Chrysler 300M, Dodge Interpid. Manual — part 402
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. 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.
(1) Transfer the evaporator probe to the new evap-
orator. Place the evaporator probe in the same loca-
tion as on the previous evaporator(Refer to 24 -
HEATING
&
AIR
CONDITIONING/CONTROLS/
EVAPORATOR
TEMPERATURE
SENSOR
-
INSTALLATION).
(2) Place the evaporator in the lower HVAC hous-
ing.
(3) Insert the access plate inside the HVAC hous-
ing and orientate it so that the locking tab is one-
quarter turn clockwise to where the tab snaps into
the HVAC case detent. Note that the plate will be
flush with the outside of the HVAC housing.
(4) Turn the plate one-quarter turn counter-clock-
wise to seat the locking tab in the HVAC case detent.
(5) Place the top half of the HVAC housing on the
lower half. Tighten fasteners to 2.2 N·m (20 in.
lbs.)(Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/HVAC HOUSING - ASSEM-
BLY).
(6) Install the recirculation door and housing on
the HVAC housing and tighten the screws to 2.2 N·m
(20 in. lbs.).
(7) Install the recirculation door actuator. (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - INSTALLA-
TION)
(8) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
(9) Evacuate the A/C system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(10) Charge the A/C system(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
A/C EXPANSION VALVE
DESCRIPTION
The “H valve” type thermal expansion valve (TXV)
is located at the point where the refrigerant lines
join the a/c evaporator on the engine compartment
side of the dash panel.
The expansion valve is a factory calibrated unit
and cannot be adjusted or repaired. If faulty or dam-
aged, the expansion valve must be replaced.
OPERATION
High-pressure, high temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the evaporator coil. A temperature sensor in
the expansion valve control head monitors the tem-
perature of the refrigerant leaving the evaporator coil
through the suction line, and adjusts the orifice size
at the liquid line to let the proper amount of refrig-
erant into the evaporator coil to meet the vehicle
cooling requirements. Controlling the refrigerant flow
through the evaporator ensures that none of the
refrigerant leaving the evaporator is still in a liquid
state, which could damage the compressor.
DIAGNOSIS AND TESTING - A/C EXPANSION
VALVE
The expansion valve can fail in three different
positions (open, closed or restricted). Note, that in
each case, it is defective and requires replace-
ment.
In an Open Position: this will result in a noisy
compressor or no cooling. The cause can be a broken
spring, broken ball or excessive moisture in the A/C
system. If the spring or ball are found to be defective,
replace the expansion valve. If excessive moisture is
found in the A/C system, recycle the refrigerant.
In a Closed Position: There will be low suction
pressure and no cooling. This may be caused by a
failed power dome or excessive moisture in the A/C
system. If the power dome on the expansion valve is
found to be defective replace the expansion valve. If
excessive moisture is found recycle the refrigerant.
A Restricted Orifice: There will be low suction
pressure and no cooling. This may be caused by
debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the expansion valve and filter/drier.
REMOVAL
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
(1) Recover the refrigerant from the system. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE -REFRIGERANT
RECOVERY)
(2) Remove the engine air inlet tube and the air
distribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER ELEMENT - REMOVAL).
LH
PLUMBING
24 - 39
A/C EVAPORATOR (Continued)
(3) Remove one nut to the a/c lines at the expan-
sion valve.
(4) Loosen the bolt at the receiver/drier to pivot
the lines away from the expansion valve.
(5) Plug or cap the open end of the refrigerant
lines.
(6) Gently pull the a/c line out of the expansion
valve.
(7) Remove two #30 torx bolts retaining the expan-
sion valve to the a/c evaporator.
(8) Remove the expansion valve from the vehicle.
CAUTION: Always install new O-rings when replac-
ing the a/c expansion valve.
INSTALLATION
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold (whenever possi-
ble).
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. 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.
NOTE: Always install new seals or gaskets when
replacing the expansion valve. Failure to do so
could result in an A/C refrigerant leak.
(1) Install the a/c expansion valve on the a/c evap-
orator. Tighten the fasteners to 7 N·m (5 ft. lbs.).
(2) Connect the lines to the expansion valve and
tighten the retaining nut to 8 N·m (6 ft. lbs.).
(3) Tighten the bolt at the receiver/drier to 13.6
N·m (10 ft. lbs.).
(4) Install the engine air inlet tube and the air dis-
tribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER ELEMENT - INSTALLATION).
(5) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(6) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
HEATER CORE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
The HVAC housing must be removed from the
vehicle to service the heater core.
(1) Open the hood and disconnect the negative bat-
tery cable remote terminal from the remote battery
post.
(2) Remove the HVAC unit housing from vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(3) With the HVAC housing out of the vehicle,
remove (2) screws retaining the heater core. Then
pull the heater core out of the HVAC housing.
INSTALLATION
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
(1) Install the heater core in the HVAC housing.
