Chrysler RG Voyager. Manual - part 1231

(4) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

HEATER RETURN HOSE

REMOVAL

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: The heater return tube is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.

(1) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).

(2) Using spring tension clamp pliers, compress

and slide the clamps off of each end of the hose being
removed (Fig. 25), (Fig. 26) or (Fig. 27).

CAUTION:
DO NOT apply excessive pressure on heater tubes
or

connections

when

removing

heater

hoses.

Excessive pressure may damage or deform the
tubes/heater core, causing an engine coolant leak.

(3) Disconnect each hose end by carefully twisting

the hose back and forth on the tube or nipple, while
gently pulling it away from the end of the tube or
nipple.

NOTE:
Replacement of the heater return hoses will be
required if the hose ends are cut for removal.

(4) If necessary, carefully cut the hose end and

peel the hose off of the tube or nipple.

INSTALLATION

(1) Using spring tension clamp pliers, compress

and slide the clamp away from the end of the heater
return hose.

(2) Install each hose end by carefully twisting the

hose back and forth while gently pushing it onto the
tube.

(3) Using spring tension clamp pliers, compress

and slide the clamps onto each end of the heater
return hose.

(4) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE).

Fig. 24 Heater Inlet Hose - 3.3L/3.8L With Rear

Heater

1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE

Fig. 25 Heater Return Hose - 2.4L Shown, 2.5L

Typical

1 - ENGINE OUTLET NIPPLE
2 - HEATER INLET HOSE
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE
7 - HEATER RETURN HOSE
8 - ENGINE INLET NIPPLE

PLUMBING - FRONT

24 - 89

HEATER INLET HOSE (Continued)

LIQUID LINE

REMOVAL

NOTE: The front A/C liquid line is serviced in two
sections. The front section connects between the
A/C condenser and the receiver/drier and includes
the high side service port. The rear section con-
nects between the receiver/drier and the A/C expan-
sion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
rear heating-A/C system, the rear section of the
front A/C liquid line also includes a hose and tube
extension that connects the front liquid line to the
liquid line for the rear A/C system.

FRONT SECTION

(1) Recover the refrigerant from the refrigerant

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

(2) Disconnect and isolate the negative battery

cable.

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

ELECTRICAL/LAMPS/LIGHTING

EXTERIOR/

HEADLAMP UNIT - REMOVAL).

(4) Remove the nut that secures the A/C liquid line

to the right end of the A/C condenser (Fig. 28).

(5) Disconnect the A/C liquid line from the A/C

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

(6) Install plugs in, or tape over the opened liquid

line fitting and the condenser outlet port.

(7) Remove the air cleaner housing and the air

inlet tube (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - REMOVAL).

(8) Disengage the retainer that secures the liquid

line routing clip to the top of the right frame rail
ahead of the front strut tower in the engine compart-
ment (Fig. 29).

(9) Remove the bolt that secures the front section

of the A/C liquid line to the receiver/drier.

(10) Disconnect the A/C liquid line from the receiv-

er/drier and remove and discard the O-ring seal.

(11) Install plugs in, or tape over the opened liquid

line fitting and the receiver/drier inlet port.

Fig. 26 Heater Return Hose - 3.3L/3.8L W/O Rear

Heater

1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE (TYPICAL)

Fig. 27 HEATER HOSES - 3.3/3.8L With Rear Heater

1 - STUD
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - TO ENGINE OUTLET NIPPLE
5 - TO UNDERBODY PLUMBING
6 - TO HEATER RETURN TUBE & HOSE

24 - 90

PLUMBING - FRONT

HEATER RETURN HOSE (Continued)

(12) Remove the front section of the A/C liquid line

from the engine compartment.

REAR SECTION

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD

PROCEDURE

REFRIGERANT

RECOVERY).

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the air cleaner housing and the air

inlet tube (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - REMOVAL).

(4) Disconnect the drain tube from the wiper mod-

ule drain on the right side of the engine compart-
ment.

(5) Remove the A/C pressure transducer (Refer to

24 - HEATING & AIR CONDITIONING/CONTROLS
-

FRONT/A/C

PRESSURE

TRANSDUCER

REMOVAL).

(6) If equipped, remove the nut that secures the

A/C ground strap to the weld stud on the top of the
right front strut tower (Fig. 29).

(7) If equipped, remove the A/C ground strap eye-

let terminal connector from the weld stud.

(8) Remove the bolt that secures the rear section

of the A/C liquid line to the receiver/drier.

(9) Disconnect the A/C liquid line from the receiv-

er/drier and remove and discard the O-ring seal.

(10) Install plugs in, or tape over the opened liquid

line fitting and the receiver/drier outlet port.

