Chrysler Town, Dodge Caravan. Manual — part 517
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plan seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N·m (17 ft. lbs.).
(11) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Install a new dual plan seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N·m (17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install and tighten the two screws that secure
the hood latch unit to the front of the radiator clo-
sure panel crossmember. Check and adjust the hood
latch as needed. Tighten the screws to 14 N·m (123
in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N·m (18 in. lbs.).
(20) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N·m (53 in.
lbs.).
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
DISCHARGE LINE
REMOVAL
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 CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD
PROCEDURE
-
REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 6).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 7).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the seal from the discharge line fitting
and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 68
PLUMBING - FRONT
RS
CONDENSER (Continued)
(9) Remove the nut that secures the discharge line
fitting to the top of the compressor (Fig. 8).
(10) Disconnect the discharge line fitting from the
compressor discharge port.
(11) Remove the seals from the discharge line fit-
ting and discard.
(12) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(13) Remove the discharge line from the engine
compartment.
INSTALLATION
(1) Position the discharge line into the engine com-
partment.
(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 on the discharge line fit-
ting.
(4) Install a new dual plane seal and reconnect the
discharge line fitting to the compressor discharge
port on the top of the compressor.
(5) Install and tighten the nut that secures the
discharge line fitting to the compressor. Tighten the
nut to 23 N·m (17 ft. lbs.).
(6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(8) Install a new dual plane seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(9) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N·m (17 ft. lbs.).
(10) Position the radiator sight shield onto the
radiator closure panel crossmember.
(11) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N·m (18 in. lbs.).
(12) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N·m (53 in.
lbs.).
(13) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(14) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
EVAPORATOR
DESCRIPTION
The evaporator is located in the heater-A/C unit
housing, behind the instrument panel. The evapora-
tor is positioned in the heater-A/C housing so that all
air that enters the housing must pass over the fins of
the evaporator before it is distributed through the
system ducts and outlets. However, air passing over
the evaporator fins will only be conditioned when the
compressor is engaged and circulating refrigerant
Fig. 7 Condenser Connections
1 - CONDENSER
2 - DISCHARGE LINE FITTING
3 - LIQUID LINE FITTING
4 - NUT
Fig. 8 Discharge Line
1 - DISCHARGE LINE
2 - NUT
3 - DISCHARGE LINE FITTING
4 - STUD
5 - DISCHARGE PORT
RS
PLUMBING - FRONT
24 - 69
DISCHARGE LINE (Continued)
through the evaporator tubes. The heater-A/C unit
housing must be removed from the vehicle to access
the evaporator for service. The evaporator cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
Refrigerant enters the evaporator from the expan-
sion valve as a low-temperature, low-pressure liquid/
vapor mixture. As air flows over the fins of the evap-
orator, the humidity in the air condenses on the fins,
and the heat from the air is absorbed by the refrig-
erant. Heat absorption causes the refrigerant to boil
and vaporize. The refrigerant becomes a low-pressure
gas when it leaves the evaporator.
REMOVAL
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),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Remove the HVAC unit housing from the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION - FRONT/HVAC HOUSING -
REMOVAL).
(2) Remove the heater core tubes from the heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING
-
FRONT/HEATER
CORE
-
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inlet
opening and the expansion valve/evaporator tube
opening on the dash panel side of the unit.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/EXPANSION VALVE - REMOVAL).
(5) Disconnect the HVAC wire harness connector
for the blower motor from the motor connector recep-
tacle on the bottom of the outboard end of the evap-
orator housing.
(6) Disengage the HVAC wire harness from the
routing clips molded into the outside of the HVAC
housing components.
(7) Remove the four screws from the dash panel
side of the unit that secure the top of the distribution
housing to the inboard end of the evaporator housing
(Fig. 9).
(8) Pull the top of the distribution housing away
from the evaporator housing far enough to disengage
the two hook formations on the bottom of the distri-
bution housing from the two receptacles on the evap-
orator housing (Fig. 10).
(9) Remove the two screws that secure the upper
intake air housing to the lower intake air housing.
(10) Remove the three screws that secure the
upper intake air housing to the top of the outboard
end of the evaporator housing. Be certain not to miss
the screw located just inside the inboard side of the
fresh air intake opening.
(11) Remove the upper intake air housing from the
top of the evaporator housing to expose the recircu-
Fig. 9 HVAC Housing
1 - DISTRIBUTION HOUSING
2 - SCREWS (3)
3 - HVAC WIRING HARNESS
4 - ROUTING CLIP
5 - EVAPORATOR HOUSING
Fig. 10 Distribution Housing Hooks
1 - RECEPTACLES ON EVAPORATOR HOUSING
2 - HOOKS ON DISTRIBUTION HOUSING
24 - 70
PLUMBING - FRONT
RS
EVAPORATOR (Continued)
lation air door and the blower wheel housing (Fig.
11).
(12) Remove the screw and washer from the upper
pivot of the recirculation door.
(13) Remove the two screws that secure the upper
half of the recirculation air door to the lower half of
the door.
(14) Remove the upper half of the recirculation air
door from the lower half of the door (Fig. 12).
(15) Remove the twelve screws around the perime-
ter of the evaporator housing that secure the upper
housing half to the lower half.
(16) Carefully separate and remove the upper half
of the evaporator housing from the lower half. Be cer-
tain not to lose the rubber grommet for the HVAC
wire harness evaporator temperature sensor take
out. This grommet is located on the inboard side of
the flange around the expansion valve/evaporator
tube opening on the dash panel side of the unit,
where it is captured in a notched area between the
upper and lower housing halves (Fig. 13).
(17) Carefully lift the evaporator and its foam
wrap out of the lower half of the evaporator housing
as a unit. Be certain not to lose the clam shell type
rubber seal that is fitted to the evaporator inlet and
outlet tubes where they exit the evaporator housing.
INSTALLATION
NOTE: If the evaporator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Carefully lower the evaporator and its foam
wrap into the lower half of the evaporator housing as
a unit. Be certain that the clam shell type rubber
seal is fitted to the evaporator inlet and outlet tubes
where they exit the evaporator housing.
(2) Position the upper half of the evaporator hous-
ing onto the lower half. Be certain that the rubber
grommet and the HVAC wire harness take out for
the evaporator temperature sensor are captured in
Fig. 11 Upper Intake Air Housing
1 - EVAPORATOR HOUSING
2- UPPER INTAKE AIR HOUSING
3 - RECIRCULATION AIR DOOR
4 - BLOWER WHEEL
Fig. 12 Recirculation Air Door
1 - EVAPORATOR HOUSING
2 - UPPER RECIRCULATION AIR DOOR
3 - LOWER INTAKE AIR HOUSING
Fig. 13 Evaporator Housing
1 - LOWER EVAPORATOR HOUSING
2 - UPPER EVAPORATOR HOUSING
3 - BLOWER WHEEL
4 - EVAPORATOR
RS
PLUMBING - FRONT
24 - 71
EVAPORATOR (Continued)
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