2003 CHRYSLER CARAVAN heater

REAR SECTION
(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 housing from 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.
(5) Remove the A/C pressure transducer from the
fitting on the front liquid line rear section. (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(6) Remove the nut that secures the A/C ground
strap to the weld stud on the top of the right front
strut tower (Fig. 28).(If equipped)
(7) Remove the A/C ground strap eyelet terminal
connector from the weld stud. (If equipped)
(8) Remove the screw that secures the liquid line
rear section fitting to the top of the filter-drier.
(9) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(10) Remove the seal from the liquid line fitting
and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(12) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(13) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(14) Remove the seals from the suction line and
liquid line fittings and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 29).
(19) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(20) Remove the seal from the underbody liquid
line fitting and discard.
(21) Install plugs in, or tape over the opened liquid
line fittings.(22) Lower the vehicle.
(23) Remove the front liquid line rear section from
the engine compartment.
INSTALLATION
The front air conditioner liquid line is serviced in
two sections. The front section connects between the
condenser and the filter/drier and includes the high
side service port on the fitting for the filter/drier. The
rear section connects between the filter/drier and the
expansion valve and includes the fitting for the A/C
pressure transducer. On models equipped with the
optional rear air conditioner, the rear section of the
front air conditioner liquid line also includes a liquid
line hose and tube extension that connects the front
liquid line to the liquid line for the rear air condi-
tioner.
FRONT SECTION
(1) Position the front section of the front liquid
line into the engine compartment.
(2) Remove the tape or plugs from the liquid line
front section fitting for the filter-drier and the filter-
drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Reconnect the liquid line fitting to the filter-
drier inlet port on the top of the filter-drier.
(5) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
Fig. 29 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
24 - 82 PLUMBING - FRONTRS
LIQUID LINE (Continued)
ProCarManuals.com

(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Install a new dual plane seal and reconnect the
liquid line fitting to the condenser outlet port on the
right side of the cooling module.
(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (16 in. lbs.).
(13) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the front liquid line
into the engine compartment.
(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) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(9) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).(10) Reinstall the A/C ground strap eyelet terminal
connector onto the weld stud on the top of the right
front strut tower. (If equipped)
(11) Install and tighten the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.) (If equipped).
(12) Reinstall the A/C pressure transducer onto
the fitting on the front liquid line rear section. (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS - FRONT/A/C PRESSURE TRANSDUCER -
INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the battery negative cable.
(16) If the vehicle is equipped with the optional
rear air conditioner, go to Step 17. If the vehicle does
not have the optional rear air conditioner, go to Step
23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
(21) 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.
(22) Lower the vehicle.
(23) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(24) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
RECEIVER/DRIER
DESCRIPTION
The filter-drier is mounted in a bracket secured to
the right front strut tower in the engine compart-
ment. The filter-drier is connected between the front
and rear sections of the liquid line between the con-
denser outlet and the evaporator inlet. The filter-
drier cannot be repaired. If the filter-drier is faulty
or damaged, or if the refrigerant system has been
contaminated or left open to the atmosphere for an
RSPLUMBING - FRONT24-83
LIQUID LINE (Continued)
ProCarManuals.com

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.
(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. 31), 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
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).
24 - 86 PLUMBING - FRONTRS
REFRIGERANT (Continued)
ProCarManuals.com

(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.
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. 32). Contact PSE or an automotive service
equipment supplier for refrigerant recovery/recycling/
charging equipment. See the operating instructionssupplied by the equipment manufacturer for proper
care and use of this equipment.
Fig. 31 Charge Determination Chart, Ambient Test Condition 85ÉF
Fig. 32 Refrigerant Recovery/Recycling Station -
Typical
1 - R-134 REFRIGERANT RECOVERY MACHINE
RSPLUMBING - FRONT24-87
REFRIGERANT (Continued)
ProCarManuals.com

