE
EXTENSION.........................99
INSTALLATION
REAR A/C EVAPORATOR..............100
REAR A/C EVAPORATOR LINE
EXTENSION........................100
A/C EXPANSION VALVE
DESCRIPTION........................100
OPERATION..........................100
DIAGNOSIS AND TESTING
REAR A/C EXPANSION VALVE..........101
REMOVAL............................101
INSTALLATION........................101
HEATER CORE
DESCRIPTION........................102
OPERATION..........................102
STANDARD PROCEDURE
REAR HEATER CORE FILLING..........102REMOVAL............................103
INSTALLATION........................104
HEATER HOSES
REMOVAL............................104
INSTALLATION........................105
LIQUID LINE
REMOVAL............................105
INSTALLATION........................106
SUCTION LINE
REMOVAL............................106
INSTALLATION........................107
UNDERBODY LINES
DESCRIPTION........................108
OPERATION..........................108
REMOVAL
UNDERBODY HEATER TUBES..........109
UNDERBODY REFRIGERANT LINES......110
INSTALLATION
UNDERBODY HEATER TUBES..........112
UNDERBODY REFRIGERANT LINES......112
A/C EVAPORATOR
DESCRIPTION
The rear A/C evaporator is located in the rear
HVAC housing, behind the right rear wheel house.
The evaporator is positioned in the rear 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 condi-
tioned when the compressor is engaged and circulat-
ing refrigerant through the evaporator tubes. The
rear HVAC housing must be removed from the vehi-
cle to access the A/C evaporator for service.
OPERATION
Refrigerant enters the rear evaporator from the
rear expansion valve as a low-temperature, low-pres-
sure liquid. As air flows over the fins of the evapora-
tor, the humidity in the air condenses on the fins,
and the heat from the air is absorbed by the refrig-
erant. Heat absorption causes the refrigerant to boil
and vaporize. The refrigerant becomes a low-pressure
gas when it leaves the evaporator.
REMOVAL
REAR A/C EVAPORATOR
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING), (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING), and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - HEATER PLUMBING).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Remove the rear evaporator line extension from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(3) Remove the rear expansion valve from the rear
evaporator (Refer to 24 - HEATING & AIR CONDI-
24 - 98 PLUMBING - REARRS

(5) Install the rear evaporator line extension onto
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear HVAC housing, behind the right rear wheel
house. It is a heat exchanger made of rows of tubes
and fins. One end of the core is fitted with a molded
plastic tank that includes integral heater core inlet
and outlet nipples. The rear heater core can be ser-
viced without removing the rear HVAC housing from
the vehicle.
OPERATION
Engine coolant is circulated through underbody
heater hoses to the rear heater core at all times. As
the coolant flows through the rear 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
rear blend door allows control of the rear heater out-
put air temperature by controlling how much of the
air flowing through the rear HVAC housing is
directed through the heater core.
The rear heater core cannot be repaired and, if
faulty or damaged, it must be replaced.
STANDARD PROCEDURE
REAR HEATER CORE FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-
fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.
2.Thermal cycling of the engine cooling system. Fol-lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
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 - HEATER PLUMBING).
PRE-FILLING
If the rear heater core or the rear HVAC housing
have been removed from the vehicle for service, the
rear heater core may be pre-filled with the proper
engine coolant mixture prior to reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
HVAC housing, and the rear HVAC housing should
be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
(4) Carefully pour the proper pre-mixed engine
coolant solution into the rear heater core through a
funnel until coolant begins to appear at the lower
hose fitting of the heater core.
(5) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(6) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
24 - 102 PLUMBING - REARRS
A/C EXPANSION VALVE (Continued)

(7) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
THERMAL CYCLING
If the rear heater core was emptied and was not
pre-filled, it will be necessary to thermal cycle the
vehicle at least two times to ensure that the rear
heater core is properly filled.
(1) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(2) Start the engine and allow it to operate until
the thermostat opens.
