2005 CHRYSLER VOYAGER engine

(9) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(10) Release the four latch tabs that secure the
heater core into the rear HVAC housing.
(11) Carefully pull the heater core straight out of
the rear HVAC housing.
(12) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear HVAC
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Carefully slide the heater core into the rear
HVAC housing.
(2) Using hand pressure, press firmly and evenly
on the heater core end plate until the four latch tabs
that secure the heater core in the rear HVAC housing
are fully engaged.
(3) Remove the plugs or tape from the heater core
fittings and both heater hoses.
(4) Reconnect the heater hoses to the rear heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(5) Install the screw that secures the front of the
rear HVAC housing to the right quarter inner panel.
Tighten the screw to 11 N´m (97 in. lbs.).
(6) Install the screw that secures the back of the
rear HVAC housing to the right D-pillar. Tighten the
screw to 11 N´m (97 in. lbs.).
(7) Install the rear heater distribution duct (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION - REAR/REAR HEATER DISTRIBUTION
DUCT - INSTALLATION).
(8) Install the right quarter trim panel and right
D-pillar trim panel (Refer to 23 - BODY/INTERIOR/
QUARTER TRIM PANEL - INSTALLATION).
(9) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
HEATER HOSES
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).
(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.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(3) Disconnect the front underbody heater inlet
and return hose by carefully twisting the hoses back
and forth on the underbody tubes, while gently pull-
ing them away from the end of the tubes (Fig. 6).
(4) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.
NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
Fig. 6 Underbody Heater Hose Connections - Front
1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - RETAINER STRAP (3)
4 - HEATER TUBES
5 - UNDERBODY LINES
24 - 104 PLUMBING - REARRS
HEATER CORE (Continued)

INSTALLATION
(1) Install the front underbody heater inlet and
return hoses by carefully twisting the hoses back and
forth on the underbody tubes, while gently pushing
them onto the end of the tubes.
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(2) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose over the tubes. Release the clamp when
it is over the tube.
(3) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
LIQUID 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).
NOTE: On models equipped with the optional rear
A/C system, the rear section of the front air condi-
tioner liquid line also includes a liquid line hose
and tube extension that connects the front liquid
line to the underbody liquid line for the rear A/C
system.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the A/C pressure transducer (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/A/C PRESSURE TRANSDUCER -
REMOVAL).(6) If equipped, remove the nut that secures the
A/C ground strap to the weld stud on the top of the
right front strut tower (Fig. 7).
(7) If equipped, remove the A/C ground strap eye-
let terminal connector from the weld stud.
(8) Remove the bolt that secures the liquid line
rear section fitting to the top of the receiver/drier.
(9) Disconnect the liquid line fitting from the
receiver/drier outlet port.
(10) Remove the O-ring seal from the liquid line
fitting and discard.
(11) Install plugs in, or tape over the opened liquid
line fitting and the receiver/drier outlet port.
(12) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(13) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(14) Remove the seals from the suction line and
liquid line fittings and discard.
(15) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(16) Raise and support the vehicle.
Fig. 7 Liquid Line
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 - REAR24 - 105
HEATER HOSES (Continued)

(17) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear heat-
er-A/C system (Fig. 8).
(18) Disconnect the front liquid line extension fit-
ting from the underbody liquid line fitting for the
rear air conditioner.
(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 liquid line from the engine com-
partment.
INSTALLATION
(1) Position the rear section of the front 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 on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid line
rear section fitting for the receiver/drier and the
receiver/drier outlet port.(7) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(8) Reconnect the liquid line fitting to the receiver/
drier outlet port on the top of the receiver/drier.
(9) Install the bolt that secures the liquid line fit-
ting 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/
A/C PRESSURE TRANSDUCER - INSTALLATION).
(13) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(14) Reinstall the air cleaner housing into the
right side of the engine compartment.
(15) Raise and support the vehicle.
(16) Remove the tape or plugs from the liquid line
rear section extension fitting and the underbody liq-
uid line fitting.
(17) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody liquid
line fitting.
(18) Reconnect the liquid line rear section exten-
sion fitting to the underbody liquid line fitting.
Tighten the fittings to 23 N´m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater-
A/C system.
(20) Lower the vehicle.
(21) Reconnect the battery negative cable.
(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).
SUCTION LINE
REMOVAL
On models equipped with the optional rear A/C
system, the front air conditioner suction line also
includes a suction line hose and tube extension that
connects the front suction line to the underbody suc-
tion line for the rear A/C system.
Fig. 8 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
24 - 106 PLUMBING - REARRS
LIQUID LINE (Continued)

