ail CHRYSLER VOYAGER 2005 Service Manual

(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 RG 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 RG models, remove the evaporator tem-
perature 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 RG models, install the evaporator tempera-
ture 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 RG models, connect the HVAC wire harness
connector to the evaporator temperature 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.
(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
Fig. 16 A/C Expansion Valve - LHD Shown, RHD
Typical
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR (RG ONLY)
3 - A/C EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
RSPLUMBING - FRONT24-83
EXPANSION VALVE (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)

(8) Disconnect the A/C liquid line from the A/C
condenser and remove and discard the O-ring seal
and gasket.
(9) Install plugs in, or tape over the opened liquid
line fitting and the condenser outlet port.
(10) 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. 28).
(11) Remove the bolt that secures the front section
of the A/C liquid line to the receiver/drier.
(12) Disconnect the A/C liquid line from the receiv-
er/drier and remove and discard the O-ring seal.
(13) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
(14) Remove the front section of the A/C liquid line
from the engine compartment.
REAR SECTION
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the A/C pressure transducer (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER -
REMOVAL).(6) If equipped, remove the nut that secures the
A/C ground strap to the weld stud on the top of the
right front strut tower (Fig. 28).
(7) If equipped, remove the A/C ground strap eye-
let terminal connector from the weld stud.
(8) Remove the bolt that secures the rear section
of the A/C liquid line to the receiver/drier.
(9) Disconnect the A/C liquid line from the receiv-
er/drier and remove and discard the O-ring seal.
(10) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(11) Remove the nut that secures the A/C suction
line and the A/C liquid line to the A/C expansion
valve.
(12) Disconnect the A/C suction line and the A/C
liquid line from the A/C expansion valve and remove
and discard the O-ring seals.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) On RHD models, remove the rear section of
the A/C liquid line from the retaining bracket located
at the top of the dash panel
Fig. 27 A/C Condenser Connections
1 - A/C CONDENSER
2 - A/C DISCHARGE LINE
3 - A/C LIQUID LINE
4 - NUT (2)Fig. 28 A/C Liquid Line - LHD Shown, RHD Typical
1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - A/C EXPANSION VALVE
7 - A/C LIQUID LINE (REAR SECTION)
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - RECEIVER/DRIER
11 - ROUTING CLIP
12 - A/C LIQUID LINE (FRONT SECTION)
24 - 90 PLUMBING - FRONTRS
LIQUID LINE (Continued)

(15) If the vehicle is equipped with the optional
rear heating-A/C system, go to Step 16. If the vehicle
is not equipped with the optional rear heating-A/C
system, go to Step 22.
(16) Raise and support the vehicle.
(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
ing-A/C system (Fig. 29).
(18) Disconnect the A/C liquid line extension fit-
ting from the underbody liquid line fitting for the
rear A/C system.
(19) Remove the O-ring seal from the underbody
liquid line fitting and discard.
(20) Install plugs in, or tape over the opened liquid
line fittings.
(21) Lower the vehicle.
(22) Remove the rear section of the A/C liquid line
from the engine compartment.
INSTALLATION
FRONT SECTION
(1) Position the front section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the liquid line
fitting and the receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it onto the liquid line fit-
ting.
(4) Connect the A/C liquid line to the receiver/
drier.(5) Install the bolt that secures the A/C liquid line
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 condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it and a new gasket onto
the liquid line fitting.
(9) Connect the A/C liquid line to the A/C con-
denser.
(10) Install the nut that secures the A/C liquid line
to the A/C 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 negative battery 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 A/C 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 onto the suction line
and liquid line fittings.
(4) Reconnect the A/C liquid line and the A/C suc-
tion line to the A/C expansion valve.
(5) Install the nut that secures the rear section of
the A/C liquid line and the A/C suction line to the
A/C expansion valve. Tighten the nut to 23 N´m (17
ft. lbs.).
(6) Remove the tape or plugs from the liquid line
fitting and the receiver/drier outlet port.
Fig. 29 Underbody A/C Line Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
RSPLUMBING - FRONT24-91
LIQUID LINE (Continued)