(3) Turn the engine off and allow it to cool.
(4) With the engine cold and not running, check
and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(5) Start the engine and allow it to operate until
the thermostat opens again.
(6) Turn the engine off and allow it to cool down
again.
(7) With the engine cold and not running, check
and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(8) Check the performance of the rear heater.
Refer to REAR HEATER PERFORMANCE CHECK.
REAR HEATER PERFORMANCE CHECK
Successful completion of the rear heater perfor-
mance check will confirm that the rear heater core is
properly filled with engine coolant. If the check is not
successful, either there is still air trapped in the rear
heater core or the rear heater plumbing is restricted.
This check should be performed with the vehicle in a
shop where the ambient temperature is about 21É C
(70É F).
(1) Start the engine and allow it to idle until it
warms up to normal operating temperature.
(2) Adjust the heater-A/C controls so that the front
heater is turned Off, the rear heater is set for full
Heat, and the rear blower motor is at its highest
speed setting.
(3) Use an accurate test thermometer to measure
the temperature of the air being discharged from the
rear heater outlet located at the base of the right
C-pillar.
(4) Proper discharge air temperature readings
should be from 57É to 63É C (135É to 145É F).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 - HEATER PLUMBING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the rear heater distribution duct from
the right quarter inner panel (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
REMOVAL).
(4) Remove the screw that secures the back of the
rear HVAC housing to the right D-pillar.
(5) Remove the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
(6) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(7) Disconnect the heater hoses at the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).
(8) Install plugs in, or tape over the opened heater
core fittings and both heater hoses (Fig. 5).
Fig. 5 Rear Heater Core
1 - REAR HVAC HOUSING OUTLET
2 - REAR HVAC UNIT HOUSING
3 - LATCH (4)
4 - REAR HEATER CORE
5 - RIGHT REAR WHEEL HOUSE
6 - REAR HEATER HOSES
RSPLUMBING - REAR24 - 103
HEATER CORE (Continued)

(5) Install plugs in, or tape over the opened refrig-
erant line fittings.
(6) Remove the screws that secure the underbody
line retaining straps to the vehicle underbody.
(7) Remove the underbody refrigerant lines from
the retaining straps.
(8) Remove the bolt or nut (depending on applica-
tion) that secures the underbody refrigerant lines to
the rear evaporator extension line tapping plate,
located behind the right rear wheel housing (Fig. 17)
and (Fig. 18).
(9) Disconnect the underbody refrigerant lines
from the rear evaporator extension line tapping plate
and remove and discard the O-ring seals.
(10) Install plugs in, or tape over the opened
underbody refrigerant line fittings and the rear evap-
orator extension line ports.
(11) Remove the underbody refrigerant lines from
the vehicle.
(12) If required, place the underbody refrigerant
lines on a workbench, remove the nylon wedges that
secure the underbody refrigerant lines to the under-
body refrigerant line sealing plate and remove the
lines from the sealing plate. (Fig. 19).
Fig. 17 Underbody A/C Line Rear Connections ±
with New Seating Element
1 - UNDERBODY LIQUID LINE
2 - NUT
3 - SEALING PLATE
4 - UNDERBODY SUCTION LINE
5 - EXTENSION LINE TAPPING PLATE
Fig. 18 Underbody A/C Line Rear Connections ±
without New Seating Element
1 - UNDERBODY LIQUID LINE
2 - BOLT
3 - EXTENSION LINE TAPPING PLATE
4 - UNDERBODY SUCTION LINE
5 - SEALING PLATE
Fig. 19 Underbody A/C Line Sealing Plate ± Typical
1 - O-RING (2)
2 - UNDERBODY LIQUID LINE
3 - NYLON WEDGE (2)
4 - SEALING PLATE
5 - VISE
6 - UNDERBODY SUCTION LINE
RSPLUMBING - REAR24 - 111
UNDERBODY LINES (Continued)

PCV VALVE
DESCRIPTION
The PCV valve contains a spring loaded plunger.
