2002 CHRYSLER CARAVAN Service Manual

dead battery open trunk engine coolant spark plugs oil reset technical data carplay

Page 2329 of 2399

CHRYSLER CARAVAN 2002 Service Manual (1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the air clean

(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the screw that secures the liquid line
front section fitting to the top of the filter-drier (Fig.
32).
(4) Disconnect the liquid line fitting from the fil-
ter-drier inlet port.
(5) Remove the seal from the liquid line fitting and
discard.
(6) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier inlet port.
(7) Remove the screw that secures the liquid line
rear section fitting to the top of the filter-drier.
(8) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.(9) Remove the seal from the liquid line fitting and
discard.
(10) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(11) Remove the two nuts that secure the filter-
drier mounting bracket to the weld studs on the side
of the right front strut tower.
(12) Remove the filter-drier and mounting bracket
unit from the studs.
INSTALLATION
NOTE: If the filter-drier is being replaced, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
(1) Position the filter-drier and mounting bracket
unit onto the weld studs on the side of the right front
strut tower.
(2) Install and tighten the two nuts that secure
the filter-drier mounting bracket to the studs.
Tighten the nuts to 10 N´m (89 in. lbs.).
(3) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(5) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(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).
Fig. 32 Front Liquid Lines
1 - A/C GROUND STRAP
2 - NUT
3 - WELD STUD
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - EXPANSION VALVE
7 - FRONT LIQUID LINE REAR SECTION
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - FILTER-DRIER
11 - ROUTING CLIP
12 - FRONT LIQUID LINE FRONT SECTION
24 - 86 PLUMBING - FRONTRS
RECEIVER/DRIER (Continued)
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CHRYSLER CARAVAN 2002 Service Manual 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

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 technicians
that the air conditioning system is equipped with
R-134a.
DIAGNOSIS AND TESTING
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 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 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. 33). Refer to
the appropriate diagnostic information.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 33).
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.
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.
RSPLUMBING - FRONT24-87
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CHRYSLER CARAVAN 2002 Service Manual (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

(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.
(4) Raise the liquid line (discharge) pressure to
about 1793 kPa (260 psi) by placing a piece of card-
board over part of the front side of the condenser. To
place the cardboard properly, remove the upper radi-
ator sight shield from the front fascia. Cover only
enough of the condenser to raise and maintain the
liquid line pressure at the specified level.
(5) Observe the liquid line (discharge) pressure
and liquid line temperature. Using the Charge Deter-
mination Chart (Fig. 33), determine whether the
refrigerant system is operating within the Proper
Charge Range.
(a) If the refrigerant system is operating in the
Undercharged area of the chart, add 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant to
the system.
(b) If the refrigerant system is operating in the
Overcharged area of the chart, reclaim 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant from
the system.(6) Recheck the system charge level following each
refrigerant adjustment. Continue this process until
the system readings are in the Proper Charge Range
area on the Charge Determination Chart.
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
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).
If the air conditioning system is not cooling prop-
erly, determine if the refrigerant system is fully-
charged. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/REFRIGER-
ANT - DIAGNOSIS AND TESTING - REFRIGER-
ANT SYSTEM CHARGE LEVEL).
If the refrigerant system is low or empty; a leak at
a refrigerant line, connector fitting, component, or
component seal is likely. While an oily residue on or
near refrigerant system lines, connector fittings, com-
ponents, or component seals can indicate the general
Fig. 33 Charge Determination Chart, Ambient Test Condition 85ÉF
24 - 88 PLUMBING - FRONTRS
REFRIGERANT (Continued)
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CHRYSLER CARAVAN 2002 Service Manual location of a possible refrigerant leak, the exact leak
location should be confirmed with an electronic leak
detector prior to component repair or replacement.
An electronic leak detector designed for

