Chrysler RG Voyager. Manual — part 1229
neath the engine compartment (Refer to 23 - BODY/
EXTERIOR/BELLY PAN - REMOVAL).
(8) Remove the nut that secures the A/C discharge
line to the A/C compressor (Fig. 13).
(9) Disconnect the A/C discharge line from the A/C
compressor and remove and discard the O-ring seal
and gasket.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(11) Remove the A/C discharge line from the
engine compartment.
INSTALLATION
(1) Position the A/C discharge line into the engine
compartment.
(2) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it and a new gasket onto
the discharge line fitting.
(4) Install the A/C discharge line to the A/C com-
pressor.
(5) Install the nut that secures the A/C discharge
line to the A/C compressor. Tighten the nut to 23
N·m (17 ft. lbs.).
(6) On models with the 2.5L and 2.8L diesel
engine, install the belly pan (Refer to 23 - BODY/EX-
TERIOR/BELLY PAN - INSTALLATION).
(7) Lower the vehicle.
(8) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it and a new gasket onto
the discharge line fitting.
(10) Install the A/C discharge line to the A/C con-
denser.
(11) Install the nut that secures the A/C discharge
line to the A/C condenser. Tighten the nut to 23 N·m
(17 ft. lbs.).
(12) Install the right headlamp unit (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING
-
EXTERIOR/
HEADLAMP UNIT - INSTALLATION).
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
A/C EVAPORATOR
DESCRIPTION
The A/C evaporator (Fig. 14) for the front heating-
A/C system is located within the front HVAC hous-
ing, behind the instrument panel. The front A/C
evaporator and insulator are positioned in the front
HVAC housing so that all air entering the housing
must pass over the evaporator fins before it is dis-
tributed through the front heating-A/C system ducts
and outlets. However, air passing over the evaporator
fins will only be conditioned when the A/C compres-
sor is engaged and circulating refrigerant through
the front A/C evaporator.
Fig. 12 A/C Discharge Line to A/C Condenser -
Typical
1 - A/C CONDENSER
2 - A/C DISCHARGE LINE
3 - A/C LIQUID LINE
4 - NUT (2)
Fig. 13 A/C Discharge Line to Compressor - Typical
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
RS
PLUMBING - FRONT
24 - 81
A/C DISCHARGE LINE (Continued)
The front A/C evaporator tubes are connected and
sealed to the A/C expansion valve by use of rubber
O-rings and a tapping block.
The front A/C evaporator can only be serviced by
removing and disassembling the front HVAC hous-
ing.
OPERATION
Refrigerant enters the front A/C evaporator from
the front A/C expansion valve as a low-temperature,
low-pressure mixture of liquid and gas. As air flows
over the fins of the front A/C evaporator, the humid-
ity in the air condenses on the fins, and the heat
from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas when
it leaves the front A/C evaporator.
The front A/C evaporator cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Remove the front HVAC housing (Fig. 15)
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION
-
FRONT/HVAC
HOUSING
-
REMOVAL).
(2) Disassemble the front HVAC housing as neces-
sary to access the front A/C evaporator (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- FRONT/HVAC HOUSING - DISASSEMBLY).
(3) Open the rubber flange seal and carefully lift
the front A/C evaporator and insulator out of the
lower half of the front HVAC housing.
NOTE: If the insulator is deformed or damaged, it
must be replaced.
(4) If required, remove the insulator from the front
A/C evaporator.
INSTALLATION
NOTE: If the front A/C 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) If removed, install the insulator over the front
A/C evaporator.
NOTE: Make sure that the evaporator drain within
the front HVAC housing is clean and unrestricted
and that the insulator and the rubber flange seal are
properly positioned.
(2) Install the front A/C evaporator into the lower
half of the front HVAC housing and close the rubber
flange seal.
(3) Assemble the front HVAC housing (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/HVAC HOUSING - ASSEMBLY).
(4) Install the front HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- FRONT/HVAC HOUSING - INSTALLATION).
Fig. 14 A/C Evaporator
1 - FRONT A/C EVAPORATOR
2 - INSULATOR
3 - EVAPORATOR TUBES
4 - O-RING SEALS
Fig. 15 A/C Evaporator
1 - LOWER FRONT HVAC HOUSING
2 - UPPER FRONT HVAC HOUSING
3 - FRONT BLOWER MOTOR
4 - FRONT A/C EVAPORATOR
24 - 82
PLUMBING - FRONT
RS
A/C EVAPORATOR (Continued)
EXPANSION VALVE
DESCRIPTION
The front A/C expansion valve (Fig. 16) controls
the amount of refrigerant entering the front A/C
evaporator. The front A/C expansion valve is of a
thermostatic expansion valve (TXV) design and con-
sists of an aluminum H-valve type body with an inte-
gral thermal sensor. The front A/C expansion valve is
located in the engine compartment at the dash panel,
between the A/C refrigerant lines and the A/C evap-
orator.