(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 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 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 ofthis 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).
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.
RSPLUMBING - FRONT24-89
REFRIGERANT (Continued)
ProCarManuals.com

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.
(5) Remove the nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage 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 (Fig. 34).( If Equipped).
(10) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve.(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(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) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 35).
(17) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.
(18) Remove the seal from the underbody suction
line fitting and discard.
(19) Install plugs in, or tape over the opened suc-
tion line fittings.
(20) Lower the vehicle.
(21) Remove the suction line from the engine com-
partment.
INSTALLATION
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.
Fig. 34 Suction Line
1 - EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - ROUTING CLIP (If Equipped)
5 - SUCTION LINE
Fig. 35 Underbody Connections
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES
RSPLUMBING - FRONT24-91
SUCTION LINE (Continued)
ProCarManuals.com

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) Position the suction line into the engine com-
partment.
(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. (If Equipped).
(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) Install a new dual plan seal and reconnect the
suction line fitting to the compressor 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.
(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 theengine 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 (Low
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 - 92 PLUMBING - FRONTRS
SUCTION LINE (Continued)
ProCarManuals.com

PLUMBING - REAR
TABLE OF CONTENTS
page page
EVAPORATOR
DESCRIPTION.........................94
OPERATION...........................94
REMOVAL
REMOVAL - REAR EVAPORATOR.........94
REMOVAL - EVAPORATOR LINE
EXTENSION.........................95
INSTALLATION
INSTALLATION - REAR EVAPORATOR.....96
INSTALLATION - EVAPORATOR LINE
EXTENSION.........................96
EXPANSION VALVE
DESCRIPTION.........................96
OPERATION...........................97
DIAGNOSIS AND TESTING - EXPANSION
VALVE ..............................97
REMOVAL.............................97
INSTALLATION.........................98
HEATER CORE
DESCRIPTION.........................98
OPERATION...........................98STANDARD PROCEDURE - HEATER CORE
FILLING.............................98
REMOVAL.............................99
INSTALLATION........................100
HEATER HOSE
REMOVAL............................100
INSTALLATION........................101
SUCTION LINE
REMOVAL............................101
INSTALLATION........................102
UNDERBODY LINES
DESCRIPTION........................103
OPERATION..........................103
REMOVAL
REMOVAL - REAR HEATER LINES.......104
REMOVAL - REAR AIR CONDITIONING
LINES.............................104
INSTALLATION
INSTALLATION - REAR HEATER LINES....105
INSTALLATION - REAR AIR CONDITIONING
LINES.............................105
EVAPORATOR
DESCRIPTION
The rear evaporator is located in the rear heater-
A/C unit housing, behind the right rear wheel house.
The evaporator is positioned in the rear heater-A/C
housing so that all air that enters the housing must
pass over the fins of the evaporator before it is dis-
tributed through the system ducts and outlets. How-
ever, air passing over the evaporator fins will only be
conditioned when the compressor is engaged and cir-
culating refrigerant through the evaporator tubes.
The rear heater-A/C unit housing must be removed
from the vehicle to access the evaporator for service.
The evaporator cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
OPERATION
Refrigerant enters the rear evaporator from the
rear expansion valve as a low-temperature, low-pres-
sure liquid. As air flows over the fins of the evapora-
tor, the humidity in the air condenses on the fins,
and the heat from the air is absorbed by the refrig-
erant. Heat absorption causes the refrigerant to boil
and vaporize. The refrigerant becomes a low-pressure
gas when it leaves the evaporator.
REMOVAL
REMOVAL - REAR EVAPORATOR
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),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Remove the rear heater-A/C unit housing from
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).
(2) Remove the rear evaporator line extension from
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - REMOVAL - EVAPORATOR LINE EXTEN-
SION).
(3) Remove the rear expansion valve from the rear
evaporator. (Refer to 24 - HEATING & AIR CONDI-
24 - 94 PLUMBING - REARRS
ProCarManuals.com