location of a possible refrigerant leak, the exact leak
location should be confirmed with an electronic leak
detector prior to component repair or replacement.
An electronic leak detector designed for R-134a
refrigerant is recommended for locating and confirm-
ing refrigerant system leaks. See the operating
instructions supplied by the equipment manufacturer
for proper care and use of this equipment.
To detect a leak in the refrigerant system, perform
one of the following procedures as indicated by the
results of the refrigerant system charge level test.
SYSTEM EMPTY
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(2) Connect and dispense 0.283 kilograms (0.625
pounds or 10 ounces) of R-134a refrigerant into the
evacuated refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
REFRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE).
(3) Proceed to the SYSTEM LOW procedures.
SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) 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, then turning the engine off.
(a) Front windows are open.
(b) Rear air conditioner Off (if equipped).
(c) Transaxle in Park.
(d) Front heater-A/C controls set to outside air,
panel mode, blower high, and compressor engaged.
(3) Wait five to seven minutes and, with the
engine not running, use a electronic R-134a leak
detector and search for leaks. Because R-134a refrig-
erant is heavier than air, the leak detector probe
should be moved slowly along the bottom side of all
refrigerant lines, connector fittings and components.
(4) To inspect an evaporator for leaks, insert the
electronic leak detector probe into a floor outlet or
the recirculation air intake.
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 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. 34). Refer to
the appropriate diagnostic information.
²Using a manifold gauge set, a thermocouple and
the Charge Determination Chart (Fig. 34).
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.
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-
RSPLUMBING - FRONT24-89
REFRIGERANT (Continued)
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CHRYSLER CARAVAN 2002 Service Manual 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 possib

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.
(4) Raise the liquid line (discharge) pressure to
about 1793 kPa (260 psi) by placing a piece of card-
board over part of the front side of the condenser. To
place the cardboard properly, remove the upper radi-
ator sight shield from the front fascia. Cover only
enough of the condenser to raise and maintain the
liquid line pressure at the specified level.
(5) Observe the liquid line (discharge) pressure
and liquid line temperature. Using the Charge Deter-
mination Chart (Fig. 34), determine whether therefrigerant system is operating within the Proper
Charge Range.
(a) If the refrigerant system is operating in the
Undercharged area of the chart, add 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant to
the system.
(b) If the refrigerant system is operating in the
Overcharged area of the chart, reclaim 0.057 kilo-
gram (0.125 pound or 2 ounces) of refrigerant from
the system.
(6) Recheck the system charge level following each
refrigerant adjustment. Continue this process until
the system readings are in the Proper Charge Range
area on the Charge Determination Chart (Fig. 34).
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
RECOVERY/RECYCLING STATION
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 must be used
(Fig. 35). Contact PSE or an automotive service
equipment supplier for refrigerant recovery/recycling/
charging equipment. See the operating instructions
Fig. 34 Charge Determination Chart, Ambient Test Condition 85ÉF
24 - 90 PLUMBING - FRONTRS
REFRIGERANT (Continued)
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CHRYSLER CARAVAN 2002 Service Manual supplied by the equipment manufacturer for proper
care and use of this equipment.
MANIFOLD GAUGE SET CONNECTIONSCAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are

supplied by the equipment manufacturer for proper
care and use of this equipment.
MANIFOLD GAUGE SET CONNECTIONSCAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 36). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
²LOW PRESSURE GAUGE HOSE- The low
pressure hose (Blue with Black stripe) attaches to
the suction (low side) service port. This port is
located on the suction line, near the compressor at
the front of the engine compartment.
²HIGH PRESSURE GAUGE HOSE- The high
pressure hose (Red with Black stripe) attaches to the
discharge (high side) service port. This port is located
on the liquid line near the filter-drier at the rear of
the engine compartment.
²RECOVERY/RECYCLING/EVACUATION/
CHARGING HOSE- The center manifold hose (Yel-
low, or White, with Black stripe) is used to recover,
evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold
gauge set are opened, the refrigerant in the system
will escape through this hose.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE
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).
After all refrigerant system leaks have been
repaired and the refrigerant system has been evacu-
ated, a refrigerant charge can be injected into the
system. For the proper amount of the refrigerant
charge, refer to REFRIGERANT CHARGE CAPAC-
ITY . A R-134a refrigerant recovery/recycling/charg-
ing station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. See the operating instructions supplied
by the equipment manufacturer for proper care and
use of this equipment.
REFRIGERANT CHARGE CAPACITY
The R-134a refrigerant system charge capacity for
this vehicle is:
Fig. 35 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134 REFRIGERANT RECOVERY MACHINE
Fig. 36 Manifold Gauge Set - Typical
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK STRIPE)
4 - HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
RSPLUMBING - FRONT24-91
REFRIGERANT (Continued)
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CHRYSLER CARAVAN 2002 Service Manual ²Single or Dual Zone (Front Unit Only - with
2.5L Turbo Diesel)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 Zon

