2005 CHRYSLER VOYAGER oil

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)

(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate.
(15) On RG models, disconnect the HVAC wire
harness connector from the evaporator temperature
sensor.
(16) Remove the A/C expansion valve from the
evaporator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
(19) On RG models, remove the evaporator tem-
perature sensor retainer and evaporator temperature
sensor from the A/C expansion valve, if required.
INSTALLATION
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) On RG models, install the evaporator tempera-
ture sensor and retainer onto the A/C expansion
valve, if removed.
(2) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the A/C expansion valve.(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(4) Position the A/C expansion valve onto the evap-
orator inlet and outlet tube fittings.
(5) Install the two screws that secure the A/C
expansion valve to the evaporator tube tapping plate
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(6) On RG models, connect the HVAC wire harness
connector to the evaporator temperature sensor.
(7) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
(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
Fig. 16 A/C Expansion Valve - LHD Shown, RHD
Typical
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR (RG ONLY)
3 - A/C EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
RSPLUMBING - FRONT24-83
EXPANSION VALVE (Continued)

(3) Align the engine compartment ends of both
heater core tubes with the openings in the dash
panel seal and push them simultaneously forward
through the seal far enough to engage the heater
core ends of the tubes with the heater core supply
and return ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
NOTE: The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes
as required so that the sealing plate fits flush
against the heater core supply and return ports,
which indicates that the tubes are properly indexed.
(5) Index both heater core tubes to the heater core
ports.
(6) Install the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports. Tighten the screw to 3 N´m (27 in. lbs.).
(7) Install the silencer under the driver side end of
the instrument panel.
(8) Connect the heater hoses to the heater hose
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/HEATER INLET HOSE - INSTAL-
LATION) and(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER RETURN
HOSE - INSTALLATION).
(9) Reconnect the battery negative cable.
(10) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
FRONT HEATER CORE
(1) While pushing the brake pedal downward and
pulling the accelerator pedal upward far enough for
clearance, slide the heater core into the distribution
housing.
(2) Install the two screws that secure the heater
core mounting plate to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).(3) Install the heater core tubes (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/
HEATER CORE - INSTALLATION).
(4) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm (Refer
to 5 - BRAKES/HYDRAULIC/MECHANICAL/
POWER BRAKE BOOSTER - INSTALLATION).
(5) Reinstall the brake lamp switch into its mount-
ing bracket (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION).
(6) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(7) Reconnect the battery negative cable.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(9) Operate system for two thermostat cycles to
assure the elimination of any air that may be
trapped within the cooling system.
HEATER INLET HOSE
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).
NOTE: The heater inlet hose is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
24 - 86 PLUMBING - FRONTRS
HEATER CORE (Continued)

HEATER RETURN HOSE
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).
NOTE: The heater return tube is constructed from
formed steel tubing and rubber hoses. Depending
on application, the ends are secured to the heater
core, engine oil cooler or the engine by spring ten-
sion clamps.
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Using spring tension clamp pliers, compress
and slide the clamps off of each end of the hose being
removed (Fig. 23), (Fig. 24) or (Fig. 25).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes/heater core, causing an engine coolant leak.
(3) Disconnect each hose end by carefully twisting
the hose back and forth on the tube or nipple, while
gently pulling it away from the end of the tube or
nipple.
NOTE:
Replacement of the heater return hoses will be
required if the hose ends are cut for removal.
(4) If necessary, carefully cut the hose end and
peel the hose off of the tube or nipple.
Fig. 23 Heater Return Hose - 2.4L Shown, 2.5L
Typical
1 - ENGINE OUTLET NIPPLE
2 - HEATER INLET HOSE
3 - HEATER CORE OUTLET
4 - HEATER CORE INLET
5 - SCREW
6 - HEATER TUBE
7 - HEATER RETURN HOSE
8 - ENGINE INLET NIPPLE
Fig. 24 Heater Return Hose - 3.3L/3.8L W/O Rear
Heater
1 - ENGINE OUTLET NIPPLE
2 - HEATER CORE OUTLET
3 - HEATER CORE INLET
4 - HEATER RETURN TUBE (TYPICAL)
24 - 88 PLUMBING - FRONTRS