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) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner top cover and snorkel
from the air cleaner housing located on the right side
of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment (Fig. 9).
(10) Remove the nut that secures the suction line
and liquid line fittings to the front expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the front expansion valve.
(12) Remove the O-ring seals from the suction line
and liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Raise and support the vehicle.
(15) Cut the tie strap located just forward of the
connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 10).
(16) Disconnect the suction line extension fitting
from the underbody suction line fitting for the rear
air conditioner.
(17) Remove the O-ring seal from the underbody
suction line fitting and discard.
(18) Install plugs in, or tape over the opened suc-
tion line fittings.
(19) Lower the vehicle.
(20) Remove the suction line from the engine com-
partment.
INSTALLATION
(1) Position the suction line into the engine com-
partment.
(2) Remove the tape or plugs from the suction line
and liquid line fittings and both expansion valve
ports.
Fig. 9 Suction Line
1 - A/C EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - RETAINING CLIP
5 - SUCTION LINE
Fig. 10 Underbody 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 - REAR24 - 107
SUCTION LINE (Continued)

(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the suction line
and liquid line fittings.
(4) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(5) Install the nut that secures the suction line
and liquid line fittings to the front expansion valve.
Tighten the nut to 23 N´m (17 ft. lbs.).
(6) Engage the retainer that secures the suction
line routing clip to the receiver/drier mounting
bracket on the side of the right front strut tower in
the engine compartment.
(7) Remove the tape or plugs from the compressor
suction port and the suction line fitting.
(8) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the suction line fit-
ting.
(9) Reconnect the suction line fitting to the com-
pressor suction port.
(10) Install the nut that secures the suction line
fitting to the A/C compressor. Tighten the nut to 23
N´m (17 ft. lbs.).
(11) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(12) Reinstall the air cleaner top cover and snorkel
onto the air cleaner housing located on the right side
of the engine compartment.
(13) Reconnect the battery negative cable.
(14) Raise and support the vehicle.
(15) Remove the tape or plugs from the suction
line extension fitting and the underbody suction line
fitting.
(16) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the underbody suction
line fitting.(17) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fitting
to 23 N´m (17 ft. lbs.).
(18) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(19) Lower the vehicle.
(20) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(21) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
The underbody heater-A/C plumbing is used only
on models with the optional rear heater-A/C system
(Fig. 11). The underbody suction line, liquid line, and
heater tubes can each be serviced separately.
OPERATION
The rear heater and A/C lines are all serviced as
individual components. When disconnecting any lines
or connections, make sure that the area around the
line or connection is clean of any dirt or residue that
may enter and contaminate the rear heating-A/C sys-
tem (Fig. 12) and (Fig. 13).
Fig. 11 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
24 - 108 PLUMBING - REARRS
SUCTION LINE (Continued)

WARNING: HIGH PRESSURES ARE PRODUCED IN
THE REFRIGERANT SYSTEM WHEN THE A/C COM-
PRESSOR IS OPERATING. HIGH TEMPERATURE
COOLANT IS PRESENT IN THE HEATER PLUMBING
WHEN THE ENGINE IS OPERATING. EXTREME
CARE MUST BE EXERCISED WHEN SERVICING
THE REAR HEATER AND A/C LINES TO PREVENT
POSSIBLE PERSONAL INJURY.
Any kinks or sharp bends in the rear heater-A/C
plumbing will reduce the capacity of the entire heat-
ing-A/C system. Kinks and sharp bends reduce the
system flow. High pressures are produced in the
refrigerant system when the A/C compressor is oper-
ating. High temperature coolant is present in the
heater plumbing when the engine is operating.
Extreme care must be exercised to make sure that
each of the connections is pressure-tight and leak
free.
REMOVAL
UNDERBODY HEATER TUBES
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).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).(2) Raise and support vehicle.
(3) Disconnect the underbody heater tubes at the
rear of the vehicle by releasing the insert in the
underbody heater tube quick connect fittings and
carefully pulling downward on the heater tube fit-
tings (Fig. 14).
(4) Lower the underbody heater tubes and drain
any residual coolant from the tubes into a suitable
container.
Fig. 12 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
Fig. 13 Front Extension Lines to Underbody Lines ±
Typical
RSPLUMBING - REAR24 - 109
UNDERBODY LINES (Continued)

