2004 CHRYSLER VOYAGER ABS

WARNING: THE HEAT SINK FOR THE BLOWER
MOTOR POWER MODULE MAY GET VERY HOT
DURING NORMAL OPERATION. IF THE BLOWER
MOTOR WAS TURNED ON PRIOR TO SERVICING
THE BLOWER MOTOR POWER MODULE, WAIT
FIVE MINUTES TO ALLOW THE HEAT SINK TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor power module (Fig. 21).
(4) Remove the two screws that secure the blower
motor power module to the HVAC housing.
(5) Remove the blower motor power module from
the HVAC housing.
INSTALLATION
(1) Position the blower motor power module into
the HVAC housing.
(2) Install the two screws that secure the blower
motor power module to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the blower
motor power module.
(4) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(5) Reconnect the negative battery cable.
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The recirculation door actuator is a reversible,
12-volt direct current (DC), servo motor. The single
recirculation door actuator is located on the passen-
ger side end of the HVAC housing, on the air inlet
housing. The recirculation door actuator is mechani-
cally connected to the recirculation-air door. The
recirculation door actuator is interchangeable with
the actuators for the blend-air door(s) and the mode
door. Each actuator is contained within an identical
black molded plastic housing with an integral wire
connector receptacle. Two integral mounting tabs
allow the actuator to be secured with two screws to
the air inlet housing. Each actuator also has an iden-
tical output shaft with splines that connects it to the
linkage that drives the recirculation-air door. The
recirculation door actuator does not require mechan-
ical indexing to the recirculation-air door, as it is
electronically calibrated by the A/C-heater control.
OPERATION
The recirculation door actuator is connected to the
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire lead and con-
nector of the HVAC wire harness. The recirculation
door actuator can move the recirculation door in two
directions. When the heater-A/C control module pulls
the voltage on one side of the motor connection high
and the other connection low, the recirculation air
door will move in one direction. When the module
reverses the polarity of the voltage to the motor, the
recirculation air door moves in the opposite direction.
When the module makes the voltage to both connec-
tions high or both connections low, the recirculation
air door stops and will not move. These same motor
connections also provide a feedback signal to the
heater-A/C control module. This feedback signal
allows the module to monitor the operation and rela-
tive position of the recirculation door actuator and
the recirculation air door. The heater-A/C control
module learns the recirculation air door stop posi-
tions during the calibration procedure and will store
a Diagnostic Trouble Code (DTC) for any problems it
detects in the recirculation door actuator circuits.
The recirculation door actuator can be diagnosed
using a DRBIIItscan tool. Refer to Body Diagnostic
Procedures for more information. The recirculation
door actuator cannot be adjusted or repaired and, if
damaged or faulty, it must be replaced.
Fig. 21 Blower Motor Power Module - Typical
1 - POWER MODULE
2 - LOWER GLOVE BOX OPENING REINFORCEMENT
3 - HVAC HOUSING
24 - 32 CONTROLS - FRONTRS
POWER MODULE - BLOWER MOTOR (Continued)

(6) If required, remove the three screws that
secure the rear A/C-heater control to the bezel and
remove the control from the bezel (Fig. 2).
INSTALLATION
(1) If removed, position the rear A/C-heater control
onto the bezel.
(2) If removed, install the three screws that secure
the rear A/C-heater control to the bezel. Tighten the
screws to 2 N´m (17 in. lbs.).
(3) Position the rear A/C-heater control near the
headliner.
(4) Connect the wire harness connector to the rear
A/C-heater control.
(5) Insert the locator tabs on the back of the rear
A/C-heater control bezel over the forward edge of the
headliner opening.
(6) Slide the rear A/C-heater control bezel forward
far enough to align the snap clips on the bezel with
the receptacles on the headliner.
(7) Using hand pressure, press the top edge of the
rear A/C-heater control bezel upward until the two
snap clips are fully seated in their receptacles.
(8) Reconnect the battery negative cable.
(9) Using the DRB-IIItreset the Rear Tempera-
ture Selector calibration values.
