Chrysler RG Voyager. Manual — part 1234
(8) Remove the seals from the evaporator line
extension fittings and discard.
(9) Install plugs in, or tape over the opened evap-
orator line extension fittings and both expansion
valve ports.
INSTALLATION
REAR A/C EVAPORATOR
NOTE: If the rear 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) Carefully lower the rear A/C evaporator and its
foam wrap into the lower half of the rear HVAC
housing.
(2) Position the upper half of the rear HVAC hous-
ing onto the lower half.
(3) Install the three metal spring clips that secure
the upper half of the rear HVAC housing to the lower
half.
(4) Install the three screws that secure the upper
half of the rear HVAC housing to the lower half.
Tighten the screws to 2 N·m (17 in. lbs.).
(5) Install the rubber grommet that seals the evap-
orator inlet and outlet tubes to the rear HVAC hous-
ing near the rear A/C expansion valve.
(6) Install the rear A/C expansion valve onto the
rear A/C evaporator (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/A/C EXPAN-
SION VALVE - INSTALLATION).
(7) Install the rear evaporator extension line onto
the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C EVAPORATOR - EVAPORATOR EXTENSION
LINE - INSTALLATION).
(8) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).
REAR EVAPORATOR LINE EXTENSION
(1) Remove the tape or plugs from the evaporator
line extension fittings and both expansion valve
ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
line extension fittings.
(3) Position the evaporator line extension to the
rear A/C expansion valve and the lower rear HVAC
housing.
(4) Position the evaporator line extension seal
plate over the expansion valve stud.
(5) Install the nut that secures the evaporator line
extension seal plate to the expansion valve stud.
Tighten the nut to 23 N·m (17 ft. lbs.).
(6) Position the expansion valve bracket over the
expansion valve stud.
(7) Install the two screws that secure the expan-
sion valve bracket to the lower rear HVAC housing.
Tighten the screws to 2 N·m (17 in. lbs.).
(8) Install the nut that secures the expansion
valve bracket to the expansion valve stud. Tighten
the nut to 23 N·m (17 ft. lbs.).
(9) Install the foam insulating over the rear A/C
expansion valve.
(10) Position the flange over the rear evaporator
line extension and into the lower rear HVAC housing.
(11) Install the screw that secures the flange to
the rear lower HVAC housing. Tighten the screw to 2
N·m (17 in. lbs.).
(12) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).
A/C EXPANSION VALVE
DESCRIPTION
The rear “H” valve-type thermal expansion valve
(TXV) is located at the rear of the rear HVAC hous-
ing between the evaporator line extension and the
evaporator coil. High-pressure, low temperature liq-
uid refrigerant from the liquid line passes through
the expansion valve orifice, converting it into a low-
Fig. 4 Rear A/C Evaporator Line Extension
1 - UPPER REAR HVAC HOUSING
2 - LOWER REAR HVAC HOUSING
3 - EXPANSION VALVE BRACKET
4 - EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - FOAM INSULATING
RS
PLUMBING - REAR
24 - 101
A/C EVAPORATOR (Continued)
pressure, low-temperature mixture of liquid and gas
before it enters the evaporator coil.
OPERATION
The rear A/C expansion valve controls the high-
pressure, low temperature liquid refrigerant from the
rear liquid line and converts it into a low-pressure,
low-temperature mixture of liquid and gas before it
enters the rear A/C evaporator. A mechanical sensor
in the rear A/C expansion valve monitors the temper-
ature and pressure of the refrigerant leaving the rear
A/C evaporator through the rear suction line, and
adjusts the orifice size at the rear liquid line port to
let the proper amount of refrigerant into the rear A/C
evaporator to meet the vehicle A/C cooling require-
ments. Controlling the refrigerant flow through the
rear A/C evaporator ensures that none of the refrig-
erant leaving the rear A/C evaporator is still in a liq-
uid state, which could damage the A/C compressor.
For diagnosis and testing of the rear A/C expansion
valve, refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/A/C EXPANSION VALVE
- DIAGNOSIS AND TESTING.
