2003 CHRYSLER CARAVAN heating

REMOVAL
The rear blower motor and blower wheel are ser-
viced only as a balanced unit. If either component is
faulty or damaged, the entire unit must be replaced.
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) Disconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(3) Remove the three screws that secure the
blower motor to the outboard side of the rear heater-
A/C unit housing (Fig. 5).
(4) Remove the blower motor and blower wheel
from the rear heater-A/C unit housing.
INSTALLATION
(1) Position the blower motor and blower wheel
onto the outboard side of the rear heater-A/C unit
housing.
(2) Install and tighten the three screws that secure
the blower motor to the rear heater-A/C unit housing.
Tighten the screws to 2 N´m (18 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(4) 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).REAR HEATER-A/C HOUSING
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),
(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) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
Fig. 5 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
24 - 56 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)
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(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Raise and support the vehicle.
(5) Disconnect the underbody refrigerant line seal-
ing plate from the rear heater-A/C unit evaporator
extension line sealing plate that extends through the
rear floor panel behind the right rear wheel housing
(Fig. 6).
(6) Remove the seals from the liquid line and suc-
tion line fittings and discard.
(7) Install plugs in, or tape over the opened liquid
line and suction line fittings and both ports in the
evaporator extension line sealing plate.
(8) Remove the three nuts that secure the rear
heater-A/C unit mounting studs to the rear floor
panel behind the right rear wheel housing (Fig. 7).
(9) Lower the vehicle.
(10) Remove the right quarter trim panel and
right D-pillar trim panel from the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - REMOVAL).
(11) Remove the rear A/C distribution duct from
the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear heater-A/C unit housing from the rear
HVAC wire harness connector located near the
expansion valve at the back of the unit.
(13) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.(14) Remove the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear heater-A/C unit housing.
(15) Remove the rear heater distribution duct from
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
REMOVAL).
(16) Take the proper precautions to protect the
carpeting below the rear heater core from spilled
engine coolant and have absorbent toweling readily
available to clean up any spills.
(17) Disconnect the heater hoses at the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - REMOV-
AL).
(18) Install plugs in, or tape over the opened
heater core fittings and both heater hoses.
(19) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(20) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar
(Fig. 8).
(21) Remove the screw that secures the front of
the rear heater-A/C unit housing to the right quarter
inner panel.
(22) Lift the rear heater-A/C unit housing up far
enough for the lower mounting studs and the evapo-
rator extension lines to clear the mounting holes in
the rear floor panel.
(23) Remove the rear heater-A/C unit housing from
the vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
Fig. 6 Refrigerant Lines
1 - UNDERBODY REFRIGERANT LINE SEALING PLATE
Fig. 7 Rear Heater-A/C Unit Mounting Studs
1 - REAR HEATER-A/C UNIT MOUNTING STUDS
RSDISTRIBUTION - REAR24-57
REAR HEATER-A/C HOUSING (Continued)
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INSTALLATION
NOTE: If the rear heater core or the rear heater-A/C
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Position the rear heater-A/C unit housing into
the vehicle with the evaporator extension line sealing
plate inserted into the rectangular hole in the rear
floor panel behind the right rear wheel house.
(2) Align the rear heater-A/C unit housing lower
mounting studs with the mounting holes in the rear
floor panel and lower the unit to the floor.
(3) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).(4) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Reinstall the rear heater distribution duct onto
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
INSTALLATION).
(8) Install and tighten the two screws that secure
the bottom of the quarter trim panel attaching
bracket to the rear heater-A/C unit housing. Tighten
the screws to 1.7 N´m (15 in. lbs.).
(9) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel.
Fig. 8 Rear Heater-A/C Housing
1 - U-NUT (3)
2 - REAR HEATER-A/C HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
24 - 58 DISTRIBUTION - REARRS
REAR HEATER-A/C HOUSING (Continued)
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(10) Reconnect the body wire harness connector for
the rear heater-A/C unit housing to the rear HVAC
wire harness connector located near the expansion
valve at the back of the unit.
(11) Reinstall the auxiliary A/C distribution duct
onto the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - INSTALLATION).
