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Dodge Caliber. Manual - part 1425

WARNING: The engine cooling system is designed to develop internal pressures up to 145 kilopascals (21
pounds per square inch). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs,
radiator drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot and
under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening the cooling system
for service. Failure to observe this warning can result in serious burns from the heated engine coolant.

CAUTION

CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or
parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will
result.

CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These
refrigerant oils are not compatible and damage to the A/C system will result.

CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/re-
charging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the
recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks
through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C
system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is
recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or
seal conditioners voids the warranty for the A/C system.

CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with caution,
even after the system has been discharged. Never open or loosen a connection before recovering the refrig-
erant.

CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and
refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may
cause operational troubles or even serious damage if present in more than very small quantities. Before
disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from
entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant
system or uncap a replacement component until you are ready to service the system. Immediately after
disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will
prevent contamination from entering the A/C system.

CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a con-
tainer of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after
using. Store refrigerant oil only in a clean, airtight, and moisture-free container.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the
A/C system. Failure to follow this caution will result in serious A/C compressor damage.

CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head
pressure and can cause compressor noise and A/C system failure.

PLUMBING

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DIAGNOSIS AND TESTING

REFRIGERANT SYSTEM LEAKS

WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested
with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures
are potentially dangerous and may result in fire or explosion causing property damage, personal injury or
death.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If acci-
dental system discharge occurs, ventilate work area before resuming service.

NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually
inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C
system leak location.

NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to com-
pletely evacuate and recharge the A/C system.

Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa
(50 psi) (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT). If less than 345 kPa (50 psi), proceed to SYSTEM EMPTY . If greater than 345
kPa (50 psi), go to SYSTEM LOW .

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or

greater vacuum) (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE). Determine if the system holds a vacuum for 15 minutes. If vacuum is
held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2.

2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system

(refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE) and proceed to Step 1 of the System Low procedure.

SYSTEM LOW

1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.

2. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes.

•

Doors or windows open

•

Transaxle in Park or Neutral with the parking brake set (depending on application)

•

A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged

CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant
system.

3. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a

refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant
leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air
outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye.

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PLUMBING

STANDARD PROCEDURE

REFRIGERANT SYSTEM SERVICE EQUIPMENT

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

WARNING: Eye protection must be worn when servicing an air conditioning refrigerant system. Turn off
(rotate clockwise) all valves on the equipment being used, before connecting to or disconnecting from the
refrigerant system. Failure to observe these warnings may result in personal injury or death.

When servicing the A/C system, an R-134a refrigerant
recovery/recycling/charging station that meets SAE
standard J2210 must be used (1). Contact an automo-
tive service equipment supplier for refrigerant recov-
ery/recycling/charging

equipment.

Refer

the

operating instructions supplied by the equipment man-
ufacturer for proper care and use of this equipment.

A manifold gauge set (1) may be needed with some
recovery/recycling/charging equipment. The manifold
gauge set should have manual shut-off valves (2 and
6), or automatic back-flow valves located at the ser-
vice port connector end of the manifold gauge set
hoses (4 and 5). This will prevent refrigerant from
being released into the atmosphere.

MANIFOLD GAUGE SET CONNECTIONS

CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not compatible
and system damage will result.

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•

LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to the low side
service port. This port is located on the A/C liquid line near the right front strut tower.

•

HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to the high side
service port. This port is located on the A/C discharge line near the A/C condenser.

•

RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow, or White,
with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When the low or high pres-
sure valves on the manifold gauge set are opened, the refrigerant in the system will escape through this hose.

REFRIGERANT SYSTEM RECOVERY

An R-134a refrigerant recovery/recycling/charging sta-
tion (1) that meets SAE standard J2210 must be used
to recover the refrigerant from the R-134a refrigerant
system. Refer to the operating instructions supplied by
the equipment manufacturer for the proper care and
use of this equipment.

REFRIGERANT SYSTEM EVACUATE

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the
A/C system. Failure to follow this caution will result in serious A/C compressor damage.

NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil
is very difficult to remove and will cause a reliability problem with the A/C compressor.

If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of
time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be
used. This will eliminate the possibility of contaminating the refrigerant system.

If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled.
Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating
levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at
near room temperature when exposed to vacuum. To evacuate the refrigerant system:

NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the cou-
pling is fully closed. This will reduce the amount of effort required to make the connection.

1. Recover the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-

CEDURE - REFRIGERANT SYSTEM RECOVERY).

2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set

with vacuum pump and refrigerant recovery equipment (refer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - REFRIGERANT SYSTEM SERVICE EQUIPMENT). Do not operate the
engine with a vacuum on the A/C system.

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PLUMBING

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