2004 CHRYSLER VOYAGER tow

inserted in a small well in the body of the expansion
valve that is filled with a special silicone-based ther-
mal grease. A small molded plastic push-in retainer
secures the sensor to a threaded hole in the top sur-
face of the expansion valve. Two terminals within a
molded plastic connector receptacle on the sensor
connect it to the vehicle electrical system through a
take out and connector of the HVAC wire harness.
The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the tem-
peratures it monitors. The A/C-heater control is con-
nected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator tem-
perature increases, the resistance of the sensor
decreases and the voltage monitored by the control
decreases. The control uses this monitored voltage
reading to an indication of the evaporator tempera-
ture. The A/C-heater control is programmed to
respond to this input by sending electronic messages
to the powertrain control module (PCM) over the pro-
grammable communications interface (PCI) data bus,
and the PCM then cycles the A/C compressor clutch
as necessary to optimize A/C system performance andto protect the system from evaporator freezing. The
external location of the sensor allows the sensor to be
removed or installed without disturbing the refriger-
ant in the system. The evaporator temperature sen-
sor is diagnosed using a DRBIIItscan tool. Refer to
Body Diagnostic Procedures.
REMOVAL
REMOVAL - AUTOMATIC TEMPERATURE
CONTROL (ATC)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the windshield wiper assembly from
the vehicle (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Remove the temperature sensor retainer from
the expansion valve (Fig. 17).
(5) Pull the evaporator temperature sensor away
from the expansion valve far enough to access the
red release ring on the wiring connector. Push the
red ring toward the connector to release the lock and
disconnect the wire harness connector from the tem-
perature sensor.
(6) Remove the evaporator temperature sensor
from the engine compartment.
Fig. 16 Evaporator Temperature Sensor - ATC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - A/C EXPANSION VALVE
Fig. 17 Evaporator Temperature Sensor - ATC
System
1 - RIGHT FRONT STRUT TOWER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - DASH PANEL
5 - RETAINER
24 - 28 CONTROLS - FRONTRS
EVAPORATOR TEMPERATURE SENSOR (Continued)

DISTRIBUTION - FRONT
TABLE OF CONTENTS
page page
AIR FILTER
DESCRIPTION.........................43
REMOVAL.............................43
INSTALLATION.........................44
AIR OUTLETS
DESCRIPTION.........................44
REMOVAL
REMOVAL - CENTER BEZEL OUTLETS....44
REMOVAL - DEMISTER OUTLET..........45
REMOVAL - INSTRUMENT PANEL OUTLET . 45
INSTALLATION
INSTALLATION - CENTER BEZEL OUTLETS . 45
INSTALLATION - DEMISTER OUTLET......46
INSTALLATION - INSTRUMENT PANEL
OUTLET............................46
BLOWER MOTOR
DESCRIPTION.........................46
OPERATION...........................46
DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................47
REMOVAL.............................47INSTALLATION.........................49
DEFROSTER DUCT
REMOVAL.............................50
INSTALLATION.........................50
FLOOR DISTRIBUTION DUCTS
REMOVAL.............................50
INSTALLATION.........................50
HVAC HOUSING
REMOVAL
REMOVAL...........................51
DISSASEMBLY.......................51
INSTALLATION
ASSEMBLY..........................53
INSTALLATION.......................54
INSTRUMENT PANEL DEMISTER DUCTS
REMOVAL.............................55
INSTALLATION.........................55
INSTRUMENT PANEL DUCTS
REMOVAL.............................55
INSTALLATION.........................55
AIR FILTER
DESCRIPTION
A dust and odor air filter is standard equipment on
models equipped with the three zone temperature
control systems (Fig. 1). The filter element is the
same size as the front air conditioner evaporator to
ensure ample filtering capacity. A removable door on
the bottom of the front HVAC housing below the
glove box provides easy access to the filter element
for replacement. The filter should be checked and
replaced at least once every 24,000 km (15,000 miles)
and checked if heater-A/C system performance seems
lower than expected.
REMOVAL
(1) Locate the air filter door on the bottom of the
lower HVAC housing just outboard of the passenger
side of the instrument panel center stack (Fig. 2).
(2) Slide the air filter door latch toward the rear of
the vehicle until it engages the opened stop on the
door.
(3) Pull the air filter door straight downward to
disengage it from the air filter opening of the lower
HVAC housing.(4) Use your fingers to reach through the air filter
opening of the lower HVAC housing far enough to
grasp the air filter.Fig. 1 Air Filter - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - LOWER EDGE OF INSTRUMENT PANEL
3 - AIR FILTER (IF EQUIPPED)
4 - CENTER FLOOR BRACKET COVER
5 - FILTER SEALING EDGES (IF EQUIPPED)
6 - AIR FILTER OPENING (IF EQUIPPED)
RSDISTRIBUTION - FRONT24-43

