2001 CHRYSLER VOYAGER refrigerant type

(6) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (18 in. lbs.).
(7) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Reconnect the liquid line fitting to the filter-
drier inlet port on the top of the filter-drier.
(10) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 2 N´m (18 in. lbs.).
(11) Reinstall the air cleaner housing into the
right side of the engine compartment.
(12) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas. Even though
R-134a does not contain chlorine, it must be
reclaimed and recycled just like CFC-type refriger-
ants. This is because R-134a is a greenhouse gas and
can contribute to global warming.
OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system. R-134a
refrigerant system service ports, service tool couplers
and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an
R-134a system is not accidentally contaminated with
the wrong refrigerant (R-12). There are also labels
posted in the engine compartment of the vehicle and
on the compressor identifying to service techniciansthat the air conditioning system is equipped with
R-134a.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: The proper amount of R-134a refrigerant for
the refrigerant system in this model is:
²Single or Dual Zone (Front Unit Only)- 0.96
kilograms (2.13 pounds or 34 ounces)
²Three Zone (Front and Rear Units)- 1.31
kilograms (2.88 pounds or 46 ounces)
The procedure that follows should be used to deter-
mine whether the refrigerant system contains the
proper refrigerant charge. Symptoms of an improper
refrigerant charge (low) include: poor air conditioner
performance, fog emitted from the air conditioner
outlets, a hissing sound from the expansion valve/
evaporator area. There are two different methods
with which the refrigerant charge level may be
tested:
²Using a DRBIIItscan tool, a thermocouple and
the Charge Determination Chart (Fig. 31). Refer to
the appropriate diagnostic information.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 31).
A temperature probe is required to measure liquid
line temperature. The clamp-on, Type K thermocou-
ple temperature probe used in this procedure is
available through the DaimlerChrysler Professional
Service Equipment (PSE) program. This probe (PSE
#66-324-0014 or #80PK-1A) is compatible with tem-
perature-measuring instruments that accept Type K
thermocouples, and have a miniature connector
input. Other temperature probes are available
through aftermarket sources; however, all references
in this procedure will reflect the use of the probe
made available through the PSE program.
In order to use the temperature probe, a digital
thermometer will also be required. If a digital ther-
mometer is not available, an adapter is available
through the PSE program that will convert any stan-
dard digital multimeter into a digital thermometer.
This adapter is designed to accept any standard Type
K thermocouple. If a digital multimeter is not avail-
able, this tool is also available through the PSE pro-
gram.
RSPLUMBING - FRONT24-87
RECEIVER/DRIER (Continued)

ND-8 PAG refrigerant oil. Use only refrigerant oil of
this same type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance. PAG
refrigerant oil is much more hygroscopic than min-
eral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil
container should always be kept tightly capped until
it is ready to be used. After use, recap the oil con-
tainer immediately to prevent moisture contamina-
tion.
STANDARD PROCEDURE - REFRIGERANT OIL
LEVEL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
When an air conditioning system is assembled at
the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The receiver/drier, evaporator, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.
It is important to have the correct amount of oil in
the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.
It will not be necessary to check the oil level in the
compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
Refrigerant oil must be added when an receiver/
drier, evaporator or condenser is replaced. See the
Refrigerant Oil Capacities chart for the proper
amount of refrigerant oil to add. When a compressoris replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of fresh new
refrigerant oil that was drained out of the old com-
pressor.
REFRIGERANT OIL CAPACITIES
Front A/C Front & Rear
A/C
COMPONENT ml fl oz ml fl oz
Compressor 150 5.0 220 7.4
Filter-Drier 30 1.0 30 1.0
Condenser 30 1.0 30 1.0
Front Evaporator 60 2.0 60 2.0
Rear Evap. (including
underbody lines)N/A N/A 60 2.0
Compressor Drain and measure the oil
from the old compressor -
See text above.
SUCTION LINE
REMOVAL
The front air conditioner suction line includes the
low side service port on a section of tubing located
near the compressor. On models equipped with the
optional rear air conditioner, the front air conditioner
suction line also includes a suction line hose and
tube extension that connects the front suction line to
the suction line for the rear air conditioner.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
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.
24 - 92 PLUMBING - FRONTRS
REFRIGERANT OIL (Continued)

