2005 CHRYSLER CARAVAN battery

INSTRUMENT PANEL DUCTS
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 screws that secure the panel ducts
to the instrument panel armature.
(5) Disengage the panel ducts from the panel out-
lets.
(6) Remove the panel ducts from the instrument
panel.
INSTALLATION
(1) Position the panel ducts to the instrument
panel.
(2) Engage the panel ducts to the panel outlets.
(3) Install the screws that secure the panel ducts
to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
RSDISTRIBUTION - FRONT24-55

DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillaR (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear distribution duct upwards far
enough to disengage it from the outlet at the top of
the rear HVAC housing (Fig. 2).
(3) While pulling the lower end of the rear distri-
bution duct away from the rear HVAC housing out-
let, disengage the upper end of the distribution duct
from the headliner duct.
(4) Remove the rea distribution duct from the
vehicle.
INSTALLATION
(1) Align the upper end of the rear distribution
duct to the headliner duct.
(2) Slide the upper end of the rear distribution
duct onto the headliner duct far enough to align the
lower end of the duct with the outlet at the top of the
rear HVAC housing.
(3) Slide the rear distribution duct downwards far
enough to engage it onto the outlet at the top of the
rear HVAC housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
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. The blower motor
and wheel are located near the top of the rear HVAC
housing in the passenger compartment behind the
right rear wheel house. The rear HVAC housing must
be removed from the vehicle to access the blower
motor for service. The blower motor and blower
motor wheel are a factory balanced unit and cannot
be adjusted or repaired. If faulty or damaged, the
blower motor and blower wheel must be replaced as
a unit.
OPERATION
On models equipped with the Manual Temperature
Control (MTC) system, the rear blower motor will
operate only whenever the ignition switch is in the
On position, the front blower control switch is in any
position except Off and the rear blower control switch
on the front A/C-heater control is in any position
except Off. On models equipped with the Automatic
Temperature Control (ATC) system, the blower motor
will operate whenever the ignition switch is in the
On position, the A/C-heater control power is turned
on and the rear blower control switch on the front
A/C-heater control is in any position except Off. The
rear blower motor can only be turned off by turning
off the rear system at the front A/C-heater control.
The rear blower motor receives battery current
whenever the rear blower motor relay is energized.
The rear blower motor relay output circuit is pro-
tected by a fuse in the Integrated Power Module
(IPM) located in the engine compartment near the
battery. In the MTC system, the rear 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 rear blower
motor speed is controlled by an electronic blower
motor power module, which uses a pulse width mod-
ulated input from the ATC control module and feed-
back from the rear blower motor to regulate the
blower motor ground path it provides. The rear
blower motor and wheel are used to control the veloc-
ity of air moving through the rear HVAC housing.
The rear blower motor controls the velocity of the air
flowing through the rear HVAC housing by spinning
the blower wheel within the housing at the selected
speed or, in the ATC system, at the selected or pro-
grammed speed.
Fig. 2 Rear Distribution Duct
1 - HEADLINER DUCT
2 - REAR DISTRIBUTION DUCT
3 - REAR HVAC HOUSING OUTLET
RSDISTRIBUTION - REAR24-57

