Chrysler RG Voyager. Manual - part 1234

(8) Remove the seals from the evaporator line

extension fittings and discard.

(9) Install plugs in, or tape over the opened evap-

orator line extension fittings and both expansion
valve ports.

INSTALLATION

REAR A/C EVAPORATOR

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

(1) Carefully lower the rear A/C evaporator and its

foam wrap into the lower half of the rear HVAC
housing.

(2) Position the upper half of the rear HVAC hous-

ing onto the lower half.

(3) Install the three metal spring clips that secure

the upper half of the rear HVAC housing to the lower
half.

(4) Install the three screws that secure the upper

half of the rear HVAC housing to the lower half.
Tighten the screws to 2 N·m (17 in. lbs.).

(5) Install the rubber grommet that seals the evap-

orator inlet and outlet tubes to the rear HVAC hous-
ing near the rear A/C expansion valve.

(6) Install the rear A/C expansion valve onto the

rear A/C evaporator (Refer to 24 - HEATING & AIR

CONDITIONING/PLUMBING - REAR/A/C EXPAN-
SION VALVE - INSTALLATION).

(7) Install the rear evaporator extension line onto

the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C EVAPORATOR - EVAPORATOR EXTENSION
LINE - INSTALLATION).

(8) Install the rear HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).

REAR EVAPORATOR LINE EXTENSION

(1) Remove the tape or plugs from the evaporator

line extension fittings and both expansion valve
ports.

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

refrigerant oil and install them on the evaporator
line extension fittings.

(3) Position the evaporator line extension to the

rear A/C expansion valve and the lower rear HVAC
housing.

(4) Position the evaporator line extension seal

plate over the expansion valve stud.

(5) Install the nut that secures the evaporator line

extension seal plate to the expansion valve stud.
Tighten the nut to 23 N·m (17 ft. lbs.).

(6) Position the expansion valve bracket over the

expansion valve stud.

(7) Install the two screws that secure the expan-

sion valve bracket to the lower rear HVAC housing.
Tighten the screws to 2 N·m (17 in. lbs.).

(8) Install the nut that secures the expansion

valve bracket to the expansion valve stud. Tighten
the nut to 23 N·m (17 ft. lbs.).

(9) Install the foam insulating over the rear A/C

expansion valve.

(10) Position the flange over the rear evaporator

line extension and into the lower rear HVAC housing.

(11) Install the screw that secures the flange to

the rear lower HVAC housing. Tighten the screw to 2
N·m (17 in. lbs.).

(12) Install the rear HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).

A/C EXPANSION VALVE

DESCRIPTION

The rear “H” valve-type thermal expansion valve

(TXV) is located at the rear of the rear HVAC hous-
ing between the evaporator line extension and the
evaporator coil. High-pressure, low temperature liq-
uid refrigerant from the liquid line passes through
the expansion valve orifice, converting it into a low-

Fig. 4 Rear A/C Evaporator Line Extension

1 - UPPER REAR HVAC HOUSING
2 - LOWER REAR HVAC HOUSING
3 - EXPANSION VALVE BRACKET
4 - EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - FOAM INSULATING

PLUMBING - REAR

24 - 101

A/C EVAPORATOR (Continued)

pressure, low-temperature mixture of liquid and gas
before it enters the evaporator coil.

OPERATION

The rear A/C expansion valve controls the high-

pressure, low temperature liquid refrigerant from the
rear liquid line and converts it into a low-pressure,
low-temperature mixture of liquid and gas before it
enters the rear A/C evaporator. A mechanical sensor
in the rear A/C expansion valve monitors the temper-
ature and pressure of the refrigerant leaving the rear
A/C evaporator through the rear suction line, and
adjusts the orifice size at the rear liquid line port to
let the proper amount of refrigerant into the rear A/C
evaporator to meet the vehicle A/C cooling require-
ments. Controlling the refrigerant flow through the
rear A/C evaporator ensures that none of the refrig-
erant leaving the rear A/C evaporator is still in a liq-
uid state, which could damage the A/C compressor.

For diagnosis and testing of the rear A/C expansion

valve, refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/A/C EXPANSION VALVE
- DIAGNOSIS AND TESTING.

The rear A/C expansion valve is factory calibrated

and cannot be adjusted or repaired and, if faulty or
damaged, it must be replaced.

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.

(1) Remove the rear HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - REMOVAL).

(2) Carefully remove the foam insulating from

around the rear A/C expansion valve (Fig. 5).

(3) Remove the rear evaporator line extension from

the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C

EVAPORATOR

LINE

EXTENSION - REMOVAL).

(4) Remove the two screws that secure the rear

A/C expansion valve to the rear evaporator tube seal-
ing plate.

(5) Remove the rear A/C expansion valve from the

rear evaporator tubes and remove and discard the
seals.

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

orator tube fittings, evaporator ports and all expan-
sion valve ports.

INSTALLATION

(1) Remove the tape or plugs from the rear A/C

evaporator tube fittings, rear A/C evaporator ports
and all rear expansion valve ports.

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

refrigerant oil and install them on the rear evapora-
tor tube fittings.

(3) Position the rear A/C expansion valve onto the

rear evaporator tubes.

(4) Install the two screws that secure the rear A/C

expansion valve to the rear evaporator tube sealing
plate. Tighten the screws to 11 N·m (97 in. lbs.).

(5) Install the rear evaporator line extension onto

the rear A/C expansion valve (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - REAR/
A/C

EVAPORATOR

LINE

EXTENSION - INSTALLATION).

(6) Install the foam insulating over the rear A/C

expansion valve.