The rear A/C expansion valve is factory calibrated
and cannot be adjusted or repaired and, if faulty or
damaged, it must be replaced.
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) Remove the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - REMOVAL).
(2) Carefully remove the foam insulating from
around the rear A/C expansion valve (Fig. 5).
(3) Remove the rear evaporator line extension from
the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C
EVAPORATOR
-
EVAPORATOR
LINE
EXTENSION - REMOVAL).
(4) Remove the two screws that secure the rear
A/C expansion valve to the rear evaporator tube seal-
ing plate.
(5) Remove the rear A/C expansion valve from the
rear evaporator tubes and remove and discard the
seals.
(6) Install plugs in, or tape over the opened evap-
orator tube fittings, evaporator ports and all expan-
sion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the rear A/C
evaporator tube fittings, rear A/C evaporator ports
and all rear 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 rear A/C expansion valve onto the
rear evaporator tubes.
(4) Install the two screws that secure the rear A/C
expansion valve to the rear evaporator tube sealing
plate. Tighten the screws to 11 N·m (97 in. lbs.).
(5) Install the rear evaporator line extension onto
the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C
EVAPORATOR
-
EVAPORATOR
LINE
EXTENSION - INSTALLATION).
(6) Install the foam insulating over the rear A/C
expansion valve.
(7) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).
HEATER CORE
DESCRIPTION
The rear heater core (Fig. 6) 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 heater core is
fitted with a molded plastic tank that includes the
Fig. 5 Rear A/C Evaporator Line Extension
1 - UPPER REAR HVAC HOUSING
2 - LOWER REAR HVAC HOUSING
3 - EXPANSION VALVE BRACKET
4 - REAR EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - REAR A/C EXPANSION VALVE
24 - 102
PLUMBING - REAR
RS
A/C EXPANSION VALVE (Continued)
mounting provisions for the heater core and connec-
tions for the heater core inlet and outlet tubes.
The rear heater core can be serviced 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-air door allows control of the rear heater
output air temperature by controlling how much of
the air flowing through the rear HVAC housing is
directed through the rear heater core.
The rear heater core cannot be repaired and, if
faulty or damaged, it must be replaced.
STANDARD PROCEDURE
REAR HEATER CORE FILLING
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.
The rear heater core is positioned in the rear
HVAC housing at a higher level than the radiator fill
opening. Therefore, when the cooling system is
drained and refilled, gravity will not totally refill the
rear heater core. This may result in two problems:
1. Insufficient coolant level in the engine cooling
system, which may result in engine overheating.
2. Air entrapped within the rear heater core,
which may result in insufficient rear heater perfor-
mance.
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.
Following are descriptions of both prevention
methods, as well as a method to verify rear heater
performance.
PRE-FILLING
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.
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) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 7).
(3) 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 rear heater core.
(4) Connect the heater hoses to the rear heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER HOSE -
INSTALLATION).
(5) 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.
Fig. 6 Rear Heater Core
1 - REAR HEATER CORE
2 - MOUNTING PROVISION (2)
3 - HEATER CORE TUBES
RS
PLUMBING - REAR
24 - 103
HEATER CORE (Continued)
(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 21° C
(70° F).
(1) Start the engine and allow it to idle until it
warms up to normal operating temperature.
(2) Adjust the A/C-heater controls so that the front
heater is turned Off and the rear heater is set for full
Heat with the rear blower motor 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 57° to 63° C (135° to 145° F).
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) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Remove the trim panels from the right inner
quarter panel and the right D-pillar (Refer to 23 -
BODY/INTERIOR/QUARTER
TRIM
PANEL
-
REMOVAL).
(3) Remove the rear heater distribution duct (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION
-
REAR/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 inner quarter 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.
(6) Disconnect the heater hoses from the rear
heater core (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).
(7) Install plugs in, or tape over the opened heater
core fittings and both heater hoses (Fig. 8).
(8) Release the four retaining tabs that secure the
rear heater core to the rear HVAC housing and
remove the heater core.
Fig. 7 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
24 - 104
PLUMBING - REAR
RS
HEATER CORE (Continued)
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