(1) Position the suction line into the engine com-
partment (Fig. 34).
(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 on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install and tighten the nut that secures the
suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Reconnect the suction line fitting to the com-
pressor suction port.
(10) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) If the vehicle is equipped with the optional
rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting (Fig. 35).
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.
(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. 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 heater
and air conditioner.
(20) Lower the vehicle.
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
SERVICE PORTS
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Remove the protective cap from the A/C service
port (Fig. 36).
(2) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(3) Using a standard Schrader-type valve core tool,
remove the valve core from the A/C service port.
(4) Install a plug in or tape over the opened A/C
service port.
Fig. 36 A/C Service Port - Typical
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
24 - 94 PLUMBING - FRONTRS
SUCTION LINE (Continued)

INSTALLATION
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Lubricate the A/C service port valve core with
clean refrigerant oil prior to installation. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the A/C service port.CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
(4) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(5) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(6) Reinstall the protective cap onto the A/C ser-
vice port.
RSPLUMBING - FRONT24-95
SERVICE PORTS (Continued)

(12) Install plugs in, or tape over the opened evap-
orator line extension fittings and both expansion
valve ports.
INSTALLATION - REAR EVAPORATOR
NOTE: If the evaporator is being replaced, add 60
milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Carefully lower the evaporator and its foam
wrap into the lower half of the rear heater-A/C hous-
ing.
(2) Position the upper half of the rear heater-A/C
housing onto the lower half (Fig. 1).
(3) Install the three small metal spring clips that
secure the upper half of the rear heater-A/C housing
to the lower half.
(4) Install and tighten the three screws that secure
the upper half of the rear heater-A/C housing to the
lower half. Tighten the screws to 2 N´m (18 in. lbs.).
(5) Install the rubber grommet that seals the evap-
orator inlet and outlet tubes to the rear heater-A/C
housing near the expansion valve.
(6) Reinstall the rear expansion valve onto the
rear evaporator. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EXPANSION
VALVE - INSTALLATION).
(7) Reinstall the rear evaporator extension line
onto the expansion valve. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - REAR/EVAPO-
RATOR - INSTALLATION - EVAPORATOR EXTEN-
SION LINE).
(8) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
INSTALLATION - 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
expansion valve and the rear heater-A/C housing
base (Fig. 3).
(4) Position the evaporator line extension seal
plate over the expansion valve stud.
(5) Install and tighten 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 and tighten the two screws that secure
the expansion valve bracket to the lower rear heater-
A/C unit housing. Tighten the screws to 2 N´m (18 in.
lbs.).
(8) Install and tighten the nut that secures the
expansion valve bracket to the expansion valve stud.
Tighten the nut to 23 N´m (17 ft. lbs.).
(9) Carefully restore the expansion valve foam
insulator wrap back around the expansion valve.
(10) Position the plate that captures and seals the
evaporator line extension onto the rear heater-A/C
unit housing base (Fig. 2).
(11) Install and tighten the screw that secures the
capture plate to the base of the rear heater-A/C unit
housing. Tighten the screw to 2 N´m (18 in. lbs.).
(12) Reinstall the rear heater-A/C unit housing
into the vehicle. (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION - REAR/REAR
HEATER-A/C HOUSING - INSTALLATION).
EXPANSION VALVE
DESCRIPTION
The rear ªHº valve-type thermal expansion valve
(TXV) is located at the rear of the rear heater-A/C
unit housing between the evaporator line extension
and the evaporator coil. High-pressure, low tempera-
ture liquid refrigerant from the liquid line passes
through the expansion valve orifice, converting it into
a low-pressure, low-temperature mixture of liquid
and gas before it enters the evaporator coil. Models
equipped with the optional Automatic Temperature
Control (ATC) system also have an electric solenoid
that is located on the inboard side of and integral to
the rear expansion valve. The expansion valve is a
factory calibrated unit and cannot be adjusted or
repaired. If faulty or damaged, the expansion valve
must be replaced.
OPERATION
A mechanical sensor in the expansion valve control
head monitors the temperature and pressure of the
refrigerant leaving the evaporator coil through the
suction line, and adjusts the orifice size at the liquid
line to let the proper amount of refrigerant into the
evaporator coil to meet the vehicle cooling require-
ments. Controlling the refrigerant flow through the
evaporator ensures that none of the refrigerant leav-
ing the evaporator is still in a liquid state, which
could damage the compressor. The expansion valve
solenoid on models equipped with the optional ATC
system electrically blocks refrigerant from passing
through the expansion valve orifice and circulating
24 - 98 PLUMBING - REARRS
EVAPORATOR (Continued)