The plunger meters the amount of crankcase vapors
routed into the combustion chamber based on intake
manifold vacuum (Fig. 10) or (Fig. 11).
OPERATION
When the engine is not operating or during an
engine backfire, the spring forces the plunger backagainst the seat. This prevents vapors from flowing
through the valve (Fig. 12).
When the engine is at idle or cruising, high mani-
fold vacuum is present. At these times manifold vac-
uum is able to completely compress the spring and
pull the plunger to the top of the valve (Fig. 13). In
this position there is minimal vapor flow through the
valve.
During periods of moderate intake manifold vac-
uum the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow
through the valve (Fig. 14).
DIAGNOSIS AND TESTING - PCV SYSTEM
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
OR ADJUSTMENT WITH THE ENGINE OPERATING.
(1) With engine idling, remove the hose from the
PCV valve. If the valve is not plugged, a hissing
noise will be heard as air passes through the valve. A
strong vacuum should also be felt when a finger is
placed over the valve inlet.
Fig. 10 PCV VALVE 2.4L
1 - PCV Valve
Fig. 11 PCV VALVE 3.3/3.8L
Fig. 12 Engine Off or Engine Backfire No Vapor
Flow
Fig. 13 High Intake Manifold Vacuum Minimal Vapor
Flow
Fig. 14 Moderate Intake Manifold Vacuum Maximum
Vapor Flow
25 - 18 EVAPORATIVE EMISSIONSRS

INDEX
ABS FASTENER TORQUE,SPECIFICATIONS ...................... 5-91
ABSORBER - DESCRIPTION, SHOCK .......2-36
ABSORBER - INSTALLATION, SHOCK ......2-38
ABSORBER - OPERATION, SHOCK ........2-36
ABSORBER - REMOVAL, SHOCK ..........2-36
ABSORBER (UPPER BUSHING) - ASSEMBLY, SHOCK .................... 2-37
ABSORBER (UPPER BUSHING) - DISASSEMBLY, SHOCK .................2-37
A/C CLUTCH BREAK-IN, STANDARD PROCEDURE ........................ 24-15
A/C COMPRESSOR CLUTCH COIL, DIAGNOSIS AND TESTING .............24-14
A/C COMPRESSOR CLUTCH RELAY - DESCRIPTION ....................... 24-18
A/C COMPRESSOR CLUTCH RELAY - INSTALLATION ....................... 24-19
A/C COMPRESSOR CLUTCH RELAY - OPERATION ......................... 24-18
A/C COMPRESSOR CLUTCH RELAY - REMOVAL .......................... 24-19
A/C COMPRESSOR CLUTCH/COIL - DESCRIPTION ....................... 24-13
A/C COMPRESSOR CLUTCH/COIL - OPERATION ......................... 24-13
A/C COMPRESSOR, DESCRIPTION .......24-72
A/C COMPRESSOR, INSTALLATION .......24-74
A/C COMPRESSOR MOUNTING BRACKET, 2.4L ENGINE ...........24-74,24-75
A/C COMPRESSOR NOISE DIAGNOSIS, DIAGNOSIS AND TESTING .............24-72
A/C COMPRESSOR, OPERATION .........24-72
A/C COMPRESSOR, REMOVAL ..........24-73
A/C CONDENSER - DESCRIPTION ........24-75
A/C CONDENSER - OPERATION ..........24-75
A/C COOL DOWN TEST, DIAGNOSIS AND TESTING ............................ 24-6
