engine CHRYSLER VOYAGER 2005 Service Manual

(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the front expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Reconnect the suction line fitting to the com-
pressor suction port.
(10) Install the nut that secures the suction line
fitting to the A/C compressor. Tighten the nut to 23
N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) Raise and support the vehicle.
(15) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(16) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.(17) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fitting
to 23 N´m (17 ft. lbs.).
(18) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(19) Lower the vehicle.
(20) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(21) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
The underbody heater-A/C plumbing is used only
on models with the optional rear heater-A/C system
(Fig. 11). The underbody suction line, liquid line, and
heater tubes can each be serviced separately.
OPERATION
The rear heater and A/C lines are all serviced as
individual components. When disconnecting any lines
or connections, make sure that the area around the
line or connection is clean of any dirt or residue that
may enter and contaminate the rear heating-A/C sys-
tem (Fig. 12) and (Fig. 13).
Fig. 11 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
24 - 108 PLUMBING - REARRS
SUCTION LINE (Continued)

WARNING: HIGH PRESSURES ARE PRODUCED IN
THE REFRIGERANT SYSTEM WHEN THE A/C COM-
PRESSOR IS OPERATING. HIGH TEMPERATURE
COOLANT IS PRESENT IN THE HEATER PLUMBING
WHEN THE ENGINE IS OPERATING. EXTREME
CARE MUST BE EXERCISED WHEN SERVICING
THE REAR HEATER AND A/C LINES TO PREVENT
POSSIBLE PERSONAL INJURY.
Any kinks or sharp bends in the rear heater-A/C
plumbing will reduce the capacity of the entire heat-
ing-A/C system. Kinks and sharp bends reduce the
system flow. High pressures are produced in the
refrigerant system when the A/C compressor is oper-
ating. High temperature coolant is present in the
heater plumbing when the engine is operating.
Extreme care must be exercised to make sure that
each of the connections is pressure-tight and leak
free.
REMOVAL
UNDERBODY HEATER TUBES
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) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).(2) Raise and support vehicle.
(3) Disconnect the underbody heater tubes at the
rear of the vehicle by releasing the insert in the
underbody heater tube quick connect fittings and
carefully pulling downward on the heater tube fit-
tings (Fig. 14).
(4) Lower the underbody heater tubes and drain
any residual coolant from the tubes into a suitable
container.
Fig. 12 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
Fig. 13 Front Extension Lines to Underbody Lines ±
Typical
RSPLUMBING - REAR24 - 109
UNDERBODY LINES (Continued)

(5) Using spring tension clamp pliers, compress
and slide the clamps off of the rubber hoses at the
front of the underbody heater tubes (Fig. 15).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(6) Disconnect the heater hoses by carefully twist-
ing the hoses back and forth on the rear heater
extension tubes, while gently pulling them away
from the end of the tubes.
(7) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
(8) Remove the screws that secure the underbody
line retaining straps to the vehicle underbody.
(9) Remove the underbody heater tubes from the
retaining straps.
(10) Remove the underbody heater tubes from the
vehicle.
UNDERBODY REFRIGERANT LINES
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 - STANDARD PROCE-
DURE - REFRIGERANT RECOVERY).
(2) Raise and support vehicle.
(3) Disconnect the exhaust system from the
exhaust hanger rubber isolators and position the
exhaust system out of the way (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(4) Disconnect the underbody refrigerant lines
from the front liquid and suction line extension tubes
and remove and discard the O-ring seals. (Fig. 16).
Fig. 15 Underbody Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 16 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 14 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
24 - 110 PLUMBING - REARRS
UNDERBODY LINES (Continued)

INSTALLATION
UNDERBODY HEATER TUBES
(1) Position the underbody heater tubes onto the
vehicle underbody.
(2) Install the underbody heater tubes into the
underbody line retaining straps.
(3) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.
(4) Connect the rubber hoses at the front of the
underbody heater tubes to the rear heater extension
tubes.
(5) Using spring tension clamp pliers, compress
and slide the clamps that secure the heater hoses
over the extension tubes. Release the clamp when it
is correctly positioned over the tube.
(6) Connect the rear underbody heater tube quick
connections to the rear heater core extension tubes.
(7) Lower the vehicle.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
UNDERBODY REFRIGERANT LINES
(1) If removed, install the underbody refigerant
lines into the underbody refrigerant line sealing plate
and install the nylon wedges that secure the refrig-
erant lines to the sealing plate.
(2) Position the underbody refrigerant lines onto
the vehicle underbody.
(3) Install the underbody refrigerant lines into the
underbody line retaining straps.
(4) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.(5) Remove the tape or plugs from the rear under-
body refrigerant line fittings and the rear evaporator
extension line ports.
(6) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(7) Connect the underbody refrigerant lines to the
rear evaporator extension line tapping plate.
(8) Install the bolt or nut (depending on applica-
tion) that secures the underbody refrigerant line
sealing plate to the rear evaporator extension line
tapping plate. Tighten the bolt or nut to 23 N´m (17
ft. lbs.).
(9) Remove the tape or plugs from the front liquid
and suction line extension tubes and the underbody
refrigerant line fittings.
(10) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(11) Connect the underbody refrigerant line fit-
tings to the front liquid and suction line extension
tubes. Tighten the fittings to 23 N´m (17 ft. lbs.).
(12) Position the exhaust system and install it to
the exhaust hanger rubber isolators (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(13) Lower the vehicle.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
24 - 112 PLUMBING - REARRS
UNDERBODY LINES (Continued)