(11) Remove the nut that secures the A/C suction

line and the A/C liquid line to the A/C expansion
valve.

(12) Disconnect the A/C suction line and the A/C

liquid line from the A/C expansion valve and remove
and discard the O-ring seals.

(13) Install plugs in, or tape over the opened suc-

tion line and liquid line fittings and both expansion
valve ports.

(14) On RHD models, remove the rear section of

the A/C liquid line from the retaining bracket located
at the top of the dash panel

(15) If the vehicle is equipped with the optional

rear heating-A/C system, go to Step 16. If the vehicle
is not equipped with the optional rear heating-A/C
system, go to Step 22.

(16) Raise and support the vehicle.
(17) Cut the tie strap located just forward of the

connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
ing-A/C system (Fig. 30).

(18) Disconnect the A/C liquid line extension fit-

ting from the underbody liquid line fitting for the
rear A/C system.

(19) Remove the O-ring seal from the underbody

liquid line fitting and discard.

Fig. 28 A/C Condenser - Typical

1 - A/C CONDENSER
2 - A/C DISCHARGE LINE
3 - A/C LIQUID LINE
4 - NUT (2)

Fig. 29 A/C Liquid Line - LHD Shown, RHD Typical

1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - A/C EXPANSION VALVE
7 - A/C LIQUID LINE (REAR SECTION)
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - RECEIVER/DRIER
11 - ROUTING CLIP
12 - A/C LIQUID LINE (FRONT SECTION)

PLUMBING - FRONT

24 - 91

LIQUID LINE (Continued)

(20) Install plugs in, or tape over the opened liquid

line fittings.

(21) Lower the vehicle.
(22) Remove the rear section of the A/C liquid line

from the engine compartment.

INSTALLATION

FRONT SECTION

(1) Position the front section of the A/C liquid line

into the engine compartment.

(2) Remove the tape or plugs from the liquid line

fitting and the receiver/drier inlet port.

(3) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it onto the liquid line fit-
ting.

(4) Connect the A/C liquid line to the receiver/

drier.

(5) Install the bolt that secures the A/C liquid line

to the receiver/drier. Tighten the bolt to 11 N·m (97
in. lbs.).

(6) Engage the retainer that secures the liquid line

routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.

(7) Install the air cleaner housing and air inlet

tube (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER HOUSING - INSTALLATION).

(8) Remove the tape or plugs from the condenser

outlet port and the liquid line fitting.

(9) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it and a new gasket onto
the liquid line fitting.

(10) Connect the A/C liquid line to the A/C con-

denser.

(11) Install the nut that secures the A/C liquid line

to the A/C condenser. Tighten the nut to 23 N·m (17
ft. lbs.).

(12) Install the right headlamp unit (Refer to 8 -

ELECTRICAL/LAMPS/LIGHTING

EXTERIOR/

HEADLAMP UNIT - INSTALLATION).

(13) Reconnect the negative battery cable.
(14) Evacuate the refrigerant system (Refer to 24 -

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

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

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

REAR SECTION

(1) Position the rear section of the A/C liquid line

into the engine compartment.

(2) Remove the tape or plugs from the suction line

and liquid line fittings and both expansion valve
ports.

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

refrigerant oil and install them onto the suction line
and liquid line fittings.

(4) Reconnect the A/C liquid line and the A/C suc-

tion line to the A/C expansion valve.

(5) Install the nut that secures the rear section of

the A/C liquid line and the A/C suction line to the
A/C expansion valve. Tighten the nut to 23 N·m (17
ft. lbs.).

(6) Remove the tape or plugs from the liquid line

fitting and the receiver/drier outlet port.

(7) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the liquid line fitting.

(8) Reconnect the A/C liquid line to the receiver/

drier.

(9) Install the bolt that secures the A/C liquid line

to the receiver/drier. Tighten the bolt to 11 N·m (97
in. lbs.).

(10) If equipped, reinstall the A/C ground strap

eyelet terminal connector onto the weld stud on the
top of the right front strut tower (if equipped).

(11) If equipped, install the nut that secures the

A/C ground strap to the weld stud. Tighten the nut
to 12 N·m (106 in. lbs.).

(12) Install the A/C pressure transducer (Refer to

24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - INSTAL-
LATION).

(13) Connect the drain tube to the wiper module

drain on the right side of the engine compartment.

(14) Install the air cleaner housing and air inlet

tube (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER HOUSING - INSTALLATION)..

Fig. 30 Underbody A/C Line Connections

1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES

24 - 92

PLUMBING - FRONT

LIQUID LINE (Continued)

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