²Single or Dual Zone (Front Unit Only - with
2.5L Turbo Diesel)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
kilograms (2.88 pounds or 46 ounces)
CHARGING PROCEDURE
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(2) A manifold gauge set and a R-134a refrigerant
recovery/recycling/charging station that meets SAE
Standard J2210 should still be connected to the
refrigerant system.
(3) Measure the proper amount of refrigerant and
heat it to 52É C (125É F) with the charging station.
See the operating instructions supplied by the equip-
ment manufacturer for proper use of this equipment.
(4) Open both the suction and discharge valves,
then open the charge valve to allow the heated
refrigerant to flow into the system.
(5) When the transfer of refrigerant has stopped,
close both the suction and discharge valves.
(6) If all of the refrigerant charge did not transfer
from the dispensing device, open all of the windows
in the vehicle and set the heater-air conditioner con-
trols so that the compressor is engaged and the
blower motor is operating at its lowest speed setting.
Run the engine at a steady high idle (about 1400
rpm). If the compressor will not engage, test the com-
pressor clutch control circuit and repair as required.
(7) Open the suction valve to allow the remaining
refrigerant to transfer to the refrigerant system.
WARNING: TAKE CARE NOT TO OPEN THE DIS-
CHARGE (HIGH PRESSURE) VALVE AT THIS TIME.
(8) Close the suction valve and test the system
performance. (Refer to 24 - HEATING & AIR CON-
DITIONING - STANDARD PROCEDURE - A/C PER-
FORMANCE TEST).
(9) Disconnect the charging station and manifold
gauge set from the refrigerant system service ports.
(10) Reinstall the caps onto the refrigerant system
service ports.
(11) Run the HVAC Control Cooldown test to ver-
ify proper operation(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFOREPERFORMING 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).
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. A R-134a refrigerant recovery/re-
cycling/charging station that meets SAE Standard
J2210 must be used to evacuate the refrigerant sys-
tem. See the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment. To evacuate the refrigerant system,
use the following procedure:
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 and a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 to the refriger-
ant system.
(2) Open both the suction and discharge valves
and start the charging station vacuum pump.
(3) When the suction gauge has read 88 kPa (26
in. Hg.) vacuum or greater for 45 minutes, close both
the suction and discharge valves and turn off the
vacuum pump. If the refrigerant system fails to
reach the specified vacuum, the system has a leak
that must be corrected. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM LEAKS).
(4) If the refrigerant system maintains the speci-
fied vacuum for thirty minutes, restart the vacuum
pump, open both the suction and discharge valves,
and evacuate the system for an additional ten min-
utes.
(5) Close both the suction and discharge valves,
and turn off the charging station vacuum pump.
(6) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
24 - 92 PLUMBING - FRONTRS
REFRIGERANT (Continued)
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CHRYSLER CARAVAN 2002 Service Manual STANDARD PROCEDURE - REFRIGERANT
RECOVERY
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/

STANDARD PROCEDURE - REFRIGERANT
RECOVERY
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).
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system, whenever the refrigerant system must
be opened for service. See the operating instructions
supplied by the equipment manufacturer for the
proper care and use of this equipment.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each con-
tains a different additive package. The 10S20H com-
pressor used in this vehicle are designed to use an
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 compressor
is 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.
RSPLUMBING - FRONT24-93
REFRIGERANT (Continued)
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