Chrysler Town, Dodge Caravan. Manual — part 523
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) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the 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 filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment. (If Equipped).
(7) Remove the tape or plugs from the compressor
suction 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) Install a new dual plan seal and reconnect the
suction line fitting to the compressor suction port.
(10) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N·m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.
(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fit-
tings to 23 N·m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(20) Lower the vehicle.
(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).
SERVICE PORTS
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) Remove the protective cap from the A/C service
port (Fig. 36).
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD
PROCEDURE
-
REFRIGERANT
RECOVERY).
(3) Using a standard Schrader-type valve core tool,
remove the valve core from the A/C service port (Low
Fig. 36 A/C Service Port - Typical
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 92
PLUMBING - FRONT
RS
SUCTION LINE (Continued)
side only). If the high side requires service replace-
ment of the line is required).
(4) Install a plug in or tape over the opened A/C
service port.
INSTALLATION
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) Lubricate the A/C service port valve core with
clean refrigerant oil prior to installation. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the A/C service port (Low side only). If the high side
requires service replacement of the line assembly is
required).
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
(4) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(5) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT
-
STANDARD
PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(6) Reinstall the protective cap onto the A/C ser-
vice port.
RS
PLUMBING - FRONT
24 - 93
SERVICE PORTS (Continued)
PLUMBING - REAR
TABLE OF CONTENTS
page
page
EVAPORATOR
. . . . . . . . . . . . . . . . . . . . . . . . . 94
. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION - REAR EVAPORATOR
INSTALLATION - EVAPORATOR LINE
EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . 96
EXPANSION VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . 96
. . . . . . . . . . . . . . . . . . . . . . . . . . . 97
DIAGNOSIS AND TESTING - EXPANSION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
. . . . . . . . . . . . . . . . . . . . . . . . . 98
HEATER CORE
. . . . . . . . . . . . . . . . . . . . . . . . . 98
. . . . . . . . . . . . . . . . . . . . . . . . . . . 98
STANDARD PROCEDURE - HEATER CORE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
. . . . . . . . . . . . . . . . . . . . . . . . 100
HEATER HOSE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
. . . . . . . . . . . . . . . . . . . . . . . . 101
SUCTION LINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
. . . . . . . . . . . . . . . . . . . . . . . . 102
UNDERBODY LINES
. . . . . . . . . . . . . . . . . . . . . . . . 103
. . . . . . . . . . . . . . . . . . . . . . . . . . 103
REMOVAL - REAR AIR CONDITIONING
LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
INSTALLATION - REAR HEATER LINES
INSTALLATION - REAR AIR CONDITIONING
LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
EVAPORATOR
DESCRIPTION
The rear evaporator is located in the rear heater-
A/C unit housing, behind the right rear wheel house.
The evaporator is positioned in the rear heater-A/C
housing so that all air that enters the housing must
pass over the fins of the evaporator before it is dis-
tributed through the system ducts and outlets. How-
ever, air passing over the evaporator fins will only be
conditioned when the compressor is engaged and cir-
culating refrigerant through the evaporator tubes.
The rear 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 rear evaporator from the
rear expansion valve as a low-temperature, low-pres-
sure liquid. As air flows over the fins of the evapora-
tor, 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
REMOVAL - REAR EVAPORATOR
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 rear heater-A/C unit housing from
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).
(2) Remove the rear evaporator line extension from
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING
-
REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(3) Remove the rear expansion valve from the rear
evaporator. (Refer to 24 - HEATING & AIR CONDI-
24 - 94
PLUMBING - REAR
RS
TIONING/PLUMBING - REAR/EXPANSION VALVE
- REMOVAL).
(4) Remove the rubber grommet that seals the
evaporator inlet and outlet tubes to the rear heater-
A/C housing near the expansion valve.
(5) Remove the three screws that secure the upper
half of the rear heater-A/C housing to the lower half
(Fig. 1).
(6) Remove the three small metal spring clips that
secure the upper half of the rear heater-A/C housing
to the lower half.
(7) Carefully separate and remove the upper half
of the rear heater-A/C housing from the lower half.
(8) Remove the evaporator from the lower half of
the rear heater-A/C housing.
REMOVAL - EVAPORATOR LINE EXTENSION
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 rear heater-A/C unit housing from
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).
(2) Remove the screw that secures the plate that
captures and seals the evaporator line extension
within the base of the rear heater-A/C unit housing
(Fig. 2).
(3) Remove the capture plate from the rear heater-
A/C unit housing base.
(4) Carefully peel back the expansion valve foam
insulator wrap far enough to access the evaporator
line extension sealing plate on the bottom of the
expansion valve (Fig. 3).
(5) Remove the two screws that secure the expan-
sion valve bracket to the lower rear heater-A/C unit
housing.
Fig. 1 Rear Evaporator
1 - UPPER REAR HEATER-A/C HOUSING
2 - EVAPORATOR
3 - LOWER REAR HEATER-A/C HOUSING
Fig. 2 Evaporator Line Extension Plate
1 - REAR HEATER-A/C HOUSING BASE
2 - PLATE
3 - EVAPORATOR LINE EXTENSION
Fig. 3 Evaporator Line Extension
1 - UPPER REAR HEATER-A/C HOUSING
2 - LOWER REAR HEATER-A/C HOUSING
3 - EXPANSION VALVE BRACKET
4 - EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - INSULATOR WRAP
RS
PLUMBING - REAR
24 - 95
EVAPORATOR (Continued)
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