Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 137
(2) After instrument panel has been removed, sepa-
rate the defroster/demister ducts from the air distribu-
tion duct.
(3) Remove the air distribution duct-to-instrument
panel mounting screws (Fig. 6).
DEFROSTER DUCTS/DEMISTER DUCTS AND
HOSES
REMOVAL AND INSTALLATION
(1) Instrument panel assembly must be removed.
Refer to group 8e, Instrument Panel and Gauges.
(2) After instrument panel has been removed, sepa-
rate the defroster/demister ducts from the air distribu-
tion duct.
(3) Remove the demister tubes and hoses (Fig. 7).
HEATER HOSES
REMOVAL AND INSTALLATION
Review Safety Precautions and Warnings the
in General Information section before proceed-
ing with this operation.
(1) Drain engine cooling system. Refer to Group 7,
Cooling System.
(2) Loosen clamps at each end of hose to be removed
(Figs. 8 or 9).
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple.
CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant into heater A/C unit.
To install, reverse the preceding operation.
Fig. 5 Mode Door Vacuum Actuators
Fig. 6 Air Distribution Duct
Fig. 7 Defroster Ducts/Demister Ducts and Hoses
Fig. 8 Heater Hose Routing — V6 Engine
.
HEATING AND AIR CONDITIONING
24 - 43
WATER CONTROL VALVE
REMOVAL AND INSTALLATION
(1) Drain engine cooling system. Refer to Group 7,
Cooling System.
(2) Locate and loosen clamps at water control valve
(Fig. 10).
(3) Disconnect the vacuum line and heater hoses
from water control valve (mark the heater hoses to
assure correct valve installation).
To install, reverse the preceding operation.
AMBIENT SWITCH
The ambient switch is located in front of the con-
denser.
REMOVAL AND INSTALLATION
(1) Disconnect the wiring connector.
(2) Remove the mounting screw and the ambient
temperature switch.
To install, reverse removal procedure.
ELECTRONIC CYCLING CLUTCH SWITCH (ECCS)
REMOVAL AND INSTALLATION
(1) Disconnect the 4 pin connector at the ECCS.
(2) Remove the tie strap securing the capillary tube
splice to the suction line (Fig. 11).
(3) Remove two attaching screws securing the
switch to the refrigerant line manifold plate at the
expansion valve.
(4) Separate the switch from the manifold plate and
slip the capillary tube from the well on the suction
line.The capillary-tube-well is filled with a spe-
cial temperature conductive grease. Save this
special grease and re-use it when installing the
switch.
To install, reverse the preceding operation.
CONDENSER FAN CONTROL SWITCH—VARIABLE
DISPLACEMENT COMPRESSOR SYSTEM
The Fan Control Switch is located on the plumbing
discharge line at the A/C compressor (Fig. 12).
CAUTION: Refrigerant discharge is not necessary
when removing the Condenser Fan Control Switch.
However, a small amount of refrigerant will vent from
the switch port.
Fig. 9 Heater Hose Routing — 2.5L Engine
Fig. 10 Water Control Valve
Fig. 11 Remove or Install Electronic Cycling Clutch
Switch
Fig. 12 Condenser Fan Control Switch
24 - 44
HEATING AND AIR CONDITIONING
.
REMOVAL AND INSTALLATION
(1) Disconnect wire connector from condenser fan
control switch.
(2) Loosen and quickly rotate the switch counter-
clockwise and separate from the high pressure line
switch port.
To install, reverse the preceding operation.
LOW OR DIFFERENTIAL PRESSURE CUT-OFF
SWITCH
REMOVAL AND INSTALLATION
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Disconnect the boot like wire connector at the
cut-off switch.
(2) Using a sender unit type socket, remove the
switch from the expansion valve (Fig. 13 or 14).
To install, assure an adequate seal by using a small
amount of thread sealing tape on the replacement
switch and reverse the preceding steps.
Evacuate and charge the system.
EXPANSION VALVE
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Remove the boot-type wire connector from the
pressure
cut-off switch.
(2) Remove the attaching bolt in center of refriger-
ant line-plumbing sealing plate (Fig. 15).
(3) Carefully pull the refrigerant line-sealing plate
assembly from the expansion valve towards front of
vehicle. Do not scratch the expansion valve sealing
surfaces with pilot tubes.
(4) Cover the openings on refrigeration line-sealing
plate assembly to prevent dirt or moisture contamina-
tion.
(5) Remove two screws securing the expansion valve
to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket on the
evaporator sealing plate.
(2) Carefully hold the expansion valve to the evapo-
rator sealing plate (do not scratch sealing surface).
Install two attaching screws and tighten to 11
6 3 NIm
(100
6 30 inch lbs.).
(3) Remove and replace the aluminum gasket on the
refrigerant line-sealing plate assembly.
(4) Carefully hold the refrigerant line-sealing plate
assembly
Fig. 13 Low Pressure Cut-Off Switch and Expansion
Valve—Typical
Fig. 14 Differential Pressure Cut-Off Switch and Ex-
pansion Valve—Typical
Fig. 15 Expansion Valve
.
HEATING AND AIR CONDITIONING
24 - 45
to the expansion valve, install bolt and tighten to 23
6 3 NIm
(200
6 30 inch lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL AND INSTALLATION
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Remove the vehicle jack.
(2) Remove the two high pressure refrigerant lines
from the sides of the filter-drier assembly (Fig. 16).
Then carefully separate lines from filter-drier. Discard
the old gaskets.
(3) Cover the open ends of the refrigerant lines to
minimize refrigerant system contamination.
(4) Remove two mounting strap bolts and lift the
filter-drier from vehicle. If replacing the filter-drier
assembly, transfer the mounting strap to replacement
part.
To install, replace both refrigerant line-to-filter-drier
gaskets. Then reverse the preceding operation.
Evacuate and recharge system.
CONDENSER ASSEMBLY
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL AND INSTALLATION
(1) Remove grill assembly. Refer to Group 23, Body.
(2) Remove refrigerant line attaching nut (Fig. 17)
and separate refrigerant line assembly from condenser
sealing plate.
(3) Cover the open ends of the refrigerant lines and
condenser to minimize refrigeration system contami-
nation.
(4) Remove bolts securing the condenser assembly to
the radiator core support. Then lift the condenser
assembly from vehicle.
To install, replace all O-rings and gaskets, coat all
sealing surfaces with approved wax-free refrigerant
oil. Then reverse the preceding operation.
Evacuate and recharge system.
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL AND INSTALLATION
(1) To remove the blower motor, the lower right
instrument panel assembly must be removed. Refer to
Group 8E, Instrument Panel and Gauges.
(2) Remove
blower
assembly-to-heater
housing
mounting screws.
(3) Allow the blower assembly to drop down, and
remove assembly from vehicle.
Fig. 16 Filter-Drier—Typical
Fig. 17 A/C Condenser Removal and
Installation—Typical
24 - 46
HEATING AND AIR CONDITIONING
.
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