2005 CHRYSLER CARAVAN cooling

NOTE: Prior to a vehicle being removed from ser-
vice or stored for more than two weeks, the com-
pressor should be operated to ensure adequate
refrigerant oil distribution throughout the system
components. Turn on the air conditioner for a min-
imum of five minutes with outside air and the high-
est blower speed selected.
BELT NOISE
If the compressor drive belt slips at initial start-up,
it does not necessarily mean the compressor has
failed. The following procedure can be used to iden-
tify a compressor drive belt noise problem.
A. Start the vehicle and run at idle.
B. Turn the air conditioner On and listen for belt
squeal.
C. If belt squeal is heard, turn the air conditioner
Off immediately.
If the belt squeal stops when the air conditioner is
turned Off, perform the following repair procedures.
(1) Using an appropriate sized oil filter wrench or
a strap wrench, grasp the outer diameter of the com-
pressor clutch hub. While facing the compressor,
rotate the hub clockwise, then counterclockwise. If
the hub rotates, proceed to the next step. If the hub
will not rotate, the compressor is internally damaged,
and must be replaced.
(2) Turn the hub clockwise five complete revolu-
tions and remove the tool.
(3) Start the vehicle and run at idle.
(4) Turn the air conditioner On. Observe the com-
pressor and the system for normal operation, noting
cooling performance and noise levels. Operate for five
minutes before turning the air conditioner Off. If
acceptable cooling performance is observed during
compressor operation, the compressor does not need
to be replaced.
(5) Inspect the drive belt for wear, damage, and
proper tension. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND TEST-
ING).
REMOVAL
A/C COMPRESSOR
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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
RECOVERY).
(2) Disconnect and isolate the negative battery
cable.
(3) Remove the nuts that secure the A/C suction
line and the A/C discharge line to the A/C compres-
sor.
(4) Disconnect the A/C suction line and the A/C
discharge line from the A/C compressor.
(5) Remove the O-ring seal and gasket from the
suction and discharge line fittings and discard.
(6) Install plugs in, or tape over the opened suc-
tion and discharge fittings and the compressor ports.
(7) Raise and support the vehicle.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Disconnect the wire harness connector from the
compressor clutch coil wire connector located on the
top of the A/C compressor (Fig. 4) or (Fig. 5).
(10) On models with the 2.4L, 2.5L and 2.8L
engine, remove the four bolts that secure the A/C
compressor to the mounting bracket on the engine
(2.4L), or the cylinder block (2.5L/2.8L).
Fig. 4 A/C Compressor - 2.4L Shown, 2.5L/2.8L
Typical
1 - CLUTCH COIL WIRE CONNECTOR
2 - DISCHARGE PORT
3 - A/C COMPRESSOR
4 - SUCTION PORT
5 - BOLT (4)
6 - A/C COMPRESSOR MOUNTING BRACKET
RSPLUMBING - FRONT24-73
A/C COMPRESSOR (Continued)

²The upper bolt at the rear of the compressor.
²The lower bolt at the rear of the compressor.
(4) Connect the wire harness connector to the com-
pressor clutch coil wire connector.
(5) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(6) Lower the vehicle.
(7) Remove the tape or plugs from the suction and
discharge line fittings and the compressor ports.
(8) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them and a new gasket
onto the suction and discharge line fittings.
(9) Connect the A/C suction line and the A/C dis-
charge line to the A/C compressor.
(10) Install the nut that secures the A/C suction
line and the A/C discharge line to the A/C compres-
sor. Tighten the nuts to 23 N´m (17 ft. lbs.).
(11) Reconnect the negative battery cable.
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
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 located in the front of the
engine compartment behind the front fascia. The A/C
condenser is a heat exchanger that allows the high-
pressure refrigerant gas being discharged by the A/C
compressor to give up its heat to the air passing over
the condenser fins, which causes the refrigerant to
cool and change to a liquid state.The A/C condenser may be removed for service
without removing the radiator and cooling fan from
the vehicle.
The A/C condenser for vehicles equipped with the
2.4L/3.3L/3.8L engines are equipped with an integral
automatic transmission cooler and mounting provi-
sions.
OPERATION
When air passes through the fins of the A/C con-
denser, the high-pressure refrigerant gas within the
A/C condenser gives up its heat. The refrigerant then
condenses as it leaves the A/C condenser and
becomes a high-pressure liquid. The volume of air
flowing over the condenser fins is critical to the
proper cooling performance of the A/C system. There-
fore, it is important that there are no objects placed
in front of the radiator grille openings at the front of
the vehicle or foreign material on the condenser fins
that might obstruct proper air flow. Also, any factory-
installed air seals or shrouds must be properly rein-
stalled following radiator or A/C condenser service.
The A/C condenser cannot be repaired and, if
faulty or damaged, it must be replaced.
Fig. 7 A/C Condenser ± 2.4L/3.3L/3.8L Engines
1 - A/C CONDENSER
2 - AUTO TRANS COOLER TAPPING BLOCK
3 - UPPER CONDENSER MOUNTING BRACKET (2)
4 - RADIATOR
5 - LOWER CONDENSER MOUNTING BRACKET (2)
RSPLUMBING - FRONT24-75
A/C COMPRESSOR (Continued)

