2005 CHRYSLER VOYAGER Module

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)

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)

(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)

(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)