Chrysler RG Voyager. Manual — part 1225
(18) Remove the screw that secures the back of the
rear HVAC housing to the right D-pillar (Fig. 8).
(19) Remove the screw that secures the front of
the rear HVAC housing to the inner right quarter
panel.
(20) Lift the rear HVAC housing up far enough for
the lower mounting studs and the evaporator exten-
sion lines to clear the mounting holes in the rear
floor panel and remove the housing.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core should be pre-filled
with the proper engine coolant mixture prior to
reconnecting the heater hoses to the heater core
hose fittings (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER CORE - STAN-
DARD
PROCEDURE
-
REAR
HEATER
CORE
FILLING).
(1) Position the rear HVAC housing into the vehi-
cle with the evaporator extension line sealing plate
inserted into the opening in the rear floor panel
behind the right rear wheel house.
(2) Align the rear HVAC housing lower mounting
studs with the holes in the rear floor panel and lower
the rear HVAC housing to the floor.
(3) Install the screw that secures the front of the
rear HVAC housing to the inner right quarter panel.
Tighten the screw to 11 N·m (97 in. lbs.).
(4) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N·m (97 in. lbs.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Pre-fill the rear heater core (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
REAR/HEATER CORE - STANDARD PROCEDURE -
REAR HEATER CORE FILLING).
(7) Connect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
Fig. 8 Rear HVAC Housing
1 - U-NUT (3)
2 - REAR HVAC HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE
5 - STUD (2 w/NSE, 3 wo/NSE)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
RS
DISTRIBUTION - REAR
24 - 65
HVAC HOUSING (Continued)
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(8) Install the rear floor heat duct onto the inner
right quarter panel (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION
-
REAR/REAR
FLOOR HEAT DUCT - INSTALLATION).
(9) Install the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing. Tighten the screws to 2 N·m (17
in. lbs.).
(10) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the inner quarter panel.
(11) Connect the wire harness connector to the
rear HVAC wire harness connector.
(12) Install the rear distribution duct onto the rear
HVAC housing and the rear headliner duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - REAR/AIR OUTLETS - INSTALLATION).
(13) Install the trim panels onto the right inner
quarter panel and right D-pillar (Refer to 23 - BODY/
INTERIOR/QUARTER TRIM PANEL - INSTALLA-
TION).
(14) Raise and support the vehicle.
(15) Install the three nuts that secure the rear
HVAC housing mounting studs to the rear floor panel
behind the right rear wheel housing. Tighten the
nuts to 9 N·m (80 in. lbs.).
(16) Remove the tape or plugs from the underbody
refrigerant line fittings and both ports in the rear
evaporator extension line sealing plate.
(17) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the underbody
refrigerant line fittings.
(18) Connect the underbody refrigerant line seal-
ing plate to the evaporator extension line tapping
plate.
(19) Install the nut that secures the underbody
refrigerant line sealing plate to the evaporator exten-
sion line tapping plate. Tighten the nut to 23 N·m
(17 ft. lbs.).
(20) Lower the vehicle.
(21) Reconnect the negative battery cable.
(22) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(23) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(24) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
(25) Calibrate the A/C-heater control (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/A/C
HEATER
CONTROL
-
STANDARD
PROCEDURE -A/C-HEATER CONTROL CALIBRA-
TION).
REAR FLOOR HEAT DUCT
REMOVAL
(1) Remove the trim panel from the right inner
quarter panel (Refer to 23 - BODY/INTERIOR/
RIGHT QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
floor heat duct to the right inner quarter panel (Fig.
9).
(3) Slide the rear floor heat duct forward to disen-
gage it from the rear HVAC housing and remove the
duct.
INSTALLATION
(1) Position the rear floor heat duct to rear HVAC
housing.
(2) Slide the rear floor heat duct rearward to
engage it to the rear HVAC housing.
(3) Install the two screws that secure the rear floor
heat duct to the right inner quarter panel. Tighten
the screws to 2 N·m (17 in. lbs.).
(4) Install the trim panel onto the right inner
quarter panel (Refer to 23 - BODY/INTERIOR/
RIGHT QUARTER TRIM PANEL - INSTALLA-
TION).