(12) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(13) Raise and support the vehicle.
(14) Install and tighten the three nuts that secure
the rear heater-A/C unit mounting studs to the rear
floor panel behind the right rear wheel housing.
Tighten the nuts to 9 N´m (80 in. lbs.).
(15) Remove the tape or plugs from the underbody
liquid line and suction line fittings and both ports in
the rear heater-A/C unit evaporator extension line
sealing plate that extends through the rear floor
panel behind the right rear wheel housing.
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line and
suction line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line sealing
plate.
(18) Install and tighten the screw that secures the
underbody refrigerant line sealing plate to the evap-
orator extension line sealing plate. Tighten the screw
to 23 N´m (17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
(21) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(24) Run the HVAC Cooldown test to verify proper
operation(Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).REAR HEATER DISTRIBUTION
DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel. (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
heater distribution duct to the right quarter inner
panel (Fig. 9).
(3) Slide the rear heater distribution duct forward
far enough to disengage it from the outlet on the
front of the rear heater-air conditioner unit housing.
(4) Remove the rear heater distribution duct from
the vehicle.
INSTALLATION
(1) Align the inlet end of rear heater distribution
duct with the outlet on the front of the rear heater-
air conditioner unit housing.
(2) Slide the rear heater distribution duct rear-
ward far enough to fully engage the inlet end of the
duct with the outlet on the front of the rear heater-
air conditioner unit housing.
(3) Install and tighten the two screws that secure
the rear heater distribution duct to the right quarter
inner panel. Tighten the screws to 1.6 N´m (14 in.
lbs.).
(4) Reinstall the trim onto the right quarter inner
panel. (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - INSTALLATION).
Fig. 9 Rear Heater Distribution Duct
1 - REAR HEATER DISTRIBUTION DUCT
2 - REAR HEATER-A/C UNIT OUTLET
3 - SCREW (2)
RSDISTRIBUTION - REAR24-59
REAR HEATER-A/C HOUSING (Continued)
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REMOVAL
REMOVAL - COMPRESSOR - 2.4/3.3/3.8L
ENGINES
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 nut that secures the suction line
fitting to the top of the compressor.
(4) Disconnect the suction line fitting from the
compressor suction port.
(5) Remove the seals from the suction line fitting
and discard.
(6) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(7) Remove the nut that secures the discharge line
fitting to the top of the compressor.
(8) Disconnect the discharge line fitting from the
compressor discharge port.
(9) Remove the seals from the discharge line fit-
ting and discard.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(11) Raise and support the vehicle.
(12) Remove the serpentine accessory drive belt
from the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
REMOVAL) or (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - 3.3L/3.8L - REMOVAL).
(13) Disconnect the engine wire harness connector
for the compressor clutch coil from the coil pigtail
wire connector on the top of the compressor (Fig. 1)
or (Fig. 2).
(14) On models with the 3.3L and 3.8L engines,
disengage the retainer on the engine wire harness
compressor clutch coil take out from the bracket on
the top of the compressor.
(15) On models with the 2.4L engine, remove the
four screws that secure the compressor to the mount-
ing bracket on the engine.
(16) On models with the 3.3L and 3.8L engines,
remove the two screws and two nuts that secure the
compressor to the engine.(17) Remove the compressor from the engine com-
partment.
Fig. 1 Compressor - 2.4L Engine
1 - CLUTCH COIL CONNECTOR
2 - DISCHARGE PORT
3 - COMPRESSOR
4 - SUCTION PORT
5 - SCREW (4)
6 - COMPRESSOR MOUNTING BRACKET
Fig. 2 Compressor - 3.3L/3.8L Engine
1 - STUDS (2)
2 - CLUTCH COIL CONNECTOR
3 - DISCHARGE PORT
4 - SCREW (2)
5 - SUCTION PORT
6 - COMPRESSOR
7 - SCREW (IF EQUIPPED)
8 - NUTS (2)
24 - 64 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
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NOTE: If a replacement compressor is being
installed, be certain to drain and measure the refrig-
erant oil contained in the removed compressor.