REMOVAL
2.4L/3.3L/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).
NOTE: Before removing the A/C condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the A/C condenser and radiator. The air seals must
be reinstalled in their proper locations in order for
the A/C and engine cooling systems to perform as
designed.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
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. 8).
(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 bolts that secure the hood
latch to the front of the radiator closure panel cross-
member and move the latch out of the way over the
top of the crossmember. Mark the location of latch for
reinstallation.
(6) Disconnect the transmission oil cooler line
quick-connect fittings located on the driver side of
the A/C condenser from the transmission oil cooler
(Refer to 7 - COOLING/TRANSMISSION - STAN-
DARD PROCEDURE - TRANSMISSION COOLING).
(7) Disconnect the A/C discharge line and the A/C
liquid line from the A/C condenser (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
LIQUID LINE - REMOVAL).
(8) Install plugs in, or tape over the opened refrig-
erant line fittings and the condenser ports.
(9) Disengage the retaining clips that secure the
upper A/C condenser mounting brackets to the radi-
ator.
(10) Lift the A/C condenser straight up to disen-
gage the lower A/C condenser mounting brackets
from the radiator.
(11) Carefully remove the A/C condenser from the
engine compartment.
Fig. 8 Radiator Sight Shield ± Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
Fig. 9 A/C Condenser
1 - A/C CONDENSER
2 - LOWER CONDENSER MOUNTING BRACKET (2)
3 - REFRIGERANT LINE PORTS
4 - RETAINING CLIP (2)
5 - UPPER CONDENSER MOUNTING BRACKET (2)
6 - RADIATOR
24 - 76 PLUMBING - FRONTRS
A/C CONDENSER (Continued)

2.5L/2.8L DIESEL 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).
NOTE: Before removing the A/C condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the A/C condenser and radiator. The air seals must
be reinstalled in their proper locations in order for
the A/C and engine cooling systems to perform as
designed.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
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. 8).
(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 bolts that secure the hood
latch to the front of the radiator closure panel cross-
member and move the latch out of the way over the
top of the crossmember. Mark the location of latch for
reinstallation.
(6) Disconnect the transmission oil cooler hoses
from the left side of the cooling module (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER
LINES - REMOVAL).
(7) Disconnect the A/C discharge line and the A/C
liquid line from the A/C condenser (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - REMOVAL) and (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
LIQUID LINE - REMOVAL).
(8) Install plugs in, or tape over the opened refrig-
erant line fittings and the condenser ports.
(9) Remove the two screws that secure the top of
the mounting bracket on each side of the A/C con-
denser to the cooling module.
(10) Lift the A/C condenser, transmission oil cooler,
and mounting brackets as an assembly far enough to
disengage the lower mounting brackets from the rub-
ber isolators located on each side of the cooling mod-
ule.
(11) Remove the A/C condenser, transmission oil
cooler, and mounting brackets from the vehicle as an
assembly.
(12) Place the assembly on a workbench and
remove the two screws that secure each mounting
bracket to the A/C condenser.
(13) Remove the one screw that secures the left
mounting bracket to the side of the transmission oil
cooler.
(14) Remove the left mounting bracket from the
side of the A/C condenser and transmission oil cooler.
(15) Remove the A/C condenser from the right
mounting bracket and transmission oil cooler.
INSTALLATION
2.4L/3.3L/3.8L ENGINES
NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.7 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.
Fig. 10 Radiator Sight Shield ± Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-77
A/C CONDENSER (Continued)

(1) Position the A/C condenser into the engine
compartment.
(2) Carefully lower the A/C condenser straight
down to engage the lower mounting brackets to the
radiator.
(3) Engage the upper A/C condenser mounting
brackets to the radiator. Be sure that the upper
retaining clips are fully engaged to the upper mount-
ing brackets.
(4) Remove the tape or plugs from the opened
refrigerant line fittings and the condenser ports.
(5) Connect the A/C discharge line and the A/C liq-
uid line to the A/C condenser (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C LIQUID LINE - INSTALLATION).
(6) Connect the transmission oil cooler lines to the
A/C Condenser. Be sure that the quick-connect fit-
tings are fully engaged to the cooler tapping block
(Refer to 7 - COOLING/TRANSMISSION - STAN-
DARD PROCEDURE - TRANSMISSION COOLING).
(7) Position the hood latch onto the front of the
radiator closure panel crossmember.
(8) Install the two screws that secure the hood
latch to the crossmember. Check and adjust the hoodlatch as required. Tighten the bolts to 14 N´m (123
in. lbs.).
(9) Position the radiator sight shield onto the radi-
ator closure panel crossmember.
(10) Install the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
Tighten the screws to 2 N´m (17 in. lbs.).
(11) Install 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. Tighten the screws to 6 N´m (53 in. lbs.).
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
2.5L/2.8L DIESEL ENGINES
NOTE: If the A/C condenser is being replaced, add
50 milliliters (1.7 fluid ounce) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
NOTE: Be certain that each of the radiator and con-
denser air seals are reinstalled in their proper loca-
tions. These air seals are required for proper A/C
and engine cooling system operation.
(1) Position the A/C condenser onto the right
mounting bracket and transmission oil cooler unit.
(2) Position the left mounting bracket onto the side
of the A/C condenser and transmission oil cooler.
(3) Install the screw that secures the left mounting
bracket to the side of the transmission oil cooler.
Tighten the screw to 5 N´m (45 in. lbs.).
(4) Install the two screws that secure each mount-
ing bracket to the sides of the A/C condenser. Tighten
the screws to 5 N´m (45 in. lbs.).
NOTE: Verify that the A/C condenser isolators are
all installed and positioned correctly.
(5) Position the A/C condenser, transmission oil
cooler, and mounting brackets into the vehicle as an
assembly. Be certain that the lower mounting brack-
ets are engaged into the rubber isolators located on
each side of the cooling module.
(6) Install the two screws that secure the top of
the mounting bracket on each side of the A/C con-
denser to the cooling module. Tighten the screws to 5
N´m (45 in. lbs.).
Fig. 11 A/C Condenser ± 2.5L/2.8L Diesel Engines
1 - BOLT (2)
2 - LOWER MOUNT ISOLATOR (2)
3 - A/C CONDENSER
24 - 78 PLUMBING - FRONTRS
A/C CONDENSER (Continued)