Fig. 9 Rear Floor Heat Duct
1 - REAR FLOOR HEAT DUCT
2 - REAR HVAC HOUSING
3 - SCREW (2)
24 - 66
DISTRIBUTION - REAR
RS
HVAC HOUSING (Continued)
PLUMBING - FRONT
TABLE OF CONTENTS
page
page
PLUMBING - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 71
A/C COMPRESSOR
. . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . . . . . . . 74
. . . . . . . . . . . . . . 75
. . . . . . . . . . . . . . . . . . . . 75
A/C COMPRESSOR MOUNTING BRACKET-
2.4L/2.5L/2.8L ENGINES . . . . . . . . . . . . . . . . 76
. . . . . . . . . . . . . . . . . . . . 77
A/C COMPRESSOR MOUNTING BRACKET-
2.4L/2.5L/2.8L ENGINES . . . . . . . . . . . . . . . . 77
A/C CONDENSER
. . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . . . 79
. . . . . . . . . . . . . . 80
A/C DISCHARGE LINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
. . . . . . . . . . . . . . . . . . . . . . . . . 81
A/C EVAPORATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 81
. . . . . . . . . . . . . . . . . . . . . . . . . . . 82
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
. . . . . . . . . . . . . . . . . . . . . . . . . 82
EXPANSION VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . 83
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
. . . . . . . . . . . . . . . . . . . . . . . . . 84
HEATER CORE
. . . . . . . . . . . . . . . . . . . . . . . . . 85
. . . . . . . . . . . . . . . . . . . . . . . . . . . 85
. . . . . . . . . . . . . . . . . 86
. . . . . . . . . . . . . . . . . 87
HEATER INLET HOSE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . 88
HEATER RETURN HOSE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . . . . . 89
LIQUID LINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
. . . . . . . . . . . . . . . . . . . . . . . . . 92
RECEIVER / DRIER
. . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . . . . . . . . 93
REFRIGERANT
. . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REFRIGERANT OIL
. . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . 95
SERVICE PORT VALVE CORE
. . . . . . . . . . . . . . . . . . . . . . . . . 95
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . . . . . . . 96
SUCTION LINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . . . . . . . 97
RS
PLUMBING - FRONT
24 - 67
PLUMBING - FRONT
DESCRIPTION
The A/C refrigerant lines and hoses are used to
carry the refrigerant between the various A/C system
components. The refrigerant lines and hoses for the
R-134a system on this vehicle consist of a barrier-
hose design with a nylon tube sandwiched between
rubber layers. The nylon tube helps to contain the
R-134a refrigerant, which has a smaller molecular
structure than R-12 refrigerant. The ends of the
refrigerant lines are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.
Any kinks or sharp bends in the refrigerant lines
and hoses will reduce the capacity of the entire A/C
system and can reduce the flow of refrigerant in the
system. The radius of all bends in the flexible hose
refrigerant lines should be at least ten times the
diameter of the hose and the refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) away from the exhaust manifold(s) and
exhaust pipe(s).
OPERATION
High pressures are produced in the refrigerant sys-
tem when the A/C compressor is operating. Extreme
care must be exercised to make sure that each of the
refrigerant system connections is pressure-tight and
leak free. It is a good practice to inspect all flexible
hose refrigerant lines at least once a year to make
sure they are in good condition and properly routed.
The refrigerant lines and hoses are coupled to
other A/C system components with block-type fit-
tings. An O-ring seal, or a flat steel gasket with an
integral O-ring (dual plane seal), is used to mate the
refrigerant line fittings with A/C system components
to ensure the integrity of the refrigerant system.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNINGS
WARNING: The A/C system contains refrigerant
under high pressure. Repairs should only be per-
formed by qualified service personnel. Severe per-
sonal injury or death may result from improper
service procedures.
WARNING: Avoid breathing the refrigerant and
refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protection
when servicing the A/C refrigerant system. Serious
eye injury can result from direct contact with the
refrigerant. If eye contact occurs, seek medical
attention immediately.
WARNING: Do not expose the refrigerant to open
flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recom-
mended. Severe personal injury or death may result
from improper service procedures.
WARNING: If accidental system discharge occurs,
ventilate the work area before resuming service.
Large amounts of refrigerant released in a closed
work area will displace the oxygen and cause suf-
focation and death.
WARNING: The evaporation rate of R-134a refriger-
ant at average temperature and altitude is extremely
high. As a result, anything that comes in contact
with the refrigerant will freeze. Always protect the
skin or delicate objects from direct contact with the
refrigerant.
WARNING: The R-134a service equipment or the
vehicle refrigerant system should not be pressure
tested or leak tested with compressed air. Some
mixtures of air and R-134a have been shown to be
combustible at elevated pressures. These mixtures
are potentially dangerous, and may result in fire or
explosion causing property damage, personal injury
or death.
WARNING: The engine cooling system is designed
to develop internal pressures of 97 to 123 kilopas-
cals (14 to 18 pounds per square inch). Do not
remove or loosen the coolant pressure cap, cylin-
der block drain plugs, radiator drain, radiator
hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure.
Allow the vehicle to cool for a minimum of 15 min-
utes before opening the cooling system for service.
Failure to observe this warning can result in seri-
ous burns from the heated engine coolant.
CAUTIONS
CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Do not use R-12 equipment
or parts on a R-134a A/C system. These refrigerants
are not compatible and damage to the A/C system
will result.
CAUTION: Never use R-12 refrigerant oil in a A/C
system designed to use R-134a refrigerant oil.
These refrigerant oils are not compatible and dam-
age to the A/C system will result.
24 - 68
PLUMBING - FRONT
RS
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