Chrysler RG Voyager. Manual - part 1235

INSTALLATION

NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core should be pre-filled
with the proper engine coolant mixture prior to
reconnecting the heater hoses to the heater core
hose fittings (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - REAR/HEATER CORE - STAN-
DARD

PROCEDURE

REAR

HEATER

CORE

FILLING).

(1) Carefully position the rear heater core into the

rear HVAC housing.

(2) Using hand pressure, press firmly and evenly

on the molded plastic tank of the rear heater core
until the four retaining tabs that secure the rear
heater core in the rear HVAC housing fully engage.

(3) Remove the plugs or tape from the rear heater

core fittings and both rear heater hoses.

(4) Pre-fill the rear heater core (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
REAR/HEATER CORE - STANDARD PROCEDURE -
REAR HEATER CORE FILLING).

(5) Connect the rear heater hoses to the rear

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

(6) Install the screw that secures the front of the

rear HVAC housing to the right inner quarter panel.
Tighten the screw to 11 N·m (97 in. lbs.).

(7) Install the screw that secures the back of the

rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N·m (97 in. lbs.).

(8) Install the rear distribution duct (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- REAR/DISTRIBUTION DUCT - INSTALLATION).

(9) Install the trim panels onto the right inner

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

TRIM

PANEL

INSTALLATION).

(10) If the heater core is being replaced, flush the

cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

HEATER HOSES

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) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).

(2) Raise and support the vehicle.
(3) Using spring tension clamp pliers, compress

and slide the clamps off of each end of the hose being
removed.

CAUTION: DO NOT apply excessive pressure on
heater tubes or connections when removing heater
hoses. Excessive pressure may damage or deform
the tubes, causing an engine coolant leak.

(4) Disconnect the front underbody heater inlet

and return hose by carefully twisting the hoses back
and forth on the underbody tubes, while gently pull-
ing them away from the end of the tubes (Fig. 9).

(5) If necessary, carefully cut the hose ends and

peel the hoses off of the tubes.

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

INSTALLATION

(1) Install the front underbody heater inlet and

return hoses by carefully twisting the hoses back and

Fig. 8 Rear Heater Core

1 - REAR HVAC HOUSING OUTLET
2 - REAR HVAC UNIT HOUSING
3 - RETAINING TABS (4)
4 - REAR HEATER CORE
5 - RIGHT REAR WHEEL HOUSE
6 - REAR HEATER HOSES

PLUMBING - REAR

24 - 105

HEATER CORE (Continued)

forth on the underbody tubes, while gently pushing
them onto the end of the tubes.

CAUTION: DO NOT apply excessive pressure on
heater tubes or connections when removing heater
hoses. Excessive pressure may damage or deform
the tubes, causing an engine coolant leak.

(2) Using spring tension clamp pliers, compress

and slide the clamps that secure each end of the
heater hose over the tubes. Release the clamp when
it is over the tube.

(3) Lower the vehicle.
(4) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

LIQUID LINE

REMOVAL

NOTE: On models equipped with the rear A/C sys-
tem, 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 underbody liquid line.

(1) Recover the refrigerant from the refrigerant

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

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the air cleaner housing from the right

side of the engine compartment.

(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. 10).

(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 front liquid line to the top of the receiver/drier.

(9) Disconnect the rear section of the front liquid

line from the top of the receiver/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 port.

(11) Remove the nut that secures the suction and

liquid line to the A/C expansion valve.

(12) Disconnect the suction line and liquid lines

from the A/C expansion valve and remove and dis-
card the seals.

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

tion and liquid line fittings and expansion valve
ports.

(14) Raise and support the vehicle.
(15) Remove the tie strap and disconnect the front

liquid line from the underbody liquid line and remove
and discard the O-ring seal (Fig. 11).

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

line fittings.

(17) Lower the vehicle.
(18) Remove the liquid line from the engine com-

partment.

INSTALLATION

(1) Position the rear section of the front liquid line

into the engine compartment.

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

liquid line fittings and expansion valve ports.

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

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

Fig. 9 Underbody Heater Hose Connections - Front

1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY LINES

24 - 106

PLUMBING - REAR

HEATER HOSES (Continued)

(4) Connect the suction and liquid lines to the A/C

expansion valve.

(5) Install the nut that secures the suction and liq-

uid lines 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 for the receiver/drier and the receiver/drier
port.

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

refrigerant oil and install it on the liquid line fitting.

(8) Reconnect the liquid line to the receiver/drier.
(9) Install the bolt that secures the 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/
A/C PRESSURE TRANSDUCER - INSTALLATION).

(13) Connect the drain tube to the wiper module

drain on the right side of the engine compartment.

(14) Install the air cleaner housing into the right

side of the engine compartment.

(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the liquid line

rear section extension fitting and the underbody liq-
uid line.

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

refrigerant oil and install it on the underbody liquid
line.

(18) Connect the liquid line rear section extension

fitting to the underbody liquid line. Tighten the fit-
tings to 23 N·m (17 ft. lbs.).

(19) Install a new tie strap just forward of the con-

nections between the underbody plumbing and the
engine compartment plumbing for the rear heating-
A/C system.

(20) Lower the vehicle.
(21) Reconnect the negative battery cable.
(22) Evacuate the refrigerant system (Refer to 24 -

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

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

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

Fig. 10 Liquid Line

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)

Fig. 11 Underbody A/C Line Front Connections –

Typical

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

PLUMBING - REAR

24 - 107

LIQUID LINE (Continued)

SUCTION LINE

REMOVAL

NOTE: On models equipped with the rear A/C sys-
tem, the rear section of the front A/C suction line
also includes a hose and tube extension that con-
nects the front suction line to the underbody suc-
tion line.

(1) Recover the refrigerant from the refrigerant

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

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the air cleaner top cover and snorkel

from the air cleaner housing located on the right side
of the engine compartment.

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

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

(5) Remove the nut that secures the suction line to

the A/C compressor.

(6) Disconnect the suction line from the A/C com-

pressor and remove and discard the seal.

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

tion line fitting and the compressor port.

(8) Disengage the retainer that secures the suction

line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment (Fig. 12).

(9) Remove the nut that secures the suction and

liquid lines to the front A/C expansion valve.

(10) Disconnect the suction and liquid lines from

the front A/C expansion valve and remove and dis-
card the O-ring seals.

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

tion and liquid line fittings and expansion valve
ports.

(12) Raise and support the vehicle.
(13) Remove the tie strap and disconnect the suc-

tion line extension fitting from the underbody suction
line and remove and discard the O-ring seal (Fig. 13).

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

tion line fittings.

(15) Lower the vehicle.

(16) Remove the suction line from the engine com-

partment.

INSTALLATION

(1) Position the suction line into the engine com-

partment.

Fig. 12 Suction Line

1 - A/C EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - RETAINING CLIP
5 - SUCTION LINE

Fig. 13 Underbody 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 - 108

PLUMBING - REAR

Content .. 1233 1234 1235 1236 ..