(15) If the vehicle is equipped with the optional
rear heating-A/C system, go to Step 16. If the vehicle
is not equipped with the optional rear heating-A/C
system, go to Step 22.
(16) Raise and support the vehicle.
(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
ing-A/C system (Fig. 29).
(18) Disconnect the A/C liquid line extension fit-
ting from the underbody liquid line fitting for the
rear A/C system.
(19) Remove the O-ring seal from the underbody
liquid line fitting and discard.
(20) Install plugs in, or tape over the opened liquid
line fittings.
(21) Lower the vehicle.
(22) Remove the rear section of the A/C liquid line
from the engine compartment.
INSTALLATION
FRONT SECTION
(1) Position the front section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the liquid line
fitting and the receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it onto the liquid line fit-
ting.
(4) Connect the A/C liquid line to the receiver/
drier.(5) Install the bolt that secures the A/C liquid line
to the receiver/drier. Tighten the bolt to 11 N´m (97
in. lbs.).
(6) Engage the retainer that secures the liquid line
routing clip to the top of the right frame rail ahead of
the front strut tower in the engine compartment.
(7) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it and a new gasket onto
the liquid line fitting.
(9) Connect the A/C liquid line to the A/C con-
denser.
(10) Install the nut that secures the A/C liquid line
to the A/C condenser. Tighten the nut to 23 N´m (17
ft. lbs.).
(11) Position the radiator sight shield onto the
radiator closure panel crossmember.
(12) 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.).
(13) 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.).
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Reconnect the negative battery cable.
(16) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(17) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
REAR SECTION
(1) Position the rear section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction line
and liquid line fittings.
(4) Reconnect the A/C liquid line and the A/C suc-
tion line to the A/C expansion valve.
(5) Install the nut that secures the rear section of
the A/C liquid line and the A/C suction line to the
A/C expansion valve. Tighten the nut to 23 N´m (17
ft. lbs.).
(6) Remove the tape or plugs from the liquid line
fitting and the receiver/drier outlet port.
Fig. 29 Underbody A/C Line Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
RSPLUMBING - FRONT24-91
LIQUID LINE (Continued)

(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the A/C liquid line to the receiver/
drier.
(9) Install the bolt that secures the A/C liquid line
to the receiver/drier. Tighten the bolt to 11 N´m (97
in. lbs.).
(10) If equipped, reinstall the A/C ground strap
eyelet terminal connector onto the weld stud on the
top of the right front strut tower (if equipped).
(11) If equipped, install the nut that secures the
A/C ground strap to the weld stud. Tighten the nut
to 12 N´m (106 in. lbs.)
(12) Install the A/C pressure transducer (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER - INSTAL-
LATION).
(13) Connect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Install the air cleaner housing into the right
side of the engine compartment.
(15) On RHD models, install the liquid line into
the retaining bracket located at the top of the dash
panel.
(16) If the vehicle is equipped with the optional
rear heating-A/C system, go to Step 17. If the vehicle
does not have the optional rear heating-A/C system,
go to Step 23.
(17) Raise and support the vehicle.
(18) Remove the tape or plugs from the A/C liquid
line extension fitting and the underbody liquid line
fitting.
(19) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(20) Connect the A/C liquid line extension fitting
to the underbody liquid line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(21) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heating-
A/C system.
(22) Lower the vehicle.
(23) Reconnect the negative battery cable.
(24) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(25) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the right front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the liquid line between the
condenser outlet and the evaporator inlet. The receiv-
er/drier cannot be repaired. If the receiver/drier is
faulty or damaged, or if the refrigerant system has
been contaminated or left open to the atmosphere for
an indeterminable period or if the A/C compressor
has failed, it must be replaced.
OPERATION
The receiver/drier performs a filtering action to
prevent foreign material in the refrigerant from con-
taminating the expansion valve. Desiccant inside the
receiver/drier canister absorbs any moisture which
may have entered and become trapped within the
refrigerant system. In addition, during periods of
high demand air conditioner operation, the receiver/
drier acts as a reservoir to store surplus refrigerant.
Refrigerant enters the receiver/drier as a high-pres-
sure, low temperature liquid.
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) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the bolt that secures the liquid line
front section fitting to the top of the receiver/drier
(Fig. 30).
(4) Disconnect the liquid line fitting from the
receiver/drier inlet port.
(5) Remove the O-ring seal from the liquid line fit-
ting and discard.
(6) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier inlet port.
24 - 92 PLUMBING - FRONTRS
LIQUID LINE (Continued)

