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Chrysler RG Voyager. Manual - part 1237

(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).

PLUMBING - REAR

24 - 113

UNDERBODY LINES (Continued)

CABIN HEATER

TABLE OF CONTENTS

page

CABIN HEATER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 114

OPERATION

MANUAL TEMPERATURE CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

AUTOMATIC TEMPERATURE CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

WARNING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

DIAGNOSIS AND TESTING

SUPPLEMENTAL CABIN HEATER

. . . . . . . . 115

AIR INTAKE PIPE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 116

EXHAUST TUBE

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 117

FUEL DOSING PUMP

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . 118

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . 118

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 119

FUEL LINE

STANDARD PROCEDURE

CLEANING

. . . . . . . . . . . . . . . . . . . . . . . . . . 119

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 120

HEATER HOSES

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 121

HEATER PIPES

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 121

HEATER UNIT

REMOVAL

HEATER UNIT

. . . . . . . . . . . . . . . . . . . . . . . 122

INSTALLATION

HEATER UNIT

. . . . . . . . . . . . . . . . . . . . . . . 123

HEATER WIRING

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . 124

CABIN HEATER

DESCRIPTION

Vehicles equipped with the diesel engine are also

equipped with a supplemental cabin heater. This
cabin heater is mounted under the vehicle and oper-
ates similar to an oil fired furnace. The heater burns
small amounts of fuel to provide additional heat to
the coolant. Coolant is routed from the engine, to the
supplemental cabin heater and then to the front
heater core. This provides additional heat to the pas-
senger compartment. The supplemental cabin heater
system is interfaced to the vehicles on-board com-
puter systems and DRBIII

t diagnostics.

The supplemental cabin heater has an electronic

control module that monitors the heat output of the
heater. The cabin heater operates at full load (5 kW),
half load or idle mode (no additional heat) depending
on engine coolant temperature.

When ambient temperatures are lower than 15° C

(60° F), the supplemental cabin heater automatically
operates once each ignition cycle for five minutes.
This assures a good fuel supply is always present for
the supplemental cabin heater.

OPERATION

MANUAL TEMPERATURE CONTROL SYSTEM

The supplemental cabin heater is activated via the

temperature slide control or knob on the A/C-heater
control when equipped with the manual temperature
control (MTC) system. If the slide control or knob is
moved to or above the upper set point the cabin
heater is activated. The cabin heater can operate in a
full or partial load range as well as an idle mode all
dependent on the engine coolant temperature. The
cabin heater will also turn off if the A/C-heater tem-
perature control is lowered to less than the lower set
point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.

NOTE: Do not apply a strong vacuum source such
as a garage ventilation system directly on the sup-
plemental cabin heater exhaust line. Too strong of a
vacuum can prevent the supplemental cabin heater
from starting. If required, place the vacuum source
at least 75 mm (3 in.) away from the exhaust line.

The supplemental cabin heater only operates when

the engine is running, the mileage exceeds 8 kilome-
ter (5 mph) and the fuel tank volume exceeds 1/8 of a

24 - 114

CABIN HEATER

tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40° C (104° F).

AUTOMATIC TEMPERATURE CONTROL
SYSTEM

The automatic temperature control (ATC) system

will activate the supplemental cabin heater based on
engine coolant temperature and interior component
settings. The cabin heater can operate in a full or
partial load range as well as an idle mode all depen-
dent on the engine coolant temperature. The cabin
heater will also turn off if the A/C-heater tempera-
ture control is lowered to less than the lower set
point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.

The supplemental cabin heater only operates when

the engine is running, the mileage exceeds 8 kilome-
ter (5 mph) and the fuel tank volume exceeds 1/8 of a

tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40° C (104° F).

WARNING

WARNING: DO NOT OPERATE THE DIESEL SUP-
PLEMENTAL CABIN HEATER IN AN ENCLOSED
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
THE CABIN HEATER EXHAUST WHEN OPERATING
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
PLEMENTAL CABIN HEATER FUEL LINES ARE
SECURELY

FASTENED

THEIR

RESPECTIVE

COMPONENTS BEFORE PERFORMING ANY SER-
VICE PROCEDURES TO THE CABIN HEATER. FAIL-
URE

FOLLOW

THESE

INSTRUCTION

MAY

RESULT IN PERSONAL INJURY OR DEATH.

DIAGNOSIS AND TESTING

SUPPLEMENTAL CABIN HEATER

Refer to the Symptoms Diagnosis table for basic

checks of the diesel fueled supplemental cabin heater.

SYMPTOMS DIAGNOSIS

Symptom

Possible Causes

Smell of diesel fuel.

Check cabin heater system integration in vehicle’s fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of external
fuel. If presence of external fuel is observed on the heater unit or in the
exhaust tube or after draining and testing. Remove the cabin heater
from vehicle and repair or replace components as required.

Heater does not achieve full load
operation.

Check cabin heater operation with DRBIII

scan tool and replace

components as required.

Continuous white smoke from heater
exhaust during combustion operation.

Check cabin heater operation with DRBIII

scan tool and replace

components as required. White smoke is typical in extreme weather
conditions.

Heater can not be switched off.

Check cabin heater operation with DRBIII

scan tool and replace

components as required.

Heater does not operate.

Diagnosis cabin heater control module using the DRBIII

scan tool and

the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.

CABIN HEATER

24 - 115

CABIN HEATER (Continued)

Symptom

Possible Causes

Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an
extremely sweet smell.

Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is an
internal heater leak and cabin heater should be inspected and
components should be replaced as required.

Loss of fuel (dripping).

Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.

AIR INTAKE PIPE

REMOVAL

NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.

(1) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE).

(2) Remove clamps from the cabin heater tubes at

the lower heater port and the lower EGR connector
which are located under the hood.

(3) Remove the retaining clamp at the cabin

heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).

(4) Remove the clamp at the flexible tube to steel

tube connection (Fig. 1).

(5) Remove the two retaining screws and remove

pipe assembly (Fig. 2).

INSTALLATION

(1) Install the air intake pipe assembly and install

the two retaining screws. Tighten the screws to 7
N·m (62 in. lbs.).

(2) Attach the steel tube to the flexible tube and

position

and

then

tighten

the

retaining

clamp

securely.

(3) Install the flexible tube to the cabin heater air

intake muffler and install and tighten the retaining
clamp securely.

(4) Install the cabin heater tubes to the lower

heater connection and the lower EGR cooler connec-
tion and tighten the retaining clamps.

(5) Lower the vehicle.
(6) Refill the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM FILL).

(7) Verify function of the heater unit.

Fig. 1 Flexible Air Intake Line

1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE AIR INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE

24 - 116

CABIN HEATER

CABIN HEATER (Continued)

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