(5) Pull the air filter straight down and out of the
HVAC housing (Fig. 2).
INSTALLATION
(1) Note the ªAirflowº directional arrow imprinted
on the foam seal around the frame of the air filter.
This arrow should always be oriented towards the
center of the vehicle.
(2) With the air filter ªAirflowº arrow properly ori-
ented, carefully slide the filter fully upward into the
HVAC housing through the air filter opening.
(3) With the latch still positioned against its
opened stop, reinstall the air filter door onto the
lower HVAC housing air filter opening.
(4) Slide the air filter door latch toward the front
of the vehicle until it hits the closed stop on the door.
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the front HVAC housing through one or a
combination of the four main housing outlets: defrost,
demist, panel, or floor. Once the conditioned air exits
the unit housing, it is directed through molded plas-
tic ducts to the various outlets in the vehicle interior.
These outlets and their locations are as follows:
²Defroster Outlet- A single, centrally mounted
outlet delivers air for defrosting the large windshield.
Because outlet vanes are not needed to direct flow, a
simple, integral grid is molded into the center of the
instrument panel top cover to prevent objects from
falling into the duct. If the defroster outlet is faultyor damaged, the instrument panel top cover must be
replaced.
²Demister Outlets- There are two side window
demisters that aid in defogging and defrosting the
front door windows. One demister outlet is located at
each outboard end of the instrument panel top pad,
near the belt line at the A-pillars. The demister out-
lets can be removed from the top pad individually for
service replacement.
²Instrument Panel Outlets- There are five
panel outlets in the instrument panel, one located
near each outboard end of the instrument panel fac-
ing the rear of the vehicle, and three located near the
top of the instrument panel center bezel. On models
with manual temperature control, all five of these
outlets are fully adjustable. On models with Auto-
matic Temperature Control (ATC) system, the center
outlet in the center bezel has fixed vanes because it
also houses the remote infrared temperature sensors
for the front seat positions. The outboard outlets can
be removed individually for service replacement. The
center bezel outlets are serviced as a gang of three
outlets and, on models with ATC, also includes the
infrared sensors.
²Front Door Rear Outlets- A fully adjustable
outlet located at the rear of each front door trim
panel supplies only cooled air to the intermediate
seat passengers. Air is supplied to these outlets from
the instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. The door ducts are integral to the front
door trim panels. These outlets also incorporate a red
reflector to improve the safety and visibility of an
opened front door to traffic approaching the vehicle
from the rear at night. These outlets can be removed
from the door trim panels for service replacement.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel below the instrument panel. These out-
lets are integral to the front HVAC distribution hous-
ing.
²Rear Floor Outlets- Wide rear floor outlets
located under each front seat have integral, fixed
directional dividers to distribute heated air across
the floor for intermediate seat passengers. These out-
lets are integral to the floor distribution ducts routed
under the front floor carpet from an outlet nozzle on
the bottom of the front HVAC distribution housing.
REMOVAL
REMOVAL - CENTER BEZEL OUTLETS
The three outlets located near the top of the
instrument panel center bezel are serviced only as a
set of all three outlets. If the vehicle is equipped with
the optional automatic temperature control (ATC)
Fig. 2 Air Filter Door - Typical
1 - AIR FILTER DOOR
2-LATCH
3 - CLOSED STOP
4 - LOWER HVAC HOUSING
5 - OPENED STOP
24 - 44 DISTRIBUTION - FRONTRS
AIR FILTER (Continued)

