Heater Core - Dodge Intrepid Service Manual

24 - 40 PLUMBING
A/C EXPANSION VALVE (Continued)
In a Closed Position: There will be low suction
pressure and no cooling. This may be caused by a
failed power dome or excessive moisture in the A/C
system. If the power dome on the expansion valve is
found to be defective replace the expansion valve. If
excessive moisture is found recycle the refrigerant.
A Restricted Orifice: There will be low suction
pressure and no cooling. This may be caused by
debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the expansion valve and filter/drier.
REMOVAL
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
(1) Recover the refrigerant from the system. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE -REFRIGERANT
RECOVERY)
(2) Remove the engine air inlet tube and the air
distribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER ELEMENT - REMOVAL).
(3) Remove one nut to the a/c lines at the expan-
sion valve.
(4) Loosen the bolt at the receiver/drier to pivot
the lines away from the expansion valve.
(5) Plug or cap the open end of the refrigerant
lines.
(6) Gently pull the a/c line out of the expansion
valve.
(7) Remove two #30 torx bolts retaining the expan-
sion valve to the a/c evaporator.
(8) Remove the expansion valve from the vehicle.
CAUTION: Always install new O-rings when replac-
ing the a/c expansion valve.
INSTALLATION
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Install the a/c expansion valve on the a/c evap-
orator. Tighten the fasteners to 23 N·m (17 ft. lbs.).
(2) Connect the lines to the expansion valve and
tighten the retaining nut to 23 N·m (17 ft. lbs.).
(3) Tighten the bolt at the receiver/drier to 13.6
N·m (10 ft. lbs.).
(4) Install the engine air inlet tube and the air dis-
tribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
AIR CLEANER ELEMENT - INSTALLATION).
(5) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(6) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)

HEATER CORE

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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
The HVAC housing must be removed from the
vehicle to service the heater core.
LH