DIAGNOSIS AND TESTING
REAR BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Integrated Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Turn the ignition switch to the On position. Be
certain that the rear A/C-heater control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, check the rear blower motor relay.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector
from the rear blower motor resistor block (Manual
Temperature Control) or the rear blower motor power
module (Automatic Temperature Control). Reconnect
the battery negative cable. Turn the ignition switch
to the On position. Be certain that the rear A/C-
heater control power is turned on. Check for battery
voltage at the fused rear blower motor relay output
circuit cavity of the rear HVAC wire harness connec-
tor for the rear blower motor resistor block (MTC) or
the rear blower motor power module (ATC). If OK, go
to Step 4. If not OK, repair the open fused front
blower motor relay output circuit to the IPM as
required.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.Disconnect the rear blower motor pigtail wire connec-
tor from the rear HVAC wire harness (MTC) or the
rear blower power module (ATC). Use jumper wires
to connect a battery and ground feeds to the blower
motor pigtail wire connector. The rear blower motor
should operate. If OK with MTC, proceed to diagno-
sis of the rear blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- REAR/BLOWER MOTOR RESISTOR - DIAGNOSIS
AND TESTING). If OK with ATC, use a DRBIII scan
tool to diagnose the rear blower motor power module.
Refer to the appropriate diagnostic information. If
not OK with MTC or ATC, replace the faulty rear
blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart for basic checks of the blower motor when a
vibration or noise is present (Fig. 3).
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 -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control sys-
tem, the blower motor pigtail wire is connected to a
take out and connector of the rear HVAC wire har-
ness. With the Automatic Temperature Control sys-
tem , the blower pigtail wire is connected to a
receptacle on the blower motor power module.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

(3) Remove the three screws that secure the rear
blower motor to the outboard side of the rear HVAC
housing (Fig. 4).
(4) Remove the rear blower motor from the rear
HVAC housing.
INSTALLATION
(1) Position the rear blower motor into the rear
HVAC housing.
(2) Install the three screws that secure the blower
motor to the rear HVAC housing. Tighten the screws
to 2 N´m (17 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control system
, the blower pigtail wire is connected to a take out
and connector of the rear HVAC wire harness. With
the Automatic Temperature Control system, the
blower pigtail wire is connected to a receptacle on
the blower motor power module.(4) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
HVAC HOUSING
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) 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
RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Raise and support the vehicle.
(5) Remove the nut that secures the underbody
refrigerant line sealing plate to the rear evaporator
extension line tapping plate that extends through the
rear floor panel behind the right rear wheel housing
(Fig. 5) and (Fig. 6).
(6) Disconnect the underbody refrigerant lines
from the rear evaporator extension line tapping plate
and remove and discard the O-ring seals.
(7) Install plugs in, or tape over the opened under-
body refrigerant line fittings and the evaporator
extension line sealing plate ports.
(8) Remove the nuts from the mounting studs that
secure the rear HVAC housing to the rear floor panel
behind the right rear wheel housing (Fig. 7).
(9) Lower the vehicle.
(10) Remove the right quarter trim panel and
right D-pillar trim panel from the quarter inner
panel (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - REMOVAL).
(11) Remove the rear 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.
Fig. 4 Rear Blower Motor
1 - REAR HVAC HOUSING
2 - REAR BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER MOTOR PIGTAIL WIRE
24 - 60 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

(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
refrigerant line fittings and both ports in the rear
evaporator extension line sealing plate.
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the underbody
refrigerant line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line tapping
plate.
(18) Install the nut that secures the underbody
refrigerant line sealing plate to the evaporator exten-
sion line tapping plate. Tighten the nut to 23 N´m
(17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
(21) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(24) Run the HVAC Cooldown test to verify proper
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).REAR FLOOR HEAT DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
floor heat duct to the right quarter inner panel (Fig.
9).
(3) Slide the rear floor heat duct forward far
enough to disengage it from the outlet on the front of
the rear HVAC housing.
(4) Remove the rear floor heat duct from the vehi-
cle.
INSTALLATION
(1) Align the inlet end of rear floor heat duct with
the outlet on the front of the rear HVAC housing.
(2) Slide the rear floor heat duct rearward far
enough to fully engage the inlet end of the duct with
the outlet on the rear HVAC housing.
(3) Install the two screws that secure the rear floor
heat duct to the right quarter inner panel. Tighten
the screws to 2 N´m (17 in. lbs.).
(4) Reinstall the trim onto the right quarter inner
panel (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - INSTALLATION).
Fig. 9 Rear Floor Heat Duct
1 - REAR FLOOR HEAT DUCT
2 - REAR HVAC HOUSING OUTLET
3 - SCREW (2)
RSDISTRIBUTION - REAR24-63
HVAC HOUSING (Continued)

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
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)