Content .. 896 897 898 899 ..

Chrysler Pacifica. Manual - part 898

(11) Install the radiator air seals and the air seal

retaining pins.

(12) Install the radiator sight shield and the sight

shield retaining pins.

(13) Install the front fascia (Refer to 13 - FRAME

& BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).

(14) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

(15) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).

A/C DISCHARGE LINE

REMOVAL

WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.

NOTE: Before removing the A/C condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
A/C condenser and the 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

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Remove the front fascia (Refer to 13 - FRAME

BUMPERS/BUMPERS/FRONT

FASCIA

REMOVAL).

(3) Remove the four radiator sight shield retaining

pins and the radiator sight shield.

(4) Remove the radiator air seal retaining pins and

the air seals (Fig. 10).

(5) Remove the nut that secures the A/C discharge

line to the A/C condenser (Fig. 11).

(6) Disconnect the A/C discharge line from the A/C

condenser and remove and discard the O-ring seal
and gasket.

(7) Install plug in, or tape over the opened dis-

charge line fitting and the condenser port.

(8) Remove the nut that secures the A/C discharge

line to the A/C compressor (Fig. 12).

(9) Disconnect the A/C discharge line from the A/C

compressor and remove and discard the O-ring seal
and gasket.

(10) Install plug in, or tape over the opened dis-

charge line fitting and the compressor port.

(11) Remove the A/C discharge line from the

engine compartment.

INSTALLATION

(1) Position the A/C discharge line into the engine

compartment.

(2) Remove the tape or plugs from the discharge

line fitting and the compressor port.

(3) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it and a new gasket onto
the discharge line fitting.

Fig. 10 Radiator Air Seals

1 - AIR SEAL (RT SIDE SHOWN, LT SIDE SIMILAR)
2 - UPPER RADIATOR CROSSMEMBER
3 - UPPER CONDENSER MOUNTING BOLT (2)
4 - TRANSMISSION FLUID OIL COOLER
5 - A/C CONDENSER
6 - BOLTS (4)
7 - LOWER CONDENSER MOUNT (2)
8 - UPPER AIR SEAL
9 - PUSH PINS (12)

Fig. 11 Discharge Line to Condenser

1 - NUT
2 - LIQUID LINE FITTING
3 - CONDENSER OUTLET PORT

PLUMBING

24 - 69

A/C CONDENSER (Continued)

(4) Connect the A/C discharge line to the A/C com-

pressor.

(5) Install the nut that secures the A/C discharge

line to the A/C compressor. Tighten the nut to 23
N·m (17 ft. lbs.).

(6) Remove the tape or plugs from the discharge

line fitting and the condenser port.

(7) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it and a new gasket onto
the discharge line fitting.

(8) Connect the A/C discharge line to the A/C con-

denser.

(9) Install the nut that secures the A/C discharge

line to the A/C condenser. Tighten the nut to 23 N·m
(17 ft. lbs.).

(10) Install the radiator air seals and the air seal

retaining pins.

(11) Install the radiator sight shield and the sight

shield retaining pins.

(12) Install the front fascia (Refer to 13 - FRAME

& BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).

(13) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).

A/C EVAPORATOR

DESCRIPTION

The A/C evaporator (Fig. 13) is located within the

HVAC housing, behind the instrument panel. The
A/C evaporator and insulator are positioned in the
HVAC housing so that all air entering the housing
must pass over the evaporator fins before it is dis-
tributed through the heating-A/C system ducts and
outlets. However, air passing over the evaporator fins

will only be conditioned when the A/C compressor is
engaged and circulating refrigerant through the A/C
evaporator.

The A/C evaporator tubes are connected and sealed

to the A/C expansion valve by use of rubber O-rings
and a tapping block.

The A/C evaporator can only be serviced by remov-

ing and disassembling the HVAC housing.

OPERATION

Refrigerant enters the A/C evaporator from the A/C

expansion valve as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins
of the A/C evaporator, the humidity in the air con-
denses on the fins, and the heat from the air is
absorbed by the refrigerant. Heat absorption causes
the refrigerant to boil and vaporize. The refrigerant
becomes a low-pressure gas when it leaves the A/C
evaporator.

The A/C evaporator cannot be repaired and, if

faulty or damaged, it must be replaced.

REMOVAL

(1) Remove the HVAC housing (Fig. 14) (Refer to

24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/HVAC HOUSING - REMOVAL).

(2) Disassemble the HVAC housing as necessary to

access the A/C evaporator (Refer to 24 - HEATING &
AIR

CONDITIONING/DISTRIBUTION

FRONT/

HVAC HOUSING - DISASSEMBLY).

Fig. 12 Discharge Line to A/C Compressor

1 - A/C SUCTION LINE
2 - NUT
3 - A/C COMPRESSOR
4 - NUT
5 - A/C DISCHARGE LINE

Fig. 13 A/C Evaporator

1 - A/C EVAPORATOR
2 - INSULATOR
3 - EVAPORATOR TUBES
4 - O-RING SEALS

24 - 70

PLUMBING

A/C DISCHARGE LINE (Continued)

(3) Open the rubber flange seal and carefully lift

the A/C evaporator and insulator out of the lower
half of the HVAC housing.

NOTE: If the insulator is deformed or damaged, it
must be replaced.

(4) If required, remove the insulator from the A/C

evaporator.

INSTALLATION

NOTE: If the A/C 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) If removed, install the insulator over the A/C

evaporator.

