2001 CHRYSLER VOYAGER recommended oil

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)

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)