system, the center outlet of the three has fixed vanes
and also houses the remote front infrared tempera-
ture sensors.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(3) Place the center bezel face down on a suitable
work surface. Be certain to take the proper precau-
tions to protect the face of the center bezel from cos-
metic damage.
(4) If the vehicle is equipped with the optional
ATC system, disconnect the ATC remote infrared
temperature sensor jumper harness from the sensor
connector receptacle located on the bottom of the cen-
ter outlet housing (Fig. 3).(5) Remove the three screws that secure the bot-
tom of the outlet housing to the center bezel.
(6) Roll the bottom of the outlet housing upwards
towards the top of the center bezel far enough to dis-
engage the retainer features on the top of the outlet
housing from their receptacles at the top of the cen-
ter bezel.
(7) Remove the center bezel outlets and housing
from the center bezel as a unit.
REMOVAL - DEMISTER OUTLET
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
demister outlet away from the instrument panel top
pad until the snap features on the outlet are released
(Fig. 4).
(2) Remove the demister outlet from the demister
duct opening in the instrument panel top pad.
REMOVAL - INSTRUMENT PANEL OUTLET
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
instrument panel outlet away from the instrument
panel top pad until the snap features on the outlet
are released (Fig. 5).
(2) Remove the instrument panel outlet from the
panel duct opening in the instrument panel top pad.
INSTALLATION
INSTALLATION - CENTER BEZEL OUTLETS
(1) Position the center bezel outlets and housing
onto the center bezel as a unit.
Fig. 3 Center Air Outlets
1 - CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - SCREW (3)
4 - INSTRUMENT PANEL SWITCH BANK
5 - CONNECTOR (ATC ONLY)
6 - JUMPER HARHESS (ATC ONLY)
Fig. 4 Demister Outlet
1 - DEMISTER OUTLET
2 - INSTRUMENT PANEL TOP PAD
3 - TRIM STICK
RSDISTRIBUTION - FRONT24-45
AIR OUTLETS (Continued)

(2) Engage the retainer features on the top of the
outlet housing with their receptacles at the top of the
center bezel, then roll the bottom of the outlet hous-
ing downwards towards the center bezel.
(3) Install the three screws that secure the bottom
of the outlet housing to the center bezel. Tighten the
screws to 2 N´m (17 in. lbs.).
(4) If the vehicle is equipped with the optional
ATC system, reconnect the ATC remote infrared tem-
perature sensor jumper harness to the sensor connec-
tor receptacle located on the bottom of the center
outlet housing.
(5) Reinstall the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(6) Reconnect the battery negative cable.
INSTALLATION - DEMISTER OUTLET
(1) Position the demister outlet over the demister
duct opening in the instrument panel top pad.
(2) Using hand pressure, press the demister outlet
firmly and evenly into the instrument panel top pad
opening until the snap features on the outlet are
fully engaged.
INSTALLATION - INSTRUMENT PANEL OUTLET
(1) Position the instrument panel outlet into the
panel duct opening in the instrument panel top pad.
(2) Using hand pressure, press the instrument
panel outlet firmly and evenly into the instrument
panel top pad opening until the snap features on the
outlet are fully engaged.
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 6). The
blower motor and wheel are located near the passen-
ger side end of the HVAC housing in the passenger
compartment below the instrument panel. The
blower motor and blower motor wheel are factory bal-
anced and cannot be adjusted or repaired. If faulty or
damaged, the blower motor and blower wheel must
be replaced as an assembly.
OPERATION
On models equipped with the manual heater-A/C
system, the blower motor will operate whenever the
ignition switch is in the On position and the blower
control switch is in any position except Off. On mod-
els equipped with the Automatic Temperature Con-
trol (ATC) system, the blower motor will operate
whenever the ignition switch is in the On position
and the A/C-heater control power is turned on.
The blower motor receives battery current when-
ever the front blower motor relay is energized. The
front blower motor relay output circuit is protected
by a fuse in the Integrated Power Module (IPM)
located in the engine compartment near the battery.
In the manual heater-A/C system, the blower motor
speed is controlled by regulating the path to ground
through the blower control switch and the blower
motor resistor. In the ATC system, the blower motor
speed is controlled by an electronic blower motor
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
Fig. 5 Instrument Panel Outlet - Left Side Shown
1 - INSTRUMENT PANEL TOP PAD
2 - INSTRUMENT PANEL OUTLET
3 - TRIM STICK
Fig. 6 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
24 - 46 DISTRIBUTION - FRONTRS
AIR OUTLETS (Continued)