CABIN HEATER
TABLE OF CONTENTS
page page
CABIN HEATER
DESCRIPTION........................113
OPERATION
MANUAL TEMPERATURE CONTROL
SYSTEM...........................113
AUTOMATIC TEMPERATURE CONTROL
SYSTEM...........................114
WARNING............................114
DIAGNOSIS AND TESTING
SUPPLEMENTAL CABIN HEATER........114
AIR INTAKE PIPE
REMOVAL............................115
INSTALLATION........................115
EXHAUST TUBE
REMOVAL............................116
INSTALLATION........................116
FUEL DOSING PUMP
DESCRIPTION........................117
OPERATION..........................117REMOVAL............................117
INSTALLATION........................117
FUEL LINE
STANDARD PROCEDURE
CLEANING..........................118
REMOVAL............................118
INSTALLATION........................118
HEATER HOSES
REMOVAL............................119
INSTALLATION........................119
HEATER PIPES
REMOVAL............................119
INSTALLATION........................120
HEATER UNIT
REMOVAL............................121
INSTALLATION........................122
HEATER WIRING
REMOVAL............................122
INSTALLATION........................122
CABIN HEATER
DESCRIPTION
Vehicles equipped with the diesel engine are also
equipped with a supplemental cabin heater. This
cabin heater is mounted under the vehicle and oper-
ates similar to an oil fired furnace. The heater burns
small amounts of fuel to provide additional heat to
the coolant. Coolant is routed from the engine, to the
supplemental cabin heater and then to the front
heater core. This provides additional heat to the pas-
senger compartment. The supplemental cabin heater
system is interfaced to the vehicles on-board com-
puter systems and DRBIIItdiagnostics.
The supplemental cabin heater has an electronic
control module that monitors the heat output of the
heater. The cabin heater operates at full load (5 kW),
half load or idle mode (no additional heat) depending
on engine coolant temperature.
When ambient temperatures are lower than 15É C
(60É F), the supplemental cabin heater automatically
operates once each ignition cycle for five minutes.
This assures a good fuel supply is always present for
the supplemental cabin heater.
OPERATION
MANUAL TEMPERATURE CONTROL SYSTEM
The supplemental cabin heater is activated via the
temperature slide control or knob on the A/C-heater
control when equipped with the manual temperature
control (MTC) system. If the slide control or knob is
moved to or above the upper set point the cabin
heater is activated. The cabin heater can operate in a
full or partial load range as well as an idle mode all
dependent on the engine coolant temperature. The
cabin heater will also turn off if the A/C-heater tem-
perature control is lowered to less than the lower set
point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.
NOTE: Do not apply a strong vacuum source such
as a garage ventilation system directly on the sup-
plemental cabin heater exhaust line. Too strong of a
vacuum can prevent the supplemental cabin heater
from starting. If required, place the vacuum source
at least 75 mm (3 in.) away from the exhaust line.
RSCABIN HEATER24 - 113