This will determine how much oil the replacement
compressor must contain before it is installed.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: The filter drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
REMOVAL - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Remove the compressor from the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - REMOVAL).
(2) Remove the four screws that secure the com-
pressor mounting bracket to the engine (Fig. 3).
(3) Remove the compressor mounting bracket from
the engine.
INSTALLATION
INSTALLATION - COMPRESSOR
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT OIL - STAN-
DARD PROCEDURE - REFRIGERANT OIL LEVEL).Use only refrigerant oil of the type recommended
for the compressor in the vehicle.
NOTE: The filter drier should always be replaced
when the compressor is replaced. This will remove
any contaminants including moisture from the sys-
tem.
(1) Position the compressor into the engine com-
partment.
(2) On models with the 2.4L engine, loosely install
the four screws that secure the compressor to the
mounting bracket on the engine. Tighten the screws
to 28 N´m (21 ft. lbs.).
(3) On models with the 3.3L and 3.8L engines,
loosely install the two screws and two nuts that
secure the compressor to the engine. Tighten each of
the fasteners using the following sequence to 54 N´m
(40 ft. lbs.).
²The upper nut at the front of the compressor.
²The lower nut at the front of the compressor.
²The upper screw at the rear of the compressor.
²The lower screw at the rear of the compressor.
(4) On models with the 3.3L and 3.8L engines only,
engage the retainer on the engine wire harness com-
pressor clutch coil take out with the bracket on the
top of the compressor.
(5) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(6) Reinstall the serpentine accessory drive belt
onto the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTAL-
LATION).
(7) Lower the vehicle.
(8) Remove the tape or plugs from the compressor
discharge port and the discharge line fitting.
(9) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(10) Install a new gasket and reconnect the dis-
charge line fitting to the compressor discharge port.
(11) Install and tighten the nut that secures the
discharge line fitting to the compressor. Tighten the
nut to 23 N´m (17 ft. lbs.).
(12) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(13) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(14) Install a new gasket and reconnect the suc-
tion line fitting to the compressor suction port.
(15) Install and tighten the nut that secures the
suction line fitting to the compressor. Tighten the nut
to 23 N´m (17 ft. lbs.).
Fig. 3 Compressor Mounting Bracket - 2.4L Engine
1 - MOUNTING BRACKET
2 - SCREWS (4)
3 - ENGINE
RSPLUMBING - FRONT24-65
A/C COMPRESSOR (Continued)
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(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(18) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install and tighten the four screws that secure
the compressor mounting bracket to the engine.
Tighten the screws to 54 N´m (40 ft. lbs.).
(3) Reinstall the compressor onto the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - INSTALLA-
TION).
CONDENSER
DESCRIPTION
The condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The condenser cannot be
repaired or adjusted and, if faulty or damaged, it
must be replaced. The condenser may be removed
from the cooling module for service without removing
the cooling module from the vehicle.
OPERATION
The condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
compressor to give up its heat to the air passing over
the condenser fins. When the refrigerant gas gives up
its heat, it condenses. When the refrigerant leaves
the condenser, it has become a high-pressure liquid
refrigerant. The volume of air flowing over the con-
denser fins is critical to the proper cooling perfor-
mance of the air conditioning system. Therefore, it is
important that there are no objects placed in front of
the radiator grille openings in the front of the vehicle
or foreign material on the condenser fins that might
obstruct air flow. Also, any factory-installed air seals
or shrouds must be properly reinstalled following
radiator or condenser service.
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).
NOTE: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(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 two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 4).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the two screws that secure the hood
latch unit to the front of the radiator closure panel
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 66 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
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(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 plan 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) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Install a new dual plan seal and reconnect the
discharge line fitting to the condenser inlet port on
the right side of the cooling module.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N´m (17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install and tighten the two screws that secure
the hood latch unit to the front of the radiator clo-
sure panel crossmember. Check and adjust the hood
latch as needed. Tighten the screws to 14 N´m (123
in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) 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 (18 in. lbs.).
(20) 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.).
(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).DISCHARGE LINE
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) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 6).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 7).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the seal from the discharge line fitting
and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 68 PLUMBING - FRONTRS
CONDENSER (Continued)
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