(6) Install the four screws (from the bottom) that
secure the lower air inlet housing to the lower HVAC
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(7) Install the one screw (from the top) that
secures the lower air inlet housing to the upper air
intake housing. Tighten the screws to 2 N´m (17 in.
lbs.).
(8) Connect the blower motor pigtail harness con-
nector to the blower motor resistor block or power
module, depending how vehicle is equipped.
(9) Install the recirculation door actuator (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - INSTALLA-
TION).
(10) Install the recirculation door actuator wire
harness lead into the routing clip on the lower air
inlet housing.
(11) Reinstall the carpet.
(12) Install the passenger side door sill plate and
cowl panel.
(13) Reconnect the battery negative cable.
(14) Perform the heater-A/C control calibration
procedure (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION).
DEFROSTER DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.(4) Remove the fasteners that secure the defroster
duct to the instrument panel armature.
(5) Remove the defroster duct from the instrument
panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the defroster duct to the instrument
panel.
(2) Install the fasteners that secure the defroster
duct to the instrument panel armature.
(3) Reinstall the instrument panel in the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 11).
(3) Pull the center floor distribution duct rearward
far enough to disengage it from the floor outlet of the
HVAC housing.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required.
(2) Slide the center floor distribution duct under
the instrument panel center stack far enough to
engage it to the floor outlet of the HVAC housing.
24 - 50 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)

(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 distribution duct from the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear HVAC housing from the rear HVAC wire
harness connector located near the expansion valve
at the back of the housing.
(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 HVAC housing.
(15) Remove the rear floor heat duct from the
right quarter inner panel (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION/REAR
FLOOR HEAT 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 -
REMOVAL).
(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 HVAC housing to the right D-pillar (Fig. 7).
(21) Remove the screw that secures the front of
the rear HVAC housing to the right quarter inner
panel.
(22) Lift the rear HVAC housing up far enough for
the lower mounting studs and the evaporator exten-
sion lines to clear the mounting holes in the rear
floor panel.
(23) Remove the rear HVAC housing from the
vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
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 HVAC housing into the vehi-
cle 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 HVAC housing lower mounting
studs with the mounting holes in the rear floor panel
and lower the unit to the floor.
(3) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(4) Install the screw that secures the back of the
rear HVAC 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 floor heat duct onto the right
quarter inner panel (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/REAR FLOOR
HEAT DUCT - INSTALLATION).
(8) Install the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear HVAC housing. Tighten the screws to 2 N´m (17
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.
(10) Reconnect the body wire harness connector for
the rear HVAC housing to the rear HVAC wire har-
ness connector located near the expansion valve at
the back of the housing.
(11) Reinstall the rear distribution duct onto the
rear HVAC housing and the rear roof duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/AIR OUTLETS - 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 the three nuts that secure the rear
HVAC housing 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 evaporator extension line sealing plate that
extends through the rear floor panel behind the right
rear wheel housing.
RSDISTRIBUTION - REAR24-61
HVAC HOUSING (Continued)

(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(9) Connect the liquid line and suction line fittings
to the expansion valve.
(10) Install the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve. Tighten the nut to 23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the liquid line
rear section fitting and the receiver/drier outlet port.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(13) Connect the liquid line fitting to the receiver/
drier outlet port.
(14) Install the screw that secures the liquid line
fitting to the receiver/drier. Tighten the screw to 11
N´m (97 in. lbs.).
(15) Connect the wire harness connector to the A/C
pressure transducer.
(16) Connect the drain tube to the wiper module
drain on the right side of the engine compartment.
(17) Install the air cleaner housing.
(18) Reconnect the battery negative cable.
(19) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(20) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing, which is attached to the HVAC housing, behind
the instrument panel. It is a heat exchanger made of
rows of tubes and fins. One end of the core is fitted
with a molded plastic tank, which includes integral
heater core inlet and outlet ports. Removable heater
core tubes attach to the ports by use of a sealing
plate secured with a screw to the heater core tank.
This removable heater core tube arrangement allows
the heater core to be serviced without removing the
HVAC housing from the vehicle.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend doorallows control of the heater output air temperature
by regulating the amount of air that is flowing
through the heater core within the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
REMOVAL - HEATER CORE TUBES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/HEATER INLET HOSE -
REMOVAL) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER RETURN
HOSE - REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel.
NOTE: Take the proper precautions to protect the
carpeting below the heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to clean up any spills.
(5) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 14).
(6) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(7) Install plugs in, or tape over the opened heater
core tube fittings and both heater core ports.
(8) Pull both heater core tubes simultaneously
slightly away from the distribution housing and rear-
ward far enough to disengage the engine compart-
ment ends of the tubes from the dash panel seal.
RSPLUMBING - FRONT24-83
EXPANSION VALVE (Continued)