The supplemental cabin heater only operates when
the engine is running, the mileage exceeds 8 kilome-
ter (5 mph) and the fuel tank volume exceeds 1/8 of a
tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40É C (104É F).
AUTOMATIC TEMPERATURE CONTROL
SYSTEM
The automatic temperature control (ATC) system
will activate the supplemental cabin heater based on
engine coolant temperature and interior component
settings. The cabin heater can operate in a full or
partial load range as well as an idle mode all depen-
dent on the engine coolant temperature. The cabin
heater will also turn off if the A/C-heater tempera-
ture control is lowered to less than the lower set
point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.
NOTE: Do not apply a strong vacuum source such
as a garage ventilation system directly on the sup-
plemental cabin heater exhaust line. Too strong of a
vacuum can prevent the supplemental cabin heater
from starting. If required, place the vacuum source
at least 75 mm (3 in.) away from the exhaust line.
The supplemental cabin heater only operates when
the engine is running, the mileage exceeds 8 kilome-ter (5 mph) and the fuel tank volume exceeds 1/8 of a
tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40É C (104É F).
WARNING
WARNING: DO NOT OPERATE THE DIESEL SUP-
PLEMENTAL CABIN HEATER IN AN ENCLOSED
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
THE CABIN HEATER EXHAUST WHEN OPERATING
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
PLEMENTAL CABIN HEATER FUEL LINES ARE
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING ANY SER-
VICE PROCEDURES TO THE CABIN HEATER. FAIL-
URE TO FOLLOW THESE INSTRUCTION MAY
RESULT IN PERSONAL INJURY OR DEATH.
DIAGNOSIS AND TESTING
SUPPLEMENTAL CABIN HEATER
Refer to the Symptoms Diagnosis table for basic
checks of the diesel fueled supplemental cabin heater.
SYMPTOMS DIAGNOSIS
Symptom Possible Causes
Smell of diesel fuel. Check cabin heater system integration in vehicle's fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of external
fuel. If presence of external fuel is observed on the heater unit or in the
exhaust tube or after draining and testing. Remove the cabin heater
from vehicle and repair or replace components as required.
Heater does not achieve full load
operation.Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Continuous white smoke from heater
exhaust during combustion operation.Check cabin heater operation with DRBIIITscan tool and replace
components as required. White smoke is typical in extreme weather
conditions.
Heater can not be switched off. Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Heater does not operate. Diagnosis cabin heater control module using the DRBIIITscan tool and
the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.
24 - 114 CABIN HEATERRS
CABIN HEATER (Continued)

Symptom Possible Causes
Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an
extremely sweet smell.Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is an
internal heater leak and cabin heater should be inspected and
components should be replaced as required.
Loss of fuel (dripping). Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.
AIR INTAKE PIPE
REMOVAL
NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(2) Remove clamps from the cabin heater tubes at
the lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the cabin
heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 1).(5) Remove the two retaining screws and remove
pipe assembly (Fig. 2).
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N´m (62 in. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
clamp securely.
(4) Install the cabin heater tubes to the lower
heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.
(5) Lower the vehicle.
Fig. 1 Flexible Air Intake Line
1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE AIR INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
Fig. 2 Cabin Heater Air Intake And Heater Pipe
Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
RSCABIN HEATER24 - 115
CABIN HEATER (Continued)

(6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(7) Verify function of the cabin heater.
EXHAUST TUBE
REMOVAL
WARNING: THERE IS A POTENTIAL DANGER OF
SKIN BURNS AS THE SUPPLEMENTAL CABIN
HEATER AND ITS COMPONENTS MAY BE VERY
HOT. MAKE SURE THE CABIN HEATER IS
ALLOWED TO COOL DOWN BEFORE ANY SERVICE
WORK ON THE CABIN HEATER SYSTEM IS
ATTEMPTED.
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Remove the exhaust clamp at the flexible pipe
and steel pipe connection (Fig. 3).
(3) Remove the clamp at the flexible pipe connec-
tion and the cabin heater housing (if required).
(4) Remove the three screws holding the exhaust
pipe to the body.(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).
INSTALLATION
(1) Install the flexible exhaust pipe to the cabin
heater. Tighten the mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
exhaust. Tighten the mounting clamp securely.
(3) Loosely install the three exhaust pipe screws
and adjust pipe placement as required. Tighten the
screws securely.
(4) Install the clamp that secures the steel exhaust
pipe to the flexible exhaust pipe. Tighten the clamp
securely.
(5) Check exhaust end placement of the exhaust
pipe and make any final adjustments.
(6) Lower the vehicle.
Fig. 3 Cabin Heater Exhaust System
1 - MOUNTING SCREWS (3)
2 - STEEL HEATER EXHAUST PIPE
3 - EXHAUST CLAMP (2)4 - FLEXIBLE HEATER EXHAUST PIPE
5 - CABIN HEATER AND SHIELD
6 - EXHAUST PIPE MOUNTING CLIPS (3) (IF EQUIPPED)
24 - 116 CABIN HEATERRS
AIR INTAKE PIPE (Continued)