(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the A/C liquid line to the receiver/
drier.
(9) Install the bolt that secures the A/C liquid line
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) Connect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Install 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 heating-A/C system, go to Step 17. If the vehicle
does not have the optional rear heating-A/C system,
go to Step 23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the A/C liquid
line extension fitting and the underbody liquid line
fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Connect the A/C liquid line extension fitting
to the underbody liquid line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(21) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heating-
A/C system.
(22) Lower the vehicle.
(23) Reconnect the negative battery cable.
(24) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(25) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the right front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the liquid line between the
condenser outlet and the evaporator inlet. The receiv-
er/drier cannot be repaired. If the receiver/drier is
faulty or damaged, or if the refrigerant system has
been contaminated or left open to the atmosphere for
an indeterminable period or if the A/C compressor
has failed, it must be replaced.
OPERATION
The receiver/drier performs a filtering action to
prevent foreign material in the refrigerant from con-
taminating the expansion valve. Desiccant inside the
receiver/drier canister absorbs any moisture which
may have entered and become trapped within the
refrigerant system. In addition, during periods of
high demand air conditioner operation, the receiver/
drier acts as a reservoir to store surplus refrigerant.
Refrigerant enters the receiver/drier as a high-pres-
sure, low temperature liquid.
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 air cleaner housing from the right
side of the engine compartment.
(3) Remove the bolt that secures the liquid line
front section fitting to the top of the receiver/drier
(Fig. 30).
(4) Disconnect the liquid line fitting from the
receiver/drier inlet port.
(5) Remove the O-ring seal from the liquid line fit-
ting and discard.
(6) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
24 - 92 PLUMBING - FRONTRS
LIQUID LINE (Continued)

OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system. R-134a
refrigerant system service ports, service tool couplers
and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an
R-134a system is not accidentally contaminated with
the wrong refrigerant (R-12). There are also labels
posted in the engine compartment of the vehicle and
on the compressor identifying to service technicians
that the air conditioning system is equipped with
R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each con-
tains a different additive package. The compressor
used in this vehicle is designed to use an ND-8 PAG
refrigerant oil. Use only refrigerant oil of this same
type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance. PAG
refrigerant oil is much more hygroscopic than min-
eral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil
container should always be kept tightly capped until
it is ready to be used. After use, recap the oil con-
tainer immediately to prevent moisture contamina-
tion.
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
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).
CAUTION: Use only PAG oils that are designed to
work with R-134a refrigerant and the A/C compres-
sor in the vehicle. Refer to the underhood A/C Sys-
tem Specification Label.
It is important to have the correct amount of lubri-
cant in the A/C refrigerant system to ensure proper
lubrication of the A/C compressor. Too little lubricant
will result in damage to the compressor. Too much
lubricant will reduce the cooling capacity of the A/C
system and consequently result in higher discharge
air temperatures.
The lubricant used in the compressor is polyalka-
lene glycol PAG lubricant. Only the refrigerant lubri-
cant approved for use with this vehicle should be
used to service the system. Do not use any other
lubricant. The lubricant container should be kept
tightly capped until it is ready for use. Refrigerant
lubricant will quickly absorb any moisture it comes
in contact with.
It will not be necessary to check the oil level in the
A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or
leak from a refrigerant line, connector fitting, compo-
nent or component seal. If a leak occurs, add 30 mil-
liliters (1 fluid ounce) of the recommended
refrigerant oil to the refrigerant system after the
repair has been made. Refrigerant oil loss will be evi-
dent at the leak point by the presence of a wet, shiny
surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assembled
at the factory, all components (except the A/C com-
pressor) are refrigerant oil free. After the refrigerant
system has been charged with (R-134a) refrigerant
and operated, the oil in the A/C compressor is dis-
persed through the lines and components. The A/C
evaporator, A/C condenser, and receiver/drier will
retain a significant amount of oil. Refer to the A/C
Component Refrigerant Oil Capacities table. When a
component is replaced, the specified amount of refrig-
erant oil must be added. When the compressor is
replaced, the amount of oil that is retained in the
24 - 94 PLUMBING - FRONTRS
REFRIGERANT (Continued)

DIAGNOSIS AND TESTING
REAR 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 expansion valve should only be tested
following testing of the compressor.
NOTE: Liquid CO
2is required to test the expansion
valve. This material is available from most welding
supply facilities. Liquid CO
2is also available from
companies which service and sell fire extinguish-
ers.
When testing the 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 heater-air conditioner controls so that
the compressor 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 at 1000
rpm. 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 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
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 suit-
able super-cold material.Do not spray R-134a or
R-12 refrigerant on the expansion valve controlhead 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 expansion 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 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).
Remove all test equipment before returning the vehi-
cle to service.
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), (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) Carefully remove the foam insulator wrap from
the rear expansion valve.
(3) 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).
(4) Remove the two screws that secure the expan-
sion valve to the evaporator tube sealing plate.
(5) Remove the expansion valve from the evapora-
tor tubes.
(6) Remove the seals from the evaporator tube fit-
tings and discard.
(7) Install plugs in, or tape over the opened evap-
orator tube fittings and both expansion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the rear A/C
evaporator tube fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the rear evapora-
tor tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install the two screws that secure the rear A/C
expansion valve to the evaporator tube sealing plate.
Tighten the screws to 11 N´m (97 in. lbs.).
RSPLUMBING - REAR24 - 101
A/C EXPANSION VALVE (Continued)

(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)