2004 CHRYSLER VOYAGER CD changer

CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressure sensor
replacement occurs the tire pressure sensors must be
retrained. This is necessary to inform the Electronic
Vehicle Information Center (EVIC) that a sensor
change was made and where. Retraining is accom-
plished through the EVIC used in conjunction with a
Re-learn Magnet, Special Tool 8821.
NOTE: Use the following procedure to retrain all
four (4) road wheel tire pressure sensors. No
attempt should be made to retrain individual sen-
sors.
(1) Retrieve Re-learn Magnet, Special Tool 8821.
(2) Press MENU Button on EVIC until9RETRAIN
TIRE SENSORS - NO9is displayed.
(3) Press STEP button to select9YES9.
NOTE: There is a 60 second timer for training the
first sensor and a 60 second timer between training
the remaining sensors. If any of these timers expire,
the EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads(TRAIN-
ING ABORTED(, move the vehicle ahead at least
one foot and repeat the entire retraining procedure.
(4) Press MENU button to start retraining. Dis-
play will read9TRAIN LEFT FRONT TIRE9
NOTE: The order for retraining all four sensors is:
²Left Front
²Right Front
²Right Rear
²Left Rear
(5) Starting at left front tire, place Re-learn Mag-
net over valve stem (Fig. 17). Within approximately 5
seconds, vehicle horn will chirp indicating training
complete at that particular sensor. Remove the mag-
net.
(6) Repeat step (5) on remaining sensors as indi-
cated by EVIC until all four TPM sensors positions
are trained.
(7) Once EVIC displays9TRAINING COMPLETE9,
pressing either STEP, C/T, RESET or MENU button
will exit training routine.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem   10É (Fig. 18), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 19).
(4) Remove sensor from wheel (Fig. 19).
Fig. 17 Magnet Placement Over Valve Stem
1 - RE-LEARN MAGNET
2 - VALVE STEM
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)

INSTALLATION
NOTE: Before reinstalling a tire pressure sensor,
replace sealing grommet at base of valve stem.
(1) Wipe area clean where sensor sealing grommet
contacts wheel. Make sure surface of wheel is not
damaged.
(2) Install sensor in wheel as shown (Fig. 19). Do
not attempt to mount sensor otherwise, damage may
occur.
(3) Using a thin wall socket, install special sensor
nut (Fig. 19). Tighten nut to 4 N´m (35 in. lbs.)
torque.
CAUTION: Over-torquing the sensor nut by as little
as 12 N´m (106 in. lbs.) may result in sensor sepa-
ration from the valve stem. Under this condition,
the sensor may still function, however, the condi-
tion should be corrected immediately.
(4) Mount tire on wheel following tire changer
manufacturers instructions, paying special attention
to the following to avoid damaging tire pressure sen-
sor:
(a) Rotating Wheel Tire Changers - Once the
wheel is mounted to the changer, position the sen-
sor valve stem approximately 210É from the head
of the changer in a clockwise direction before rotat-
ing the wheel (also in a clockwise direction) to
mount the tire (Fig. 20). Use this procedure on
both the upper and lower tire beads.
(b) Rotating Tool Tire Changers - Position the
wheel on the changer so that the sensor valve stem
is approximately 210É from the head of the changer
in a clockwise direction from the mounting end of
the tool (Fig. 21) Make sure the sensor is clear of
the lower bead breaker area to avoid damaging the
sensor when the breaker rises (Fig. 21). Rotate the
tool in a counterclockwise direction to mount the
tire. Use this procedure on both the upper and
lower tire beads.
(5) Install wheel and tire assembly on vehicle.
(Refer to 22 - TIRES/WHEELS - INSTALLATION)
(6) Retrain tire pressure sensors. (Refer to 22 -
TIRES/WHEELS/TIRE PRESSURE MONITORING/
SENSOR - STANDARD PROCEDURE)
Fig. 18 Start Mount/Dismount Tool Within 10
Degrees Of Valve Stem
Fig. 19 Sensor Mounting To Wheel
1 - TIRE PRESSURE SENSOR
2 - WHEEL
3 - NUT
22 - 12 TIRES/WHEELSRS
SENSOR - TPM (Continued)

TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressures
Radial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the Tire Identification
chart to decipher the code. For example purposes, the
tire size P225/60 R 16 97 T is used in the chart. An
All Season type tire will also have eitherM+S,M&
SorM-S(indicating mud and snow traction)
imprinted on the side wall. An Extra or Light Load
marking ªXLº or ªLLº may also be listed on the side-
wall. The absence of an ªXLº or ªLLº marking infers
a standard load tire.
TIRE IDENTIFICATION
PTIRE TYPE (Not
present on all tires)P - Passenger
T - Temporary
C - Commercial
LT - Light Truck
225SECTIONAL WIDTHSHOWN IN
MILLIMETERS
60ASPECT RATIOSECTIONAL HEIGHT
÷ SECTIONAL WIDTH
(Refer to Aspect Ratio
Figure 22 )
Fig. 20 Mounting Tire Using Rotating Wheel
Machine
1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
Fig. 21 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
RSTIRES/WHEELS22-13
SENSOR - TPM (Continued)

CAUTION: Do not try to install a tire pressure sen-
sor in a steel wheel or aftermarket wheel. Use only
in original style factory wheels.
OPERATION
The tire pressure sensors are battery operated.
Each sensor transmits tire pressure data approxi-
mately once every minute at speeds above 13 mph
(20 km/h). Each sensor's (transmitter) broadcast is
uniquely coded so that the SKREEM can monitor the
states of each individual sensor on the vehicle.
Unlike prior model year TPM systems, a magnet is
not required to retrain the system. The SKREEM
automatically learns while driving after a sensor has
been replaced. (Refer to 22 - TIRES/WHEELS/TIRE
PRESSURE MONITORING/SENSOR - STANDARD
PROCEDURE) For additional information, refer to Appropriate
Diagnostic Information.
CAUTION
CAUTION: The use of tire sealants is strictly prohib-
ited for vehicles equipped with the Tire Pressure
Monitoring system. Tire sealants can clog tire pres-
sure sensors.
CAUTION: Tire pressure sensor valve stem caps
and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard
valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap
and core.
CAUTION: Do not attempt to install a tire pressure
sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for
the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE
SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fault in the system is detected, always check
air pressure in the tires first with a known accurate
air gauge and correct the inflation pressure. If any
tire is low, inspect allthe tires. If the gauge-read pressure in the tires does not
indicate a tire pressure issue, refer to the appropri-
ate diagnostic information.
STANDARD PROCEDURE - TIRE PRESSURE
SENSOR RETRAIN
CAUTION: If a sensor is replaced, the vehicle must
be parked for a minimum of 15 minutes for the sys-
tem to be ready to learn the new sensor ID code.
(1) Park the car for a minimum of 15 minutes.
(2) Drive the vehicle for a minimum of five min-
utes while maintaining a continuous speed above 13
mph (20 km/h). During this time the system will
learn the new sensor ID code and will clear any
DTC's automatically.
NOTE: If a sensor cannot be trained, refer to appro-
priate diagnostic information.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor: (a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire. (b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem   10É (Fig. 1), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 2). (4) Remove sensor from wheel (Fig. 2).
22s - 2 TIRE PRESSURE MONITORINGRS
SENSOR - TPM (Continued)

INSTALLATION
NOTE: Before reinstalling a tire pressure sensor,
replace sealing grommet at base of valve stem.(1) Wipe area clean where sensor sealing grommet
contacts wheel. Make sure surface of wheel is not
damaged. (2) Install sensor in wheel as shown (Fig. 2). Do
not attempt to mount sensor otherwise, damage may
occur. (3) Using a thin wall socket, install special sensor
nut (Fig. 2). Tighten nut to 4 N´m (35 in. lbs.) torque.
CAUTION: Over-torquing the sensor nut by as little
as 12 N´m (106 in. lbs.) may result in sensor sepa-
ration from the valve stem. Under this condition,
the sensor may still function, however, the condi-
tion should be corrected immediately.
(4) Mount tire on wheel following tire changer
manufacturers instructions, paying special attention
to the following to avoid damaging tire pressure sen-
sor: (a) Rotating Wheel Tire Changers - Once the
wheel is mounted to the changer, position the sen-
sor valve stem approximately 210É from the head
of the changer in a clockwise direction before rotat-
ing the wheel (also in a clockwise direction) to
mount the tire (Fig. 3). Use this procedure on both
the upper and lower tire beads. (b) Rotating Tool Tire Changers - Position the
wheel on the changer so that the sensor valve stem
is approximately 210É from the head of the changer
in a clockwise direction from the mounting end of
the tool (Fig. 4) Make sure the sensor is clear of
the lower bead breaker area to avoid damaging the
sensor when the breaker rises (Fig. 4). Rotate the
tool in a counterclockwise direction to mount the
tire. Use this procedure on both the upper and
lower tire beads.
Fig. 1 Start Mount/Dismount Tool Within 10 Degrees Of Valve Stem
Fig. 2 Sensor Mounting To Wheel
1 - TIRE PRESSURE SENSOR
2 - WHEEL
3 - NUT
Fig. 3 Mounting Tire Using Rotating Wheel Machine
1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
RS TIRE PRESSURE MONITORING22s-3
SENSOR - TPM (Continued)