NOTE: Verify that there is more than 1/8 of a tank of
fuel in the vehicle's fuel tank before performing this
procedure. Add fuel, if necessary.
NOTE: Failure to prime the dosing pump after drain-
ing the supplemental cabin fuel line will prevent
cabin heater activation during the first attempt to
start the cabin heater. This will also set a diagnostic
trouble code (DTC) in the cabin heater control's
memory. Do not perform the Dosing Pump Priming
procedure if an attempt was made to start the cabin
heater without priming the dosing pump first. This
will put excess fuel in the cabin heater and cause
smoke to emit from the cabin heater exhaust pipe
when cabin heater activation occurs.
(7) Connect the DRBIIItscan tool to the diagnos-
tic link connector.
(8) Turn the ignition to the ON position.
NOTE: Do not activate the dosing pump prime more
than one time. This will put excess fuel in the sup-
plemental cabin heater and cause smoke to emit
from the cabin heater exhaust pipe when cabin
heater activation occurs.
NOTE: A clicking noise heard coming from the dos-
ing pump indicates that the pump is operational.
(9) With the DRBIIItscan tool in Cabin Heater,
select System Tests and Dosing Pump Prime. Allow
the dosing pump to run for the full 45 second cycle
time. When the 45 second cycle is complete, press
Page Back on the DRBIIItscan tool key pad to exit
the Dosing Pump Prime. The Dosing Pump Priming
procedure is now complete.
HEATER HOSES
REMOVAL
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
NOTE: Complete removal of the supplemental cabin
heater from vehicle is not required, lowering the
cabin heater allows easier access to coolant line
clamps.(3) Lower the supplemental cabin heater from the
vehicle (Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/HEATER UNIT - REMOVAL).
(4) Remove the clamps from both flexible coolant
line ends.
NOTE: It is recommended that both flexible cabin
heater coolant lines be replaced if either cabin
heater coolant line is damaged.
(5) Remove both coolant lines from vehicle.
INSTALLATION
(1) Install both flexible coolant lines to the supple-
mental cabin heater and install the clamps.
(2) Install the flexible coolant lines to the coolant
pipes and install the clamps.
(3) Install the supplemental cabin heater into the
vehicle (Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/HEATER UNIT - INSTALLA-
TION).
(4) Lower the vehicle.
(5) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(6) Verify operation of the supplemental cabin
heater.
HEATER PIPES
REMOVAL
WARNING: ALLOW THE ENGINE COOLING SYSTEM
TO COOL COMPLETELY BEFORE REMOVING RADI-
ATOR CAP OR DRAINING THE ENGINE COOLING
SYSTEM. PERSONAL INJURY MAY RESULT IF THE
ENGINE COOLING SYSTEM IS OPENED WHILE
ENGINE COOLANT IS HOT AND UNDER PRES-
SURE.
NOTE: Steel heater lines from engine compartment
to the supplemental cabin heater are part of an
assembly that includes the air intake pipe. If the
cabin heater lines or air intake pipe require removal
or replacement the entire cabin heater assembly
will require removal or replacement.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(2) Remove clamps from both the EGR cooler and
the lower heater port. Separate hoses from the mat-
ing plumbing port (Fig. 6).
RSCABIN HEATER24 - 119
FUEL LINE (Continued)

(7) Connect the heater lines to the heater hoses at
the heater core and EGR port. Position spring clamps
onto the hoses.
(8) Fill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
HEATER UNIT
REMOVAL
WARNING: DO NOT OPERATE THE DIESEL SUP-
PLEMENTAL CABIN HEATER IN AN ENCLOSED
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
THE CABIN HEATER EXHAUST WHEN OPERATING
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
PLEMENTAL CABIN HEATER FUEL LINES ARE
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING ANY SER-
VICE PROCEDURES TO THE CABIN HEATER. FAIL-
URE TO FOLLOW THESE INSTRUCTION MAY
RESULT IN PERSONAL INJURY OR DEATH.(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the cabin heater and the
hose and tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board crossmember at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe-board crossmember and
rail.
(7) Remove the wiring harness from the toe-board
crossmember (Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel filler cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(9) Loosen the two fasteners at the rail. Take care
to notice that the exhaust tube bracket tab is on top
of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the flexible section of the cabin
heater exhaust tube from the exhaust tube by loos-
ening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
- REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to crossmember.
(12) Loosen the remaining fasteners which mount
the exhaust tube assembly to the vehicle.
(a) Install a suitable support device under the
cabin heater and secure the cabin heater to the
support.
(13) Loosen the remaining three fasteners to the
crossmembers.
(14) Remove the loosened fasteners that support
the cabin heater while supporting the weight of the
heater.
(15) Swing the cabin heater mounting bracket
from between the exhaust bracket and rail mounting
location. Drain any residual coolant from the cabin
heater.
Fig. 7 Cabin Heater Air Intake And Heater Pipe
Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
RSCABIN HEATER24 - 121
HEATER PIPES (Continued)