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Dodge Caliber. Manual - part 1424

BEVERAGE COOLER

NOTE: LHD model shown. RHD model similar.

1. Remove the instrument panel top cover (1) (refer to

BODY/INSTRUMENT

PANEL/COVER-IN-

STRUMENT PANEL TOP - REMOVAL).

2. Disconnect the hose (2) from the beverage cooler

outlet (3).

3. To disengage the four retaining tabs (4), slide the

beverage cooler outlet toward the center of the
cover and remove the outlet.

INSTALLATION

INSTRUMENT PANEL

NOTE: Driver side air outlet shown. Passenger side outlet similar.

NOTE: LHD model shown. RHD model similar.

1. Position the air outlet (2) onto the bezel (3).

2. Install the four screws (1) that secure the air outlet

to the bezel. Tighten the screws to 2 N·m (17 in.
lbs.).

3. Depending on the outlet being serviced, install the

instrument cluster bezel (refer to 23 - BODY/IN-
STRUMENT PANEL/BEZEL-CLUSTER - INSTAL-
LATION) or the passenger side IP bezel (refer to
23 - BODY/INSTRUMENT PANEL/BEZEL-IP PAS-
SENGER SIDE - INSTALLATION).

BEVERAGE COOLER

NOTE: LHD model shown. RHD model similar.

DISTRIBUTION

24 - 113

1. Position the beverage cooler outlet (3) to the top of

the storage bin and engage the four retaining tabs
(4) by sliding the outlet toward the center of the
instrument panel top cover (1). Make sure the tabs
are fully engaged.

2. Connect the hose (2) to the beverage cooler outlet.

3. Install the instrument panel top cover (refer to 23 -

BODY/INSTRUMENT

PANEL/COVER-INSTRU-

MENT PANEL TOP - INSTALLATION).

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DISTRIBUTION

PLUMBING

TABLE OF CONTENTS

page

PLUMBING

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DIAGNOSIS AND TESTING

REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . . 118

STANDARD PROCEDURE

REFRIGERANT SYSTEM SERVICE

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

REFRIGERANT SYSTEM RECOVERY . . . . . . . 120
REFRIGERANT SYSTEM EVACUATE . . . . . . . . 120
REFRIGERANT SYSTEM CHARGE . . . . . . . . . . 121

ACCUMULATOR-A/C

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

COMPRESSOR-A/C

DESCRIPTION

A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 125
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . 125
HUB AND PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 125

OPERATION

A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 126
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . 127
HUB AND PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 127

DIAGNOSIS AND TESTING

A/C COMPRESSOR NOISE TESTING . . . . . . . . 127

REMOVAL

PULLEY AND BEARING . . . . . . . . . . . . . . . . . . . . 128
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 129

INSPECTION

HUB AND PULLEY INSPECTION . . . . . . . . . . . . 130

INSTALLATION

PULLEY AND BEARING . . . . . . . . . . . . . . . . . . . . 131
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 132

CONDENSER-A/C

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

CORE-HEATER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

CORE-VALVE-SERVICE PORT

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

EVAPORATOR-A/C

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

LINE-A/C DISCHARGE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

LINE-A/C LIQUID

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

LINE-A/C SUCTION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

OIL-A/C REFRIGERANT

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
STANDARD PROCEDURE

REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . . . 159

REFRIGERANT-A/C

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

TUBE-A/C VARIABLE ORIFICE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

TUBE-CONDENSATION DRAIN

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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PLUMBING

DESCRIPTION

The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components.
The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon
tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a
smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight alu-
minum or steel, and commonly use braze-less fittings.

Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and
can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should
be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80
millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s).

OPERATION

High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must
be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a
good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good con-
dition and properly routed.

Depending on vehicle, model and market application, refrigerant lines are connected to each other or other A/C
system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerant system,
flat gaskets and O-rings are used to seal the refrigerant system connections.

The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced.

WARNING

WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be performed by
qualified service personnel. Severe personal injury or death may result from improper service procedures.

WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the eyes,
nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system. Serious eye injury can
result from direct contact with the refrigerant. If eye contact occurs, seek medical attention immediately.

WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recommended. Severe personal injury or death may result from
improper service procedures.

WARNING: If accidental system discharge occurs, ventilate the work area before resuming service. Large
amounts of refrigerant released in a closed work area will displace the oxygen and cause suffocation and
death.

WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high.
As a result, anything that comes in contact with the refrigerant will freeze. Always protect the skin or del-
icate objects from direct contact with the refrigerant.

WARNING: The R-134a service equipment or the vehicle refrigerant system should not be pressure tested or
leak tested with compressed air. Some mixtures of air and R-134a have been shown to be combustible at
elevated pressures. These mixtures are potentially dangerous, and may result in fire or explosion causing
property damage, personal injury or death.

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