(7) Install the rear HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/HVAC HOUSING - INSTALLATION).

HEATER CORE

DESCRIPTION

The rear heater core (Fig. 6) is located near the

front of the rear HVAC housing, behind the right
rear wheel house. It is a heat exchanger made of
rows of tubes and fins. One end of the heater core is
fitted with a molded plastic tank that includes the

Fig. 5 Rear A/C Evaporator Line Extension

1 - UPPER REAR HVAC HOUSING
2 - LOWER REAR HVAC HOUSING
3 - EXPANSION VALVE BRACKET
4 - REAR EVAPORATOR LINE EXTENSION
5 - EXPANSION VALVE STUD
6 - REAR A/C EXPANSION VALVE

24 - 102

PLUMBING - REAR

A/C EXPANSION VALVE (Continued)

mounting provisions for the heater core and connec-
tions for the heater core inlet and outlet tubes.

The rear heater core can be serviced without

removing the rear HVAC housing from the vehicle.

OPERATION

Engine coolant is circulated through underbody

heater hoses to the rear heater core at all times. As
the coolant flows through the rear heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
rear blend-air door allows control of the rear heater
output air temperature by controlling how much of
the air flowing through the rear HVAC housing is
directed through the rear heater core.

The rear heater core cannot be repaired and, if

faulty or damaged, it must be replaced.

STANDARD PROCEDURE

REAR HEATER CORE FILLING

The rear heater core is positioned in the rear

HVAC housing at a higher level than the radiator fill
opening. Therefore, when the cooling system is
drained and refilled, gravity will not totally refill the
rear heater core. This may result in two problems:

1. Insufficient coolant level in the engine cooling

system, which may result in engine overheating.

2. Air entrapped within the rear heater core,

which may result in insufficient rear heater perfor-
mance.

There are two methods that may be employed to

prevent these problems:

1. Pre-filling of the rear heater core.
2. Thermal cycling of the engine cooling system.
Following are descriptions of both prevention

methods, as well as a method to verify rear heater
performance.

PRE-FILLING

NOTE: Take the proper precautions to protect the
carpeting below the heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to clean up any spills.

If the rear heater core or the rear HVAC housing

have been removed from the vehicle for service, the
rear heater core may be pre-filled with the proper
engine coolant mixture prior to reconnecting the
heater hoses to the heater core hose fittings.

(1) The heater core should be installed in the rear

HVAC housing, and the rear HVAC housing should
be installed in the vehicle.

(2) Insert the small end of an appropriate funnel

into the upper hose fitting of the heater core (Fig. 7).

(3) Carefully pour the proper pre-mixed engine

coolant solution into the rear heater core through a
funnel until coolant begins to appear at the lower
hose fitting of the rear heater core.

(4) Connect the heater hoses to the rear heater

core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER HOSE -
INSTALLATION).

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

THERMAL CYCLING

If the rear heater core was emptied and was not

pre-filled, it will be necessary to thermal cycle the
vehicle at least two times to ensure that the rear
heater core is properly filled.

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

(2) Start the engine and allow it to operate until

the thermostat opens.

Fig. 6 Rear Heater Core

1 - REAR HEATER CORE
2 - MOUNTING PROVISION (2)
3 - HEATER CORE TUBES

PLUMBING - REAR

24 - 103

HEATER CORE (Continued)

(3) Turn the engine off and allow it to cool.
(4) With the engine cold and not running, check

and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).

(5) Start the engine and allow it to operate until

the thermostat opens again.

(6) Turn the engine off and allow it to cool down

again.

(7) With the engine cold and not running, check

and top off the engine coolant level as necessary
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).

(8) Check the performance of the rear heater.

Refer to REAR HEATER PERFORMANCE CHECK.

REAR HEATER PERFORMANCE CHECK

Successful completion of the rear heater perfor-

mance check will confirm that the rear heater core is
properly filled with engine coolant. If the check is not
successful, either there is still air trapped in the rear
heater core or the rear heater plumbing is restricted.
This check should be performed with the vehicle in a
shop where the ambient temperature is about 21° C
(70° F).

(1) Start the engine and allow it to idle until it

warms up to normal operating temperature.

(2) Adjust the A/C-heater controls so that the front

heater is turned Off and the rear heater is set for full
Heat with the rear blower motor at its highest speed
setting.

(3) Use an accurate test thermometer to measure

the temperature of the air being discharged from the

rear heater outlet located at the base of the right
C-pillar.

(4) Proper discharge air temperature readings

should be from 57° to 63° C (135° to 145° F).

REMOVAL

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).

(2) Remove the trim panels from the right inner

quarter panel and the right D-pillar (Refer to 23 -
BODY/INTERIOR/QUARTER

TRIM

PANEL

REMOVAL).

(3) Remove the rear heater distribution duct (Refer

to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION

REAR/DISTRIBUTION

DUCT

REMOVAL).

(4) Remove the screw that secures the back of the

rear HVAC housing to the right D-pillar.

(5) Remove the screw that secures the front of the

rear HVAC housing to the right inner quarter panel.

NOTE: Take the proper precautions to protect the
carpeting below the heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to clean up any spills.

(6) Disconnect the heater hoses from the rear

heater core (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER HOSE -
REMOVAL).

(7) Install plugs in, or tape over the opened heater

core fittings and both heater hoses (Fig. 8).

(8) Release the four retaining tabs that secure the

rear heater core to the rear HVAC housing and
remove the heater core.

Fig. 7 Pre-Filling Heater Core - Typical

1 - REAR HEATER CORE

24 - 104

PLUMBING - REAR

HEATER CORE (Continued)

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