INSTALLATION
INSTALLATION
NOTE: If a replacement A/C 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 A/C compressor into the engine
compartment.
(2) On models with the 2.4L and 2.5L engine,
loosely install the four bolts that secure the compres-
sor to the mounting bracket on the engine (2.4L), or
the cylinder block (2.5L). Tighten the bolts to 28 N´m
(21 ft. lbs.).
(3) On models with the 3.3L and 3.8L engines,
loosely install the two bolts and two nuts that secure
the compressor to the engine. Tighten each of the fas-
teners 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 bolt at the rear of the compressor.
²The lower bolt at the rear of the compressor.
(4) On models with the 3.3L and 3.8L engines,
engage the retainer on the engine wire harness com-
pressor clutch coil take out to the bracket on the top
of the compressor.
(5) Connect the engine wire harness connector to
the compressor clutch coil pigtail wire connector on
the top of the compressor.
(6) Reinstall the serpentine accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS).
(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 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 the nut that secures the suction line
fitting to the compressor. Tighten the nut to 23 N´m
(17 ft. lbs.).
(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 - A/C COMPRESSOR
MOUNTING BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install the four bolts that secure the compres-
sor mounting bracket to the engine. Tighten the bolts
to 54 N´m (40 ft. lbs.).
(3) Reinstall the A/C compressor onto the mount-
ing bracket (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR -
INSTALLATION).
A/C CONDENSER
DESCRIPTION
The A/C 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 A/C condenser is a
heat exchanger that allows the high-pressure refrig-
erant gas being discharged from the compressor to
give up its heat to the air passing over the condenser
fins. The A/C condenser may be removed from the
cooling module for service without removing the cool-
ing module from the vehicle.
OPERATION
When the refrigerant gas gives up its heat, it con-
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
volume of air flowing over the condenser fins is crit-
ical to the proper cooling performance of the air con-
ditioning 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
24 - 76 PLUMBING - FRONTRS
A/C COMPRESSOR (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)

(4) Install the two screws that secure the rear A/C
expansion valve to the evaporator tube sealing plate.
Tighten the screws to 11 N´m (97 in. lbs.).
(5) Install the rear evaporator line extension onto
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - REAR/EVAPORA-
TOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear HVAC housing, behind the right rear wheel
house. It is a heat exchanger made of rows of tubes
and fins. One end of the core is fitted with a molded
plastic tank that includes integral heater core inlet
and outlet nipples. The rear heater core can be ser-
viced without removing the rear HVAC housing from
the vehicle.
OPERATION
Engine coolant is circulated through underbody
heater hoses to the rear heater core at all times. As
the coolant flows through the rear 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
rear blend door allows control of the rear heater out-
put air temperature by controlling how much of the
air flowing through the rear HVAC housing is
directed through the heater core.
The rear heater core cannot be repaired and, if
faulty or damaged, it must be replaced.
STANDARD PROCEDURE - REAR HEATER
CORE FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-
fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.2.Thermal cycling of the engine cooling system. Fol-
lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
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 - HEATER PLUMBING).
PRE-FILLING
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 reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
HVAC housing, and the rear HVAC housing should
be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
(4) Carefully pour the proper pre-mixed engine
coolant solution into the rear heater core through a
funnel until coolant begins to appear at the lower
hose fitting of the heater core.
(5) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(6) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
RSPLUMBING - REAR24 - 101
A/C EXPANSION VALVE (Continued)