A/C DISCHARGE LINE - INSTALLATION . . . 24-80
A/C DISCHARGE LINE - REMOVAL .......24-79
A/C EVAPORATOR - DESCRIPTION . . 24-80,24-98
A/C EVAPORATOR - INSTALLATION ......24-81
A/C EVAPORATOR - OPERATION ....24-80,24-98
A/C EVAPORATOR - REMOVAL ..........24-81
A/C EVAPORATOR, INSTALLATION - REAR ............................. 24-100
A/C EVAPORATOR LINE EXTENSION, INSTALLATION - REAR ...............24-100
A/C EVAPORATOR LINE EXTENSION, REMOVAL - REAR .................... 24-99
A/C EVAPORATOR, REMOVAL - REAR .....24-98
A/C EXPANSION VALVE - DESCRIPTION . . 24-100
A/C EXPANSION VALVE - OPERATION ....24-100
A/C EXPANSION VALVE, DIAGNOSIS AND TESTING - FRONT .................... 24-82
A/C EXPANSION VALVE, DIAGNOSIS AND TESTING - REAR .................... 24-101
A/C HEATER CONTROL - DESCRIPTION . . . 24-19
A/C PERFORMANCE TEST, DIAGNOSIS AND TESTING ........................ 24-7
A/C PRESSURE TRANSDUCER - DESCRIPTION ....................... 24-20
A/C PRESSURE TRANSDUCER - OPERATION ......................... 24-20
A/C PRESSURE TRANSDUCER, DIAGNOSIS AND TESTING .............24-21
A/C SYSTEM - CAUTION ...............24-66
A/C SYSTEM, SPECIFICATIONS ..........24-11
A/C SYSTEM, WARNING ...............24-66
ACCELERATOR PEDAL - INSTALLATION . . . 14-28
ACCELERATOR PEDAL - REMOVAL .......14-28
ACCESSORY DRIVE BELT - DIAGNOSIS AND TESTING .........................7-7
ACCESSORY DRIVE BELT TENSION, SPECIFICATIONS .......................7-5
ACCUMULATOR - DESCRIPTION . . . 21-218,21-73
ACCUMULATOR - OPERATION ....21-218,21-73
A/C-HEATER CONTROL - DESCRIPTION . . . 24-33
A/C-HEATER CONTROL - INSTALLATION . . . 24-34
A/C-HEATER CONTROL - OPERATION .....24-33
A/C-HEATER CONTROL - REMOVAL ......24-33
A/C-HEATER CONTROL CALIBRATION, STANDARD PROCEDURE ...............24-19
ACTUATOR - DESCRIPTION, BLEND DOOR ........................ 24-22,24-34
ACTUATOR - DESCRIPTION, ENGAGE ......8N-9
ACTUATOR - DESCRIPTION, LATCH ......8N-13 ACTUATOR - DESCRIPTION, MODE
DOOR ............................. 24-29
ACTUATOR - DESCRIPTION, RECIRCULATION DOOR ................24-31
ACTUATOR - INSTALLATION, BLEND DOOR ........................ 24-22,24-35
ACTUATOR - INSTALLATION, ENGAGE ....8N-10
ACTUATOR - INSTALLATION, INSIDE HANDLE ............................ 23-27
ACTUATOR - INSTALLATION, LATCH .....8N-14
ACTUATOR - INSTALLATION, MODE DOOR ............................. 24-30
ACTUATOR - INSTALLATION, RECIRCULATION DOOR ................24-32
ACTUATOR - OPERATION, BLEND DOOR . . 24-22, 24-35
ACTUATOR - OPERATION, ENGAGE .......8N-9
ACTUATOR - OPERATION, LATCH ........8N-13
ACTUATOR - OPERATION, MODE DOOR . . . 24-29
ACTUATOR - OPERATION, RECIRCULATION DOOR ................24-31
ACTUATOR - REAR - DESCRIPTION, MODE DOOR ........................ 24-39
ACTUATOR - REAR - INSTALLATION, MODE DOOR ........................ 24-40
