Chrysler RG Voyager. Manual - part 1228

INSTALLATION

A/C COMPRESSOR

NOTE: If a replacement A/C compressor is being
installed, be certain to check the refrigerant oil level
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
Use only refrigerant oil of the type recommended
for the A/C compressor in the vehicle.

(1) Position the A/C compressor into the engine

compartment.

(2) On models with the 2.4L, 2.5L and 2.8L engine,

loosely install the four bolts that secure the A/C com-
pressor to the A/C compressor mounting bracket.
Tighten the bolts to 28 N·m (21 ft. lbs.).

(3) On models with the 3.3L and 3.8L engines,

loosely install the two bolts and the two nuts that
secure the A/C compressor to the engine. Tighten
each of the fasteners to 54 N·m (40 ft. lbs.) using the
following sequence:

• upper nut at the front of the compressor.

• lower nut at the front of the compressor.

• upper bolt at the rear of the compressor.

• lower bolt at the rear of the compressor.
(4) Connect the engine wire harness connector to

the A/C clutch coil connector. On models equipped
with the 3.3L and 3.8L engines, engage the engine
wire harness connector to the bracket located at the
top of the A/C compressor.

(5) Remove the tape or plugs from the suction and

discharge line fittings and the compressor ports.

(6) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them and a new gasket
onto the A/C suction and discharge line.

(7) Connect the A/C suction and discharge lines to

the A/C compressor.

(8) Install the nut that secures the A/C suction

and discharge lines to the A/C compressor. Tighten
the nuts to 23 N·m (17 ft. lbs.).

(9) Install the accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

INSTALLATION).

(10) On models with the 2.5L and 2.8L diesel

engine, install the belly pan (Refer to 23 - BODY/EX-
TERIOR/BELLY PAN - INSTALLATION).

(11) Lower the vehicle.
(12) Reconnect the negative battery cable.
(13) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM EVACUATE).

(14) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -

FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM CHARGE).

A/C COMPRESSOR MOUNTING BRACKET-2.4L/
2.5L/2.8L ENGINES

(1) Position the A/C compressor mounting bracket

onto the engine.

(2) Install the bolts that secure the A/C compressor

mounting bracket to the engine. Tighten the bolts to
54 N·m (40 ft. lbs.).

(3) Install the A/C compressor onto the mounting

bracket (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/A/C COMPRESSOR
- INSTALLATION).

A/C CONDENSER

DESCRIPTION

The A/C condenser (Fig. 8) is located in the front of

the engine compartment behind the front fascia. The
A/C condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
A/C compressor to give up its heat to the air passing
over the condenser fins, which causes the refrigerant
to cool and change to a liquid state.

The A/C condenser may be removed for service

without removing the radiator and cooling fan from
the vehicle.

The A/C condenser for vehicles equipped with the

2.4L, 3.3L and 3.8L engines are equipped with an
integral automatic transmission cooler and tapping
block. This design is referred to as a combination
cooler.

OPERATION

When air passes through the fins of the A/C con-

denser, the high-pressure refrigerant gas within the
A/C condenser gives up its heat. The refrigerant then
condenses as it leaves the A/C condenser and
becomes a high-pressure liquid. The volume of air
flowing over the condenser fins is critical to the
proper cooling performance of the A/C system. There-
fore, it is important that there are no objects placed
in front of the radiator grille openings at the front of
the vehicle or foreign material on the condenser fins
that might obstruct proper air flow. Also, any factory-
installed air seals or shrouds must be properly rein-
stalled following radiator or A/C condenser service.

The A/C condenser cannot be repaired and, if

faulty or damaged, it must be replaced.

PLUMBING - FRONT

24 - 77

A/C COMPRESSOR (Continued)

REMOVAL

2.4L/3.3L/3.8L ENGINES

WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT - WARNINGS)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTIONS). Failure to follow
the warnings and cautions could result in possible
personal injury or death.

NOTE: Before removing the A/C condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the A/C condenser and radiator. The air seals must
be reinstalled in their proper locations in order for
the A/C and engine cooling systems to perform as
designed.

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM RECOVERY).

(2) Remove the front fascia (Refer to 13 - FRAME

BUMPERS/BUMPERS/FRONT

FASCIA

REMOVAL).

NOTE: It is not necessary to remove the quick-con-
nect fittings from the transmission oil cooler tap-

ping block when disconnecting the transmission oil
cooler lines from the cooler.

(3) Disconnect the transmission oil cooler lines

from the quick-connect fittings located on the trans-
mission oil cooler tapping block on the left side of the
A/C condenser (combination cooler) (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE - TRANSMISSION COOLING) (Fig. 9).

(4) Disconnect the A/C discharge line and the A/C

liquid line from the right side of the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/A/C DISCHARGE LINE -
REMOVAL) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/A/C LIQUID
LINE - REMOVAL) (Fig. 10).

(5) Install plugs in, or tape over the opened A/C

discharge and liquid line fittings and the condenser
ports.

(6) Disengage the retaining clips that secure the

upper A/C condenser mounting brackets to the radi-
ator.

