Dodge Caliber. Manual — part 1433
12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash
panel and position the vacuum line out of the way.
13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6).
14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-
plane seals.
15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
16. Remove the A/C liquid and suction line assembly from the engine compartment.
INSTALLATION
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system
leak.
NOTE: LHD model shown in illustrations. RHD model similar.
1. Position the A/C liquid and suction line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
3. Lubricate the rubber O-rings on new dual-plan seals with clean refrigerant oil and install the seals onto the liquid
and suction line fittings. Use only the specified seals as they are made of special materials compatible to the
R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt
to 12 N·m (105 in. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash
panel.
PM
PLUMBING
24 - 149
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to
4.5 N·m (40 in. lbs.).
8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WASHER RESERVOIR - INSTALLATION).
9. Position the heat shield (3) onto the studs (2)
located on the dash panel in the engine compart-
ment.
10. Install the three nuts (1) that secure the heat
shield to the dash panel. Tighten the nuts to 1
N·m (10 in. lbs.).
NOTE:
Illustration
shown
with
front
fascia
removed for clarity.
11. Raise and support the vehicle.
12. Remove the tape or plugs from the liquid line fit-
ting and the condenser port.
13. Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it and a new gasket onto
the liquid line fitting. Use only the specified O-ring
as it is made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
14. Reach up through the opening in the bottom of
the front fascia and connect the A/C liquid line (1)
to the A/C condenser (2) and install the retaining
nut (3). Tighten the nut to 5 N·m (44 in. lbs.).
15. Install the A/C accumulator (refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/ACCU-
MULATOR - INSTALLATION).
16. Lower the vehicle.
17. Reconnect the negative battery cable.
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.
18. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACUATE)
19. Charge the A/C system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
24 - 150
PLUMBING
PM
LINE-A/C SUCTION
DESCRIPTION
The A/C suction line is serviced in two sections. The
upper section of the A/C suction line (1) is the refrig-
erant line that carries refrigerant from the A/C evapo-
rator to the A/C accumulator. The lower section of the
A/C suction line (2) carries refrigerant from the A/C
accumulator to the A/C compressor. The upper portion
of the A/C suction line is only serviced as an assembly
with the A/C liquid line (5).
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 lower A/C suction line and the A/C liquid/suction
line assembly has no serviceable parts except for the
rubber O-ring seals (3) and metal gaskets (4) and the
low 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 lower A/C suction line and/or the A/C liquid/suction line
assembly is removed and installed.
The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and, if leaking or damaged
they 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: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the
refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of
the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor.
NOTE: LHD model shown in illustrations. RHD model similar.
Upper A/C Suction Line
NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line.
PM
PLUMBING
24 - 151
NOTE:
Illustration
shown
with
front
fascia
removed for clarity.
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 A/C accumulator (refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/ACCUMU-
LATOR-A/C - REMOVAL).
5. Reach up through the opening in the bottom of the
front fascia located in the right front corner of the
vehicle and remove the nut (3) that secures the
A/C liquid line (1) to the A/C condenser (2).
6. Disconnect the A/C liquid line from the A/C con-
denser and remove and discard the O-ring seal
and gasket.
7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports.
8. Lower the vehicle.
9. Remove the three nuts (1) that secure the heat
shield (3) to the studs (2) located on the dash
panel in the engine compartment and remove the
heat shield.
24 - 152
PLUMBING
PM
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