On RG models, the evaporator temperature sensor
is installed on the top of the front A/C expansion
valve (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/EVAPORATOR TEMPER-
ATURE SENSOR - DESCRIPTION).
OPERATION
The A/C expansion valve controls the high-pres-
sure, low temperature liquid refrigerant from the liq-
uid line and converts it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the A/C evaporator. A mechanical sensor in the
A/C expansion valve monitors the temperature and
pressure of the refrigerant leaving the A/C evapora-
tor through the suction line, and adjusts the orifice
size at the liquid line port to let the proper amount
of refrigerant into the A/C evaporator to meet the
vehicle A/C cooling requirements. Controlling the
refrigerant flow through the A/C evaporator ensures
that none of the refrigerant leaving the A/C evapora-
tor is still in a liquid state, which could damage the
A/C compressor.
The A/C expansion valve is a factory calibrated
unit and cannot be adjusted or repaired and, if faulty
or damaged, it must be replaced.
DIAGNOSIS AND TESTING
A/C EXPANSION VALVE
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT - WARNINGS)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTIONS). Failure to follow
the warnings and cautions could result in possible
personal injury or death.
NOTE: The A/C expansion valve should only be
tested following testing of the A/C compressor.
NOTE: Liquid CO
2
is required to test the A/C expan-
sion valve. This material is available from most
welding supply facilities. Liquid CO
2
is also avail-
able from companies which service and sell fire
extinguishers.
When testing the A/C expansion valve, the work
area and the vehicle temperature must be 21° to 27°
C (70° to 85° F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the A/C-heater controls so that the A/C
compressor is operating, the temperature control is
in the highest temperature position, the mode-air
doors is directing air output to the floor and the
blower motor operating is operating at the highest
speed.
(4) Start the engine and allow it to idle. After the
engine has reached normal operating temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the A/C evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 kPa to
1655 kPa (140 psi to 240 psi). The suction (low pres-
sure) gauge should read 138 kPa to 207 kPa (20 psi
to 30 psi). If OK, go to Step 6. If not OK, replace the
faulty A/C expansion valve.
WARNING:
Protect the skin and eyes from exposure to liquid
CO
2
or personal injury can result.
(6) If the suction (low pressure) gauge reads
within the specified range, freeze the A/C expansion
valve for 30 seconds using liquid CO
2
or another suit-
Fig. 16 A/C Expansion Valve-Typical
1 - A/C EXPANSION VALVE
2 - THERMAL SENSOR
RS
PLUMBING - FRONT
24 - 83
able super-cold material.Do not spray R-134a or
R-12 refrigerant on the A/C expansion valve for
this test. The suction (low pressure) gauge reading
should drop by 69 kPa (10 psi). If OK, go to Step 7 If
not OK, replace the faulty A/C expansion valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 138 kPa to 207 kPa (20 psi to 30 psi). If not
OK, replace the faulty A/C expansion valve.
(8) When expansion valve testing is complete, test
the overall A/C system performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
REMOVAL
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT - WARNINGS)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTIONS). Failure to follow
the warnings and cautions could result in possible
personal injury or death.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the air cleaner housing and the air
inlet tube (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - REMOVAL).
(4) Remove the drain tube from the right end of
the wiper module.
(5) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 17).
(6) Remove the screw that secures the liquid line
to the receiver/drier outlet port.
(7) Disconnect the liquid line from the receiver/
drier outlet port and remove and discard the seal.
(8) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(9) Remove the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve.
(10) Disconnect the A/C suction and liquid line fit-
tings from the A/C expansion valve and remove and
discard the seals.
(11) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(12) On RG models, disconnect the HVAC wire
harness connector from the evaporator temperature
sensor.
(13) Remove the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate
and remove the expansion valve.
(14) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(15) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
(16) On RG models, remove the retaining screw
and evaporator temperature sensor from the A/C
expansion valve, if required (Refer to 24 - HEATING
&
AIR
CONDITIONING/CONTROLS
-
FRONT/
EVAPORATOR
TEMPERATURE
SENSOR
-
REMOVAL).
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 (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/EVAPORATOR
TEM-
PERATURE SENSOR - INSTALLATION).
(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.
Fig. 17 A/C Expansion Valve - LHD Shown, RHD
Typical
1 - LIQUID LINE FITTING BOLT
2 - A/C PRESSURE TRANSDUCER
3 - NUT
4 - EVAPORATOR TEMP SENSOR (RG Models)
5 - A/C EXPANSION VALVE
6 - DRAIN TUBE
7 - A/C SUCTION LINE
8 - A/C LIQUID LINE (REAR SECTION)
9 - RECEIVER/DRIER
24 - 84
PLUMBING - FRONT
RS
EXPANSION VALVE (Continued)
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