(10) Verify that the Actuator Calibration of the
Front Control has passed. If an Actuator Calibration
has not passed correct any errors before proceeding
further.
(11) Rotate the Rear Temperature Selector counter
clockwise to the Cold Position, allow the Selector to
remain in the Cold Position for 5 seconds.(12) Rotate the Rear Temperature Selector Clock-
wise to the Hot Position, allow the Selector to remain
in the Cold Position for 5 seconds.
(13) Calibration is now complete.
BLEND DOOR ACTUATOR
DESCRIPTION
The rear blend door actuator is a reversible,
12-volt Direct Current (DC), servo motor. The single
blend door actuator is located on the outboard side of
the rear HVAC housing, below the mode door actua-
tor. The blend door actuator is mechanically con-
nected to the blend air door.
The rear blend door actuator is interchangeable
with the actuator for the mode door. Each actuator is
contained within an identical black molded plastic
housing with an integral wire connector receptacle.
Two integral mounting tabs allow the actuator to be
secured with two screws to the rear HVAC housing.
Each actuator also has an identical output shaft with
splines that connects it to the pivot or linkage of the
proper door. The rear blend door actuator does not
require mechanical indexing to the blend air door
pivot, as it is electronically calibrated by the front
heater-A/C control module.
OPERATION
The rear blend door actuator is connected to the
front heater-A/C control module through the vehicle
electrical system by a dedicated two-wire take out
and connector of the rear HVAC wire harness. The
blend door actuator can move the blend air door in
two directions. When the front heater-A/C control
module pulls the voltage on one side of the motor
connection high and the other connection low, the
blend air door will move in one direction. When the
module reverses the polarity of the voltage to the
motor, the blend air door moves in the opposite direc-
tion. When the module makes the voltage to both
connections high or both connections low, the blend
air door stops and will not move. These same motor
connections also provide a feedback signal to the
front heater-A/C control module. This feedback signal
allows the module to monitor the operation and rela-
tive positions of the blend door actuator and the
blend air door. The front heater-A/C control module
learns the blend air door stop positions during the
calibration procedure and will store a Diagnostic
Trouble Code (DTC) for any problems it detects in
the blend door actuator circuits.
The rear blend door actuator can be diagnosed
using a DRBIIItscan tool. Refer to Body Diagnostic
Procedures for more information. The rear blend door
Fig. 2 Heater-A/C Control Bezel
1 - BEZEL
2 - SNAP CLIP (2)
3 - HEATER-A/C CONTROL
4 - SCREW (3)
5 - LOCATOR TAB (2)
RSCONTROLS - REAR24-35
A/C-HEATER CONTROL (Continued)

(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the rear HVAC wire harness con-
nector from the rear blower motor resistor.
(3) Check for continuity between each of the
blower motor switch input terminals of the blower
motor resistor and the resistor output terminal. In
each case there should be continuity. If OK, repair
the wire harness circuits between the blower motor
switch and the blower motor resistor, blower motor or
blower motor relay as required. If not OK, replace
the faulty blower motor resistor block.
REMOVAL
WARNING: THE REAR BLOWER MOTOR RESISTOR
BLOCK MAY GET VERY HOT DURING NORMAL
OPERATION. IF THE BLOWER MOTOR WAS
TURNED ON PRIOR TO SERVICING THE BLOWER
MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES
TO ALLOW THE BLOWER MOTOR RESISTORS TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
CAUTION: Do not operate the blower motor with the
blower motor resistor block removed from the cir-
cuit. Failure to take this precaution can result in
vehicle damage.
(1) Disconnect and isolate the battery negative
cable.
(2) 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).
(3) Disconnect the rear HVAC wire harness con-
nector from the blower motor resistor block (Fig. 6).
(4) Remove the two screws that secure the blower
motor resistor block to the rear HVAC housing.
(5) Remove the rear blower motor resistor block
from the rear HVAC housing.