ACTUATOR - REAR - OPERATION, MODE DOOR ............................. 24-39
ACTUATOR - REAR - REMOVAL, MODE DOOR ............................. 24-39
ACTUATOR - REMOVAL, BLEND DOOR . . . 24-22, 24-35
ACTUATOR - REMOVAL, ENGAGE ..........8N-9
ACTUATOR - REMOVAL, INSIDE HANDLE . . 23-27
ACTUATOR - REMOVAL, LATCH .........8N-13
ACTUATOR - REMOVAL, MODE DOOR ....24-29
ACTUATOR - REMOVAL, RECIRCULATION DOOR ............................. 24-32
ADAPTER - INSTALLATION, FRONT DISC BRAKE CALIPER ...................... 5-31
ADAPTER - INSTALLATION, OIL FILTER . . . 9-142
ADAPTER - REMOVAL, FRONT DISC BRAKE CALIPER ...................... 5-31
ADAPTER - REMOVAL, OIL FILTER .......9-142
ADAPTIVE MEMORIES, OPERATION - FUEL CORRECTION OR ................14-24
ADDING ADDITIONAL COOLANT - STANDARD PROCEDURE .................7-4
ADDITIONAL COOLANT - STANDARD PROCEDURE, ADDING ...................7-4
ADHESIVE ATTACHED - INSTALLATION, EXTERIOR NAME PLATES ..............23-51
ADHESIVE ATTACHED - REMOVAL, EXTERIOR NAME PLATES ..............23-51
ADHESIVE LOCATIONS - FOLD-IN-FLOOR ONLY - SPECIFICATIONS,
STRUCTURAL ...................... 23-228
ADHESIVE LOCATIONS - SPECIFICATIONS, STRUCTURAL ........23-218
ADJUSTABLE - INSTALLATION, PEDALS ....5-43
ADJUSTABLE - REMOVAL, PEDALS .......5-40
ADJUSTABLE PEDALS SWITCH - INSTALLATION ........................ 5-11
ADJUSTABLE PEDALS SWITCH - REMOVAL ........................... 5-11
ADJUSTE R-BOR C-PILLAR -
INSTALLATION, SEAT BELT HEIGHT ......8O-38
ADJUSTE R-BOR C-PILLAR -
REMOVAL, SEAT BELT HEIGHT ..........8O-38
ADJUSTER - DIAGNOSIS AND TESTING, DRUM BRAKE AUTOMATIC ..............5-14
ADJUSTER - INSTALLATION, FRONT SEAT TRACK MANUAL ...............23-126
ADJUSTER - INSTALLATION, FRONT SEAT TRACK POWER ................23-124
ADJUSTER - REMOVAL, FRONT SEAT TRACK MANUAL .................... 23-125
ADJUSTER - REMOVAL, FRONT SEAT TRACK POWER ..................... 23-124
ADJUSTER KNOB - INSTALLATION, SEAT BELT HEIGHT ....................... 8O-38
ADJUSTER KNOB - REMOVAL, SEAT BELT HEIGHT ....................... 8O-38
ADJUSTER NOISE DIAGNOSIS - DIAGNOSIS AND TESTING, HYDRAULIC
LASH ............................... 9-34
ADJUSTER TENSION RELEASE - STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC .................... 5-63ADJUSTER TENSION RESET -
STANDARD PROCEDURE, PARKING
BRAKE AUTOMATIC .................... 5-64
ADJUSTER/MANUAL - OCS - INSTALLATION, FRONT SEAT TRACK ....23-128
ADJUSTER/MANUAL - OCS - REMOVAL, FRONT SEAT TRACK .................23-126
ADJUSTER/POWER - OCS - INSTALLATION, FRONT SEAT TRACK ....23-125
ADJUSTER/POWER - OCS - REMOVAL, FRONT SEAT TRACK .................23-124
ADJUSTERS - INSTALLATION, HYDRAULIC LASH ..................... 9-35
ADJUSTERS - REMOVAL, HYDRAULIC LASH ............................... 9-35