(7) Lift the A/C condenser (combination cooler)

straight up to disengage the lower mounting brackets
from the radiator and carefully remove the condenser
from the engine compartment.

Fig. 8 A/C Condenser - 2.4L/3.3L/3.8L Engines

1 - A/C CONDENSER (COMBINATION COOLER)
2 - AUTO TRANS COOLER TAPPING BLOCK
3 - UPPER CONDENSER MOUNTING BRACKET (2)
4 - RADIATOR
5 - LOWER CONDENSER MOUNTING BRACKET (2)

Fig. 9 A/C Condenser - Left Hand View

1 - A/C CONDENSER (COMBINATION COOLER)
2 - AUTO TRANS COOLER TAPPING BLOCK
3 - UPPER CONDENSER MOUNTING BRACKET (2)
4 - RADIATOR
5 - LOWER CONDENSER MOUNTING BRACKET (2)

24 - 78

PLUMBING - FRONT

A/C CONDENSER (Continued)

2.5L/2.8L ENGINES

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM RECOVERY).

(2) Remove the front fascia (Refer to 13 - FRAME

BUMPERS/BUMPERS/FRONT

FASCIA

REMOVAL).

(3) Disconnect the A/C discharge line and the A/C

liquid line from the A/C condenser (Fig. 11) (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- FRONT/A/C DISCHARGE LINE - REMOVAL) and

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING

FRONT/A/C

LIQUID

LINE

REMOVAL).

(4) Install plugs in, or tape over the opened A/C

discharge and liquid line fittings and the condenser
ports.

(5) Remove the three screws that secure the auto-

matic transmission fluid cooler to the A/C condenser
and position the cooler out of the way.

(6) Remove the three bolts that secure the A/C

condenser to the cooling module.

(7) Lift the A/C condenser far enough to disengage

the condenser from the lower right mounting bracket
and remove the condenser from the engine compart-
ment.

INSTALLATION

2.4L/3.3L/3.8L ENGINES

NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.7 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.

NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.

Fig. 10 A/C Condenser - Right Hand View

1 - A/C CONDENSER (COMBINATION COOLER)
2 - LOWER CONDENSER MOUNTING BRACKET (2)
3 - CONDENSER PORTS
4 - RETAINING CLIP (2)
5 - UPPER CONDENSER MOUNTING BRACKET (2)
6 - RADIATOR

Fig. 11 A/C Condenser - 2.5L/2.8L Engines

1 - A/C CONDENSER
2 - AUTOMATIC TRANSMISSION FLUID COOLER
3 - BOLT (3)
4 - SCREW (3)
5 - LOWER MOUNTING BRACKET
6 - A/C LIQUID LINE
7 - A/C DISCHARGE LINE

PLUMBING - FRONT

24 - 79

A/C CONDENSER (Continued)

(1) Position the A/C condenser (combination cooler)

into the engine compartment.

(2) Carefully lower the A/C condenser straight

down to engage the lower mounting brackets to the
radiator.

(3) Engage the upper A/C condenser mounting

brackets to the radiator. Be sure that the upper
retaining clips are fully engaged to the upper mount-
ing brackets.

(4) Remove the tape or plugs from the opened

refrigerant line fittings and the condenser ports.

(5) Connect the A/C discharge line and the A/C liq-

uid line to the A/C condenser (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
A/C DISCHARGE LINE - INSTALLATION) and
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/A/C LIQUID LINE - INSTAL-
LATION).

(6) Connect the transmission oil cooler lines to the

quick-connect fittings located on the transmission
cooler tapping block. Be sure that the quick-connect
fittings are fully engaged to the lines (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE - TRANSMISSION COOLING).

(7) Install the front fascia (Refer to 13 - FRAME &

BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).

(8) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).

(9) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).

2.5L/2.8L DIESEL ENGINES

NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.

(1) Position the A/C condenser onto the engine

compartment.

(2) Carefully lower the A/C condenser straight

down into the lower right mounting bracket.

(3) Install the three bolts that secure the A/C con-

denser to the cooling module. Tighten the bolts to 5
N·m (45 in. lbs.).

(4) Position

the

automatic

transmission

fluid

cooler onto the A/C condenser and install the three
screws. Tighten the screws securely.

(5) Remove the tape or plugs from the opened A/C

discharge and liquid line fittings and the condenser
ports.

(6) Connect the A/C discharge line and the A/C liq-

(7) Install the front fascia (Refer to 13 - FRAME &

BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).

(8) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).

(9) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).

A/C DISCHARGE LINE

REMOVAL

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM RECOVERY).

(2) Remove the right headlamp unit (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

EXTERIOR/

HEADLAMP UNIT - REMOVAL).

(3) Remove the nut that secures the A/C discharge

line to the right end of the A/C condenser (Fig. 12).

(4) Disconnect the A/C discharge line from the A/C

condenser and remove and discard the O-ring seal
and gasket.

(5) Install plugs in, or tape over the opened dis-

charge line fitting and the condenser inlet port.

(6) Raise and support the vehicle.
(7) On models equipped with the 2.5L and 2.8L

diesel engines, remove the belly pan from under-

24 - 80

PLUMBING - FRONT

A/C CONDENSER (Continued)

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