INSTALLATION
(1) Position the rear blower motor resistor block
into the rear HVAC housing.
(2) Install the two screws that secure the rear
blower motor resistor block to the rear HVAC hous-
ing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Connect the rear HVAC wire harness connector
to the rear blower motor resistor block.
(4) 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).
(5) Reconnect the battery negative cable.
MODE DOOR ACTUATOR -
REAR
DESCRIPTION
The rear mode door actuator is a reversible, 12-volt
Direct Current (DC), servo motor. The mode door actua-
tor is located on the outboard side of the rear HVAC
housing, above the blend door actuator. The mode door
actuator is mechanically connected to the mode door.
The rear mode door actuator is interchangeable with
the actuator for the blend door. Each actuator is con-
tained within an identical black molded plastic housing
with an integral wire connector receptacle. Two integral
mounting tabs allow the actuator to be secured with
two screws to the rear HVAC housing. Each actuator
also has an identical output shaft with splines that con-
nects it to the pivot or linkage of the proper door. The
rear mode door actuator does not require mechanical
indexing to the mode door pivot, as it is electronically
calibrated by the front heater-A/C control module.
Fig. 6 Rear Blower Motor Resistor Block
1 - REAR HVAC HOUSING
2 - D-PILLAR
3 - BLOWER PIGTAIL WIRE
4 - CONNECTOR
5 - EXPANSION VALVE
6 - SCREW (2)
7 - BLOWER MOTOR RESISTOR BLOCK
RSCONTROLS - REAR24-39
BLOWER MOTOR RESISTOR (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)

(4) Remove the recirculation door actuator (Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/RECIRCULATION DOOR ACTUATOR -
REMOVAL).
(5) Disconnect the recirculation door actuator wire
harness lead from the routing clip on the lower air
inlet housing and position the wire harness aside.
(6) Disconnect the blower motor pigtail harness
connector from the blower motor resistor block or
power module, depending how vehicle is equipped.
(7) Remove the one screw (from the top) that
secures the lower air inlet housing to the upper air
inlet housing (Fig. 8).
(8) Remove the four screws (from the bottom) that
secure the lower air inlet housing to the lower HVAC
housing and upper air inlet housing.
(9) Push the rubber grommet on the blower motor
pigtail through the hole in the lower air inlet housing
(Fig. 9).
(10) Feed the blower motor pigtail and electrical
connector through the grommet hole in the lower air
inlet housing.
(11) Relocate the recirculation air door as neces-
sary to access and remove the three screws that
secure the blower motor to the lower half of the
HVAC housing.
(12) Gently flex the recirculation air door far
enough to remove the blower motor and blower wheel
from the housing.
(13) Remove the blower motor from the housing.
Note the position of the blower motor mounting tabs
(Fig. 10).
INSTALLATION
(1) Position the blower motor to the HVAC hous-
ing. Align the blower motor mounting tabs to the
proper tabs on the housing.
(2) Gently flex the recirculation air door far
enough to position the blower motor and wheel into
the lower half of the HVAC housing.
(3) Install the three screws that secure the blower
motor to the lower half of the HVAC housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(4) Feed the blower motor pigtail and electrical
connector through the grommet hole in the lower air
inlet housing and seat the rubber grommet.
(5) Position the recirculation door into the lower
air inlet housing.
Fig. 8 Air Inlet Housing - LDH Shown, RHD Typical
1 - HVAC HOUSING
2 - UPPER AIR INLET HOUSING
3 - RECIRCULATION AIR DOOR
4 - BLOWER MOTOR AND WHEEL
Fig. 9 Blower Motor Grommet - Typical
1 - BLOWER MOTOR PIGTAIL WIRE GROMMET
Fig. 10 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-49
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)

CAUTION
A/C SYSTEM
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
on the R-134a system. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with R-134a
refrigerant oil. They are not compatible and damage
to the system will result.
Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
pressure and can cause noise and system failure.
Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
If equipped, do not remove the secondary retention
clip from any spring-lock coupler connection while
the refrigerant system is under pressure. Recover
the refrigerant before removing the secondary
retention clip. Open the fittings with caution, even
after the system has been discharged. Never open
or loosen a connection before recovering the refrig-
erant.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system. Immediately after disconnecting a compo-
nent from the refrigerant system, seal the open fit-
tings with a cap or plug.
Refrigerant oil will absorb moisture from the atmo-
sphere if left uncapped. Do not open a container of
refrigerant oil until you are ready to use it. Replace
the cap on the oil container immediately after using.
Store refrigerant oil only in a clean, airtight, and
moisture-free container.
Keep service tools and the work area clean. Con-
tamination of the refrigerant system must be
avoided.
CAUTION: The use of A/C system sealers may
result in damage to A/C refrigerant recovery/evacu-
ation/recharging equipment and/or A/C systems.
Many federal, state/provincial and local regulations
prohibit the recharge of A/C systems with known
leaks. DaimlerChrysler recommends the detection
of A/C system leaks through the use of approvedleak detectors and fluorescent leak detection dyes.
Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the
entire A/C refrigerant system is recommended. A/C
systems found to be contaminated with A/C system
sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS
WARNING: R-134a SERVICE EQUIPMENT OR VEHI-
CLE A/C SYSTEM SHOULD NOT BE PRESSURE
TESTED OR LEAK TESTED WITH COMPRESSED
AIR. MIXTURE OF AIR and R-134a CAN BE COM-
BUSTIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
AVOID BREATHING A/C REFRIGERANT AND LUBRI-
CANT VAPOR OR MIST. EXPOSURE MAY IRRITATE
EYES, NOSE AND THROAT. USE ONLY APPROVED
SERVICE EQUIPMENT MEETING SAE REQUIRE-
MENTS TO DISCHARGE R-134a SYSTEM. IF ACCI-
DENTAL SYSTEM DISCHARGE OCCURS,
VENTILATE WORK AREA BEFORE RESUMING SER-
VICE.
If the A/C system is not cooling properly, determine
if the refrigerant system is fully charged with R-134a
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT/REFRIGERANT - DIAGNO-
SIS AND TESTING - REFRIGERANT SYSTEM
CHARGE LEVEL). If while performing this test A/C
liquid line pressure is less than 345 kPa (50 psi) pro-
ceed to System Empty procedure. If liquid line pres-
sure is greater than 345 kPa (50 psi) proceed to
System Low procedure. If the refrigerant system is
empty or low in refrigerant charge, a leak at any line
fitting or component seal is likely. A review of the fit-
tings, lines and components for oily residue is an
indication of the leak location.
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 to the lowest
degree of vacuum possible (approx. 28 in Hg.) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - FRONT/REFRIGERANT - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM EVACUATE).
Determine if the system holds a vacuum for 15 min-
utes. If vacuum is held, a leak is probably not
24 - 66 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)

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. 2), 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 (Fig. 2).
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING TUBING
AND FITTINGS
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
A good rule for the flexible hose lines is to keep theradius of all bends at least 10 times the diameter of
the hose. Sharper bends will reduce the flow of
refrigerant. The flexible hose lines should be routed
so they are at least 3 inches (80 mm) from the
exhaust manifold. Inspect all flexible hose lines to
make sure they are in good condition and properly
routed.
The use of correct wrenches when making connec-
tions is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities. Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.
When opening a refrigeration system, have every-
thing you will need to repair the system ready. This
will minimize the amount of time the system must
be opened. Cap or plug all lines and fittings as
soon as they are opened. This will help prevent the
entrance of dirt and moisture. All new lines and
components should be capped or sealed until they
are ready to be used. Before connecting a compo-
nent, clean the outside of the fittings thoroughly to
prevent contamination from entering the refrigerant
system.
All tools, including the refrigerant dispensing mani-
fold, the manifold gauge set, and test hoses should
be kept clean and dry.
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are pro-
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec-
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace-
ment of lines or components. The refrigerant oil will
absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
24 - 70 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)