(7) Remove the bolt that secures the liquid line
rear section fitting to the top of the receiver/drier.
(8) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(9) Remove the seal from the liquid line fitting and
discard.
(10) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(11) Remove the two nuts that secure the receiver/
drier mounting bracket to the weld studs on the side
of the right front strut tower.
(12) Remove the receiver/drier and mounting
bracket unit from the studs.
INSTALLATION
NOTE: If the receiver/drier is being replaced, add 25
milliliters (0.8 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.(1) Position the receiver/drier and mounting
bracket unit onto the weld studs on the side of the
right front strut tower.
(2) Install the two nuts that secure the receiver/
drier mounting bracket to the studs. Tighten the
nuts to 10 N´m (89 in. lbs.).
(3) Remove the tape or plugs from the liquid line
rear section fitting for the receiver/drier and the
receiver/drier outlet port.
(4) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(5) Reconnect the liquid line fitting to the receiver/
drier outlet port on the top of the receiver/drier.
(6) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(7) Remove the tape or plugs from the liquid line
front section fitting for the receiver/drier and the
receiver/drier inlet port.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(9) Reconnect the liquid line fitting to the receiver/
drier inlet port on the top of the receiver/drier.
(10) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 11 N´m
(97 in. lbs.).
(11) Reinstall the air cleaner housing into the
right side of the engine compartment.
(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).
REFRIGERANT
DESCRIPTION
The refrigerant used in this air conditioning sys-
tem is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting
chlorine. R-134a refrigerant is a non-toxic, non-flam-
mable, clear, and colorless liquefied gas. Even though
R-134a does not contain chlorine, it must be
reclaimed and recycled just like CFC-type refriger-
ants. This is because R-134a is a greenhouse gas and
can contribute to global warming.
Fig. 30 Reciever/Drier - LHD Shown, RHD Typical
1 - A/C GROUND STRAP (IF EQUIPPED)
2 - NUT (IF EQUIPPED)
3 - WELD STUD (IF EQUIPPED)
4 - A/C PRESSURE TRANSDUCER
5 - WELD STUD (2)
6 - A/C EXPANSION VALVE
7 - A/C LIQUID LINE (REAR SECTION)
8 - LIQUID LINE EXTENSION (REAR A/C ONLY)
9 - NUT (2)
10 - RECEIVER/DRIER
11 - ROUTING CLIP
12 - A/C LIQUID LINE (FRONT SECTION)
RSPLUMBING - FRONT24-93
RECEIVER / DRIER (Continued)

OPERATION
R-134a refrigerant is not compatible with R-12
refrigerant in an air conditioning system. Even a
small amount of R-12 added to an R-134a refrigerant
system will cause compressor failure, refrigerant oil
sludge or poor air conditioning system performance.
In addition, the PolyAlkylene Glycol (PAG) synthetic
refrigerant oils used in an R-134a refrigerant system
are not compatible with the mineral-based refriger-
ant oils used in an R-12 refrigerant system. R-134a
refrigerant system service ports, service tool couplers
and refrigerant dispensing bottles have all been
designed with unique fittings to ensure that an
R-134a system is not accidentally contaminated with
the wrong refrigerant (R-12). There are also labels
posted in the engine compartment of the vehicle and
on the compressor identifying to service technicians
that the air conditioning system is equipped with
R-134a.
REFRIGERANT OIL
DESCRIPTION
The refrigerant oil used in R-134a refrigerant sys-
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
wax-free lubricant. Mineral-based R-12 refrigerant
oils are not compatible with PAG oils, and should
never be introduced to an R-134a refrigerant system.
There are different PAG oils available, and each con-
tains a different additive package. The compressor
used in this vehicle is designed to use an ND-8 PAG
refrigerant oil. Use only refrigerant oil of this same
type to service the refrigerant system.
OPERATION
After performing any refrigerant recovery or recy-
cling operation, always replenish the refrigerant sys-
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
oil can cause compressor damage, and too much can
reduce air conditioning system performance. PAG
refrigerant oil is much more hygroscopic than min-
eral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil
container should always be kept tightly capped until
it is ready to be used. After use, recap the oil con-
tainer immediately to prevent moisture contamina-
tion.
STANDARD PROCEDURE
REFRIGERANT OIL LEVEL
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).
CAUTION: Use only PAG oils that are designed to
work with R-134a refrigerant and the A/C compres-
sor in the vehicle. Refer to the underhood A/C Sys-
tem Specification Label.
It is important to have the correct amount of lubri-
cant in the A/C refrigerant system to ensure proper
lubrication of the A/C compressor. Too little lubricant
will result in damage to the compressor. Too much
lubricant will reduce the cooling capacity of the A/C
system and consequently result in higher discharge
air temperatures.
The lubricant used in the compressor is polyalka-
lene glycol PAG lubricant. Only the refrigerant lubri-
cant approved for use with this vehicle should be
used to service the system. Do not use any other
lubricant. The lubricant container should be kept
tightly capped until it is ready for use. Refrigerant
lubricant will quickly absorb any moisture it comes
in contact with.
It will not be necessary to check the oil level in the
A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or
leak from a refrigerant line, connector fitting, compo-
nent or component seal. If a leak occurs, add 30 mil-
liliters (1 fluid ounce) of the recommended
refrigerant oil to the refrigerant system after the
repair has been made. Refrigerant oil loss will be evi-
dent at the leak point by the presence of a wet, shiny
surface around the leak.
REFRIGERANT OIL LEVEL CHECK
When an air conditioning system is first assembled
at the factory, all components (except the A/C com-
pressor) are refrigerant oil free. After the refrigerant
system has been charged with (R-134a) refrigerant
and operated, the oil in the A/C compressor is dis-
persed through the lines and components. The A/C
evaporator, A/C condenser, and receiver/drier will
retain a significant amount of oil. Refer to the A/C
Component Refrigerant Oil Capacities table. When a
component is replaced, the specified amount of refrig-
erant oil must be added. When the compressor is
replaced, the amount of oil that is retained in the
24 - 94 PLUMBING - FRONTRS
REFRIGERANT (Continued)