NOTE: Make sure that the evaporator drain within
the HVAC housing is clean and unrestricted and
that the insulator and the rubber flange seal are
properly positioned.

(2) Install the A/C evaporator into the lower half of

the HVAC housing and close the rubber flange seal.

(3) Assemble the HVAC housing (Refer to 24 -

HEATING & AIR CONDITIONING/DISTRIBUTION
- FRONT/HVAC HOUSING - ASSEMBLY).

(4) Install the HVAC housing (Refer to 24 - HEAT-

ING

AIR

CONDITIONING/DISTRIBUTION

FRONT/HVAC HOUSING - INSTALLATION).

EXPANSION VALVE

DESCRIPTION

The A/C expansion valve (Fig. 15) controls the

amount of refrigerant entering the A/C evaporator.
The A/C expansion valve is of a thermostatic expan-
sion valve (TXV) design and consists of an aluminum
H-valve type body with an integral thermal sensor.
The A/C expansion valve is located in the engine
compartment at the dash panel, between the A/C
refrigerant lines and the A/C evaporator.

The evaporator temperature sensor is installed on

the top of the A/C expansion valve (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/EVAPORATOR TEMPERATURE SENSOR -
DESCRIPTION).

OPERATION

The A/C expansion valve controls the high-pres-

sure, low temperature liquid refrigerant from the liq-
uid line and converts it into a low-pressure, low-
temperature mixture of liquid and gas before it
enters the A/C evaporator. A mechanical sensor in the
A/C expansion valve monitors the temperature and
pressure of the refrigerant leaving the A/C evapora-
tor through the suction line, and adjusts the orifice
size at the liquid line port to let the proper amount
of refrigerant into the A/C evaporator to meet the
vehicle A/C cooling requirements. Controlling the
refrigerant flow through the A/C evaporator ensures
that none of the refrigerant leaving the A/C evapora-
tor is still in a liquid state, which could damage the
A/C 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. 14 A/C Evaporator

1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR
4 - A/C EVAPORATOR

Fig. 15 A/C Expansion Valve-Typical

1 - A/C EXPANSION VALVE
2 - THERMAL SENSOR

PLUMBING

24 - 71

A/C EVAPORATOR (Continued)

DIAGNOSIS AND TESTING

A/C EXPANSION VALVE

NOTE: The A/C expansion valve should only be
tested following testing of the A/C compressor.

NOTE: Liquid CO

is required to test the A/C expan-

sion valve. This material is available from most
welding supply facilities. Liquid CO

is also avail-

able from companies which service and sell fire
extinguishers.

When testing the A/C expansion valve, the work

area and the vehicle temperature must be 21° to 27°
C (70° to 85° F). To test the expansion valve:

(1) Connect a charging station or manifold gauge

set to the refrigerant system service ports. Verify the
refrigerant charge level.

(2) Close all doors, windows and vents to the pas-

senger compartment.

(3) Set the A/C-heater controls so that the A/C

compressor is operating, the temperature control is
in the highest temperature position, the mode-air
doors is directing air output to the floor and the
blower motor operating is operating at the highest
speed.

(4) Start the engine and allow it to idle. After the

engine has reached normal operating temperature,
allow the passenger compartment to heat up. This
will create the need for maximum refrigerant flow
into the A/C evaporator.

(5) If the refrigerant charge is sufficient, the dis-

charge (high pressure) gauge should read 965 kPa to
1655 kPa (140 psi to 240 psi). The suction (low pres-
sure) gauge should read 138 kPa to 207 kPa (20 psi
to 30 psi). If OK, go to Step 6. If not OK, replace the
faulty A/C expansion valve.

WARNING:
Protect the skin and eyes from exposure to liquid
CO

or personal injury can result.

(6) If the suction (low pressure) gauge reads

within the specified range, freeze the A/C expansion
valve for 30 seconds using liquid CO

or another suit-

able super-cold material.Do not spray R-134a or
R-12 refrigerant on the A/C expansion valve for
this test. The suction (low pressure) gauge reading
should drop by 69 kPa (10 psi). If OK, go to Step 7 If
not OK, replace the faulty A/C expansion valve.

(7) Allow the expansion valve control head to thaw.

The suction (low pressure) gauge reading should sta-
bilize at 138 kPa to 207 kPa (20 psi to 30 psi). If not
OK, replace the faulty A/C expansion valve.

(8) When expansion valve testing is complete, test

the overall A/C system performance (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).

REMOVAL

(1) Recover the refrigerant from the refrigerant

system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

(2) Disconnect and isolate the negative battery

cable.

(3) Remove the air cleaner housing and the air

inlet tube (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - REMOVAL).

(4) Remove the drain tube from the right end of

the wiper module.

(5) Disconnect the wire harness connector from the

A/C pressure transducer (Fig. 16).

(6) Remove the screw that secures the liquid line

to the receiver/drier outlet port.

(7) Disconnect the liquid line from the receiver/

drier outlet port and remove and discard the seal.

(8) Install plugs in, or tape over the opened liquid

line fitting and the receiver/drier outlet port.

(9) Remove the nut that secures the suction line

and liquid line fittings to the stud on the A/C expan-
sion valve.

(10) Disconnect the A/C suction and liquid line fit-

tings from the A/C expansion valve and remove and
discard the seals.

(11) Install plugs in, or tape over the opened suc-

tion line and liquid line fittings and both expansion
valve ports.

(12) Disconnect the HVAC wire harness connector

from the evaporator temperature sensor.

24 - 72

PLUMBING

EXPANSION VALVE (Continued)

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