REFRIGERANT
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL 2.5L DIESEL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: The proper amount of R-134a refrigerant for
the refrigerant system in this model is:
²Single or Dual Zone (Front Unit Only - 2.5L Die-
sel) ± 0.91 kilograms (2.00 pounds or 32 ounces)
²Single or Dual Zone (Front Unit Only) - 0.96
kilograms (2.13 pounds or 34 ounces)
²Three Zone (Front and Rear Units) - 1.31 kilo-
grams (2.88 pounds or 46 ounces)
The procedure that follows should be used to deter-
mine whether the refrigerant system contains the
proper refrigerant charge. Symptoms of an improper
refrigerant charge (low) include: poor air conditionerperformance, fog emitted from the air conditioner out-
lets, a hissing sound from the expansion valve/evapo-
rator area. There are two different methods with
which the refrigerant charge level may be tested:
²Using a DRBIIItscan tool, a thermocouple and
the Charge Determination Chart (Fig. 3). Refer to
the appropriate diagnostic information.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 3).
A temperature probe is required to measure liquid
line temperature. The clamp-on, Type K thermocou-
ple temperature probe used in this procedure is
available through the DaimlerChrysler Professional
Service Equipment (PSE) program. This probe (PSE
#66-324-0014 or #80PK-1A) is compatible with tem-
perature-measuring instruments that accept Type K
thermocouples, and have a miniature connector
input. Other temperature probes are available
through aftermarket sources; however, all references
in this procedure will reflect the use of the probe
made available through the PSE program.
In order to use the temperature probe, a digital ther-
mometer will also be required. If a digital thermometer
is not available, an adapter is available through the
PSE program that will convert any standard digital
multimeter into a digital thermometer. This adapter is
designed to accept any standard Type K thermocouple.
If a digital multimeter is not available, this tool is also
available through the PSE program.
NOTE: When connecting the service equipment
couplings to the refrigerant system service ports,
be certain that the valve of each coupling is fully
closed. This will reduce the amount of effort
required to make the connection.
(1) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set or a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 to the refriger-
ant system.
(2) Attach a clamp-on thermocouple to the liquid
line. The thermocouple must be placed as close to the
A/C pressure transducer as possible to accurately
observe liquid line temperature.
(3) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run at idle under the following condi-
tions for five minutes.
(a) Front windows are open.
(b) Transaxle in Park.
(c) Front heater-A/C controls set to outside air,
full cool, panel mode, blower high, and compressor
engaged.
(d)
If the vehicle is so equipped, the rear heater-
A/C controls must be set to full cool and blower high.
Fig. 2 AIR INTAKE AND HEATER PIPE ASSEMBLY
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24a - 4 HEATING & AIR CONDITIONINGRG
HEATER PIPES - DIESEL SUPPLEMENTAL HEATER (Continued)