(7) Remove the tape or plugs from the opened
refrigerant line fittings and the condenser ports.
(8) Connect the A/C discharge line and the A/C liq-
uid line to the A/C condenser (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C
DISCHARGE LINE - INSTALLATION) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C LIQUID LINE - INSTALLATION).
(9) 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).
(10) Reposition the hood latch to the front of the
radiator closure panel crossmember.
(11) Install the two screws that secure the hood
latch to the front of the radiator closure panel cross-
member. Check and adjust the hood latch as needed.
Tighten the screws to 14 N´m (123 in. lbs.).
(12) Position the radiator sight shield onto the
radiator closure panel crossmember.
(13) Install the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
Tighten the screws to 2 N´m (17 in. lbs.).
(14) Install 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. Tighten the screws to 6 N´m (53 in. lbs.).
(15) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(16) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
A/C 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 CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT SYSTEM
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. 12).
(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 A/C discharge
line to the right side of the A/C condenser (Fig. 13).
(6) Disconnect the A/C discharge line from the A/C
condenser and remove and discard the O-ring seal
and gasket.
(7) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(8) Remove the nut that secures the A/C discharge
line to the A/C compressor (Fig. 14).
(9) Disconnect the A/C discharge line from the A/C
compressor and remove and discard the O-ring seal
and gasket.
(10) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(11) Remove the A/C discharge line from the
engine compartment.
Fig. 12 Radiator Sight Shield - Typical
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-79
A/C CONDENSER (Continued)

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) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) Disassemble the HVAC housing to access the
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
ASSEMBLY).
(3) Carefully lift the evaporator and its foam wrap
out of the lower half of the HVAC housing as a unit
(Fig. 15). Be certain not to lose the clam shell type
rubber seal that is fitted to the evaporator inlet and
outlet tubes where they exit the HVAC housing.
INSTALLATION
NOTE: If the evaporator is being replaced, add 50
milliliters (1.7 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
(1) Carefully lower the evaporator and its foam
wrap into the lower half of the HVAC housing as a
unit. Be certain that the clam shell type rubber seal
is fitted to the evaporator inlet and outlet tubes
where they exit the HVAC housing.
(2) Assemble the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY).
(3) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
EXPANSION VALVE
DESCRIPTION
The front ªHº valve-type thermal expansion valve
(TXV) is located at the dash panel between the liquid
and suction lines, and the A/C evaporator. The
assembly consists of an aluminum H-valve body and
a thermal sensor. On RG models, the evaporator tem-
perature sensor is installed on the top of the expan-
sion valve.
OPERATION
High-pressure, low temperature liquid refrigerant
from the liquid line passes through the expansion
valve orifice, converting it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the evaporator coil. A mechanical sensor in the
expansion valve control head monitors the tempera-
ture and pressure of the refrigerant leaving the evap-
orator coil through the suction line, and adjusts the
orifice size at the liquid line to let the proper amount
of refrigerant into the evaporator coil to meet the
vehicle cooling requirements. Controlling the refriger-
ant flow through the A/C evaporator ensures that
none of the refrigerant leaving the evaporator is still
in a liquid state, which could damage the compressor.
The A/C expansion valve is a factory calibrated
unit and cannot be adjusted or repaired and, if faulty
or damaged, it must be replaced.
Fig. 15 HVAC Housing - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR AND WHEEL
4 - A/C EVAPORATOR
RSPLUMBING - FRONT24-81
A/C EVAPORATOR (Continued)

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 door
allows 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
FRONT 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. 17).
(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.
(9) Remove the heater core tubes and sealing plate
as a unit from beneath the instrument panel.
(10) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
Fig. 17 Heater Core Tubes - LHD Shown, RHD
Typical
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
24 - 84 PLUMBING - FRONTRS
HEATER CORE (Continued)