Dodge Caliber. Manual — part 1431
NOTE: Typical A/C service port shown.
1. Remove the protective cap (1) from the service
port (2).
2. Recover the refrigerant from the refrigerant system
(refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
3. Using a Schrader-type valve core tool, remove the
valve core (3) from the service port.
4. Install a plug in, or tape over the opened service
port(s).
INSTALLATION
NOTE: Typical A/C service port shown.
1. Lubricate the valve core (3) with clean refrigerant
oil prior to installation. Use only refrigerant oil of
the type recommended for the A/C compressor in
the vehicle.
2. Remove the tape or plug from the service port (2).
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.
3. Using a Schrader-type valve core tool, install and
tighten the valve core into the service port(s).
CAUTION: Do NOT run the engine with a vacuum
pump in operation or with a vacuum present
within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
4. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
5. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from
contamination. Remember to always reinstall the protective cap onto the service port when refrigerant sys-
tem service is complete.
6. Install the protective cap (1) onto the service port.
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PLUMBING
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EVAPORATOR-A/C
DESCRIPTION
NOTE: LHD model shown. RHD model similar.
The A/C evaporator (1) for the heating-A/C system is
mounted in the HVAC housing, which is located
behind the instrument panel. The A/C evaporator and
its insulator (2) are positioned within the HVAC hous-
ing so that all air entering the housing must pass over
the evaporator fins before it is distributed through the
heating-A/C system ducts and outlets.
A tapping block (3) and O-ring seals are used to con-
nect and seal the A/C evaporator tubes (4) to the
underhood refrigerant lines.
The A/C evaporator can only be serviced by removing
and disassembling the HVAC housing assembly.
OPERATION
Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of
liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and
the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The
refrigerant becomes a low-pressure gas when it leaves the A/C evaporator.
The A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced.
REMOVAL
NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service of the A/C
evaporator.
NOTE: LHD model shown. RHD model similar.
1. Remove the HVAC housing and place it on a work-
bench (refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/HOUSING-HVAC
-
REMOVAL).
2. Disassemble the HVAC housing to gain access to
the A/C evaporator (refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/HOUSING-HVAC
- DISASSEMBLY).
NOTE: If the foam insulator around the A/C evap-
orator is deformed or damaged, the insulator must
be replaced.
3. Carefully lift the A/C evaporator (1) and the foam
insulator (2) out of the lower half of the HVAC
housing (3).
NOTE: If the seal around the evaporator tube tap-
ping block is deformed or damaged, the seal must be replaced.
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4. If required, remove the seal (4) from around the evaporator tube tapping block (5).
INSTALLATION
NOTE: If the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounces) of refrigerant oil to the
refrigerant system.
NOTE: LHD model shown. RHD model similar.
1. If removed, install the seal (4) onto the evaporator
tube tapping block (5).
NOTE: Make sure that the foam insulator is prop-
erly positioned in the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam
insulator (2) into the lower half of the HVAC hous-
ing (3).
3. Assemble the HVAC housing (refer to 24 - HEAT-
ING
&
AIR
CONDITIONING/DISTRIBUTION/
HOUSING-HVAC - ASSEMBLY).
4. Install the HVAC housing (refer to 24 - HEATING &
AIR
CONDITIONING/DISTRIBUTION/HOUSING-
HVAC - INSTALLATION).
PM
PLUMBING
24 - 143
LINE-A/C DISCHARGE
DESCRIPTION
NOTE: A/C discharge line for gasoline engine shown in illustration. A/C discharge line for diesel engine
similar.
The A/C discharge line (1) is the refrigerant line that
carries refrigerant from the A/C compressor to the A/C
condenser and includes the high side service port (2)
and a fitting (3) for the A/C pressure transducer (4).
CAUTION: Use only the O-ring seals specified for
the vehicle. Failure to use the correct O-ring seals
will cause the refrigerant system connections to
leak.
The A/C discharge line has no serviceable parts
except for the metal gaskets (5) and rubber O-ring
seals (6) and the high side service port valve core.
The O-ring seals used on the connections are made
from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals and gaskets must be
replaced whenever the A/C discharge line is removed
and installed.
The A/C discharge line cannot be repaired and, if
leaking or damaged it must be replaced.
REMOVAL
WARNING: Review safety precautions and warnings in this group before performing this procedure (refer to
24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal
injury or death.
NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system
(refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
3. Raise and support the vehicle.
4. Remove the splash shield from the right side frame
rail
(refer
to
23
-
BODY/EXTERIOR/SPLASH
SHIELD-RIGHT SIDE RAIL - REMOVAL).
5. Remove the nut (1) that secures the A/C discharge
line (2) to the A/C compressor (3).
6. Disconnect the A/C discharge line from the A/C
compressor and remove and discard the O-ring
seal and gasket.
7. Install plugs in, or tape over the opened discharge
line fitting and the compressor port.
8. Lower the vehicle.
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