Chrysler RG Voyager. Manual — part 1236
(2) Remove the tape or plugs from the suction and
liquid line fittings and expansion valve ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction and
liquid line fittings.
(4) Connect the suction and liquid lines to the
front A/C expansion valve.
(5) Install the nut that secures the suction and liq-
uid lines to the front A/C 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 A/C com-
pressor 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) Connect the suction line to the A/C compressor.
(10) Install the nut that secures the suction line to
the A/C compressor. Tighten the nut to 23 N·m (17 ft.
lbs.).
(11) Connect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Install the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the negative battery cable.
(14) Raise and support the vehicle.
(15) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line.
(16) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line.
(17) Connect the suction line extension fitting to
the underbody suction line. 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 heating-
A/C system.
(19) Lower the vehicle.
(20) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(21) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
Underbody lines are used on models equipped with
the rear heating-A/C system (Fig. 14). The underbody
suction line, liquid line, and heater tubes can each be
serviced separately.
OPERATION
The rear heating-A/C underbody lines are all ser-
viced as individual components. When disconnecting
any line or connection, 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 system (Fig. 15) and (Fig. 16).
WARNING: High pressures are produced in the
refrigerant system when the a/c compressor 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 per-
sonal injury or death.
Fig. 14 Rear Heater and A/C Lines – Typical
1 - REAR HEATER TUBE CONNECTIONS
2 - REAR A/C LINE CONNECTIONS
RS
PLUMBING - REAR
24 - 109
SUCTION LINE (Continued)
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 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) 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. 17).
(4) Lower the underbody heater tubes and drain
any residual coolant from the tubes into a suitable
container.
Fig. 15 Rear Heater and A/C Lines – Typical
1 - REAR HEATER TUBE CONNECTIONS
2 - REAR A/C LINE CONNECTIONS
Fig. 16 Front Extension Lines to Underbody Lines –
Typical
Fig. 17 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
24 - 110
PLUMBING - REAR
RS
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. 18).
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 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 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. 19).
(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. 20)
and (Fig. 21).
(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.
Fig. 18 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. 19 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
RS
PLUMBING - REAR
24 - 111
UNDERBODY LINES (Continued)
(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. 22).
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.
Fig. 20 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. 21 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. 22 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
24 - 112
PLUMBING - REAR
RS
UNDERBODY LINES (Continued)
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