(5) Using spring tension clamp pliers, compress
and slide the clamps off of the rubber hoses at the
front of the underbody heater tubes (Fig. 15).
CAUTION:
DO NOT apply excessive pressure on heater tubes
or connections when removing heater hoses.
Excessive pressure may damage or deform the
tubes, causing an engine coolant leak.
(6) Disconnect the heater hoses by carefully twist-
ing the hoses back and forth on the rear heater
extension tubes, while gently pulling them away
from the end of the tubes.
(7) If necessary, carefully cut the hose ends and
peel the hoses off of the tubes.NOTE:
Replacement of the heater hoses will be required if
the hose ends are cut for removal.
(8) Remove the screws that secure the underbody
line retaining straps to the vehicle underbody.
(9) Remove the underbody heater tubes from the
retaining straps.
(10) Remove the underbody heater tubes from the
vehicle.
UNDERBODY REFRIGERANT LINES
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 - STANDARD PROCE-
DURE - REFRIGERANT RECOVERY).
(2) Raise and support vehicle.
(3) Disconnect the exhaust system from the
exhaust hanger rubber isolators and position the
exhaust system out of the way (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(4) Disconnect the underbody refrigerant lines
from the front liquid and suction line extension tubes
and remove and discard the O-ring seals. (Fig. 16).
Fig. 15 Underbody Connections
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 16 Underbody A/C Line Front Connections ±
Typical
1 - SUCTION LINE EXTENSION TUBE
2 - LIQUID LINE EXTENSION TUBE
3 - RETAINING STRAP
4 - REAR HEATER EXTENSION TUBES
5 - UNDERBODY REFRIGERANT LINES
Fig. 14 Underbody Heater Tube Quick Connect
Fittings
1 - INSERT
2 - QUICK CONNECT FITTING
3 - COMPRESS INSERT FOR REMOVAL
24 - 110 PLUMBING - REARRS
UNDERBODY LINES (Continued)

INSTALLATION
UNDERBODY HEATER TUBES
(1) Position the underbody heater tubes onto the
vehicle underbody.
(2) Install the underbody heater tubes into the
underbody line retaining straps.
(3) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.
(4) Connect the rubber hoses at the front of the
underbody heater tubes to the rear heater extension
tubes.
(5) Using spring tension clamp pliers, compress
and slide the clamps that secure the heater hoses
over the extension tubes. Release the clamp when it
is correctly positioned over the tube.
(6) Connect the rear underbody heater tube quick
connections to the rear heater core extension tubes.
(7) Lower the vehicle.
(8) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
UNDERBODY REFRIGERANT LINES
(1) If removed, install the underbody refigerant
lines into the underbody refrigerant line sealing plate
and install the nylon wedges that secure the refrig-
erant lines to the sealing plate.
(2) Position the underbody refrigerant lines onto
the vehicle underbody.
(3) Install the underbody refrigerant lines into the
underbody line retaining straps.
(4) Install the bolts that secure the retaining
straps to the vehicle underbody. Tighten the screws
securely.(5) Remove the tape or plugs from the rear under-
body refrigerant line fittings and the rear evaporator
extension line ports.
(6) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(7) Connect the underbody refrigerant lines to the
rear evaporator extension line tapping plate.
(8) Install the bolt or nut (depending on applica-
tion) that secures the underbody refrigerant line
sealing plate to the rear evaporator extension line
tapping plate. Tighten the bolt or nut to 23 N´m (17
ft. lbs.).
(9) Remove the tape or plugs from the front liquid
and suction line extension tubes and the underbody
refrigerant line fittings.
(10) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the underbody
refrigerant line fittings.
(11) Connect the underbody refrigerant line fit-
tings to the front liquid and suction line extension
tubes. Tighten the fittings to 23 N´m (17 ft. lbs.).
(12) Position the exhaust system and install it to
the exhaust hanger rubber isolators (Refer to 11 -
EXHAUST SYSTEM - DESCRIPTION).
(13) Lower the vehicle.
(14) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM EVACUATE).
(15) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIGER-
ANT SYSTEM CHARGE).
24 - 112 PLUMBING - REARRS
UNDERBODY LINES (Continued)