AERATION - DIAGNOSIS AND TESTING, COOLING SYSTEM .....................7-4
AFTER AN AIRBAG DEPLOYMENT - STANDARD PROCEDURE, SERVICE .......8O-7
AIR CLEANER ELEMENT - INSTALLATION . 9-101, 9-24
AIR CLEANER ELEMENT - REMOVAL . 9-101,9-24
AIR CLEANER HOUSING - INSTALLATION . 9-102, 9-25
AIR CLEANER HOUSING - REMOVAL . 9-101,9-25
AIR CONDITIONER, DESCRIPTION - HEATER ............................. 24-1
AIR CONDITIONER, OPERATION - HEATER ............................. 24-4
AIR CONTROL MOTOR - DESCRIPTION, IDLE ............................... 14-33
AIR CONTROL MOTOR - INSTALLATION, IDLE ............................... 14-33
AIR CONTROL MOTOR - OPERATION, IDLE ............................... 14-33
AIR CONTROL MOTOR - REMOVAL, IDLE . . 14-33
AIR EXHAUSTER - DESCRIPTION, REAR QUARTER PANEL/FENDER ..............23-59
AIR EXHAUSTER - INSTALLATION, REAR QUARTER PANEL/FENDER ..............23-60
AIR EXHAUSTER - REMOVAL, REAR QUARTER PANEL/FENDER ..............23-59
AIR FILTER - DESCRIPTION ............24-42
AIR FILTER - INSTALLATION ............24-43
AIR FILTER - REMOVAL ...............24-42
AIR GAP, SPECIFICATIONS - WHEEL SPEED SENSOR ....................... 5-91
AIR INTAKE PIPE - INSTALLATION ......24-115
AIR INTAKE PIPE - REMOVAL ..........24-115
AIR OUTLETS - DESCRIPTION .....24-43,24-56
AIR OUTLETS - INSTALLATION ..........24-56
AIR OUTLETS - REMOVAL .............24-56
AIR PRESSURE TESTS - DIAGNOSIS AND TESTING, CLUTCH ...........21-153,21-8
AIR TEMPERATURE SENSOR - DESCRIPTION, INLET .................14-34
AIRBAG - DESCRIPTION, CURTAIN .......8O-12
AIRBAG - DESCRIPTION, DRIVER ........8O-16
AIRBAG - DESCRIPTION, KNEE BLOCKER . 8O-22
AIRBAG - DESCRIPTION, PASSENGER ....8O-30
AIRBAG - INSTALLATION, CURTAIN ......8O-16
AIRBAG - INSTALLATION, DRIVER .......8O-18
AIRBAG - INSTALLATION, KNEE BLOCKER .......................... 8O-23
AIRBAG - INSTALLATION, PASSENGER . . . 8O-32
AIRBAG - OPERATION, CURTAIN ........8O-13
AIRBAG - OPERATION, DRIVER .........8O-16
AIRBAG - OPERATION, KNEE BLOCKER . . . 8O-22
AIRBAG - OPERATION, PASSENGER ......8O-30
AIRBAG - REMOVAL, CURTAIN ..........8O-14
AIRBAG - REMOVAL, DRIVER ...........8O-17
AIRBAG - REMOVAL, KNEE BLOCKER ....8O-23
AIRBAG - REMOVAL, PASSENGER .......8O-30
AIRBAG DEPLOYMENT - STANDARD PROCEDURE, SERVICE AFTER AN ........8O-7
AIRBAG DISABLED INDICATOR - DESCRIPTION, PASSENGER ............8O-33
AIRBAG DISABLED INDICATOR - INSTALLATION, PASSENGER ...........8O-34
AIRBAG DISABLED INDICATOR - OPERATION, PASSENGER ..............8O-33
AIRBAG DISABLED INDICATOR - REMOVAL, PASSENGER ...............8O-34
AIRBAG SYSTEM - DIAGNOSIS AND TESTING ............................ 8O-6
AIRBAGS - STANDARD PROCEDURE, HANDLING .......................... 8O-6
RS INDEX1
Description Group-Page Description Group-Page Description Group-Page