Tighten the retaining screws to 2.2 N·m (20 in. lbs.).
24 - 40
PLUMBING
LH
A/C EXPANSION VALVE (Continued)
(2) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
(3) Connect the negative battery cable remote ter-
minal to the remote battery post.
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is located in the engine compart-
ment near the dash panel on the passenger side of
the vehicle. The receiver/drier incorporates a sight
glass for visual diagnosis of the refrigerant system.
OPERATION
High-pressure liquid refrigerant from the con-
denser flows into the receiver/drier. A drying agent,
called a desiccant, is used to remove any traces of
moisture from the refrigerant system. The receiver/
drier also performs a filtering action to prevent for-
eign material in the refrigerant from contaminating
the expansion valve. In addition, during periods of
high demand air conditioner operation, the receiver/
drier acts as a reservoir to store surplus refrigerant.
The A/C refrigerant must be removed from the sys-
tem before removing the receiver/drier using a refrig-
erant recovery machine. Replace the receiver/drier if
an A/C system is left open for an extended period of
time.
The receiver/drier cannot be repaired and, if faulty,
must be replaced.
REMOVAL
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
(1) Recover the refrigerant from the system. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE -REFRIGERANT
RECOVERY)
(2) Remove the engine air inlet tube and the air
distribution duct on vehicles equipped with 3.2/3.5
liter engine(Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL).
(3) Remove one 8mm hex bolt to the receiver/drier
bracket.
(4) Remove the nut retaining the a/c lines to the
expansion valve.
(5) Gently pry the receiver/drier bracket out of the
strut tower.
(6) Remove one a/c line at the receiver/drier (from
the condenser).
(7) Remove the receiver/drier from vehicle.
(8) Remove the small line from the receiver/drier
to the expansion valve to install on the new receiver/
drier.
NOTE: Always install new O-rings when replacing
filter/drier.
(9) Plug or cap liquid line fittings while system is
open to prevent moisture intrusion.
INSTALLATION
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold (whenever possi-
ble).
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. 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.
NOTE: Upon installation, loosely fit all parts and
lines together before individually tightening them to
prevent damage.
NOTE: Always install new O-rings and lubricate with
the proper refrigerant before installation.
(1) Install the small line from the receiver/drier to
expansion valve on the new receiver/drier.
(2) Install the receiver/drier in the vehicle.
(3) Install the a/c line at the receiver/drier. Tighten
the fastener to 13.6 N·m (10 ft. lbs.).
(4) Install the receiver/drier bracket in the strut
tower.
(5) Install the nut retaining the a/c line to the
expansion valve. Tighten to 8 N·m (6 ft. lbs.).
(6) Install the bolt to the receiver/drier bracket.
(7) Install the engine air inlet tube and the air dis-
tribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER ELEMENT - INSTALLATION).
LH
PLUMBING
24 - 41
HEATER CORE (Continued)
(8) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE -REFRIGERANT SYS-
TEM EVACUATE)
(9) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service
tool couplers and refrigerant dispensing bottles have
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated
with the wrong refrigerant (R-12). There are also
labels posted in the engine compartment of the vehi-
cle and on the compressor identifying to service tech-
nicians that the air conditioning system is equipped
with R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each
contains a different additive package. The 10PA17
compressor used in this vehicle is designed to use an
ND8 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance.
PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil
container immediately to prevent moisture contami-
nation.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
It is important to have the correct amount of lubri-
cant in the a/c system to ensure proper lubrication of
the compressor. Too little lubricant will result in
damage to the compressor. Too much lubricant will
reduce the cooling capacity of the system and conse-
quently result in higher discharge air temperatures.
The lubricant used in the compressor is polyalka-
lene glycol PAG lubricant. Only the refrigerant lubri-
cant approved for use with this vehicle (ND8 PAG
oil) should be used to service the system. Do not use
any other lubricant. The lubricant container should
be kept tightly capped until it is ready for use.
Refrigerant lubricant will quickly absorb any mois-
ture it comes in contact with.
It is not necessary to check or add lubricant unless
it has been lost. Lubricant loss at the leak point will
be evident by the presence of a wet, shiny surface
around the leak. The surface will also over time accu-
mulate dust and dirt in the area of the leak and
appear as an isolated dirty area.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assem-
bled, all components (except the compressor) are
refrigerant oil free. After the system has been
charged with (R-134a) refrigerant and operated, the
oil in the compressor is dispersed through the lines
and components. The evaporator, condenser, and
receiver/drier will retain a significant amount of oil.
Refer to the A/C Component Refrigerant Oil Capaci-
ties table. When a component is replaced, the speci-
fied amount of refrigerant oil must be added. When
the compressor is replaced, the amount of oil that is
retained in the rest of the system must be drained
from the replacement compressor. The oil capacity of
the system, minus the amount of oil still in the
24 - 42
PLUMBING
LH
RECEIVER / DRIER (Continued)
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