CaravanHomer and MrMahoney:

Your documentation was simply OUTSTANDING. I too did have the ALLDATA service manual steps, but I found the Chrysler/Plymouth service manual steps very generic - compared to some other vehicles (my Ford service manuals were much more detailed - pictures/diagrams for every step) - I found myself scratching my head on much of the ALLDATA procedures.

You guys really outdid yourselves with your two sets of instructions - I found myself flipping between both for combinations of photos and steps. CaravanHomer, your procedures were "spot on" for my 99 Voyager (just plain Voyager - not Grand Voyager). I found them to be precise and you didn't miss a beat... I saved hours of fumbling around with the guidance.

I found a few interesting things with my job - note my engine is the less common 2.4L 4cyl engine:

- did NOT have to remove the wiper assembly to get access to firewall stuff; I am guessing the 3.3 and other 6cyl variants are more crowded under there requiring removal - but I was able to easily reach back and remove the HVAC box nuts, expansion valve lines and heater hoses without doing anything. Saved time!

- Man that draincock in the radiator is a PAIN in the BUTT. That quarter turn to open and close - I was only able to get it loose enough to drain fluid in a trickle - had to let it drain overnight - but I chose that rather than break the darned thing by trying to get more of a flow and end up adding repair time. I've heard bad things about how easy those weird draincocks hold up over time, easy to strip and damage causing leaks... I almost resorted to just pulling the lower hose off (recommended by some who broke their draincocks) - but ended up working out OK.

- The green 'leak' dye was clearly visible inside the HVAC box housing on some of the insulation and lining, proving the leak. I re-sealed the weatherstripping around the new core that I could salvage off the old one and purchased some simple new weatherstripping where I couldn't salvage pieces...

- Nowhere in any documentation did I see anything about what looked like some sort of temperature sensor needle that was pressed into the vanes of the old core - right in the middle - like a meat thermometer...! I simply pulled that out, and pushed into into the new core vanes in approximately the same middle location. Was a bit nervous about this one since I could see some of the green dye around this area on my old core... Very c-a-r-e-f-u-l-l-y pressed this thermometer back into the new core vanes.

- I also replaced the receiver/drier (only $19) which really should be done with this job (particularly if you've never done it for the life of the car, as was the case w/me ) - it only took another hour or so, right there mounted to the radiator... Just needed to remove the upper radiator crossmember and I loosened a couple of front-end trim/grille pieces - then carefully used extra-long socket extender to remove the two fittings. It bolts onto radiator with a two-bolt bracket, access is achieved by following the instructions above... Beware my new drier came with wrong-sized o-rings, I thought they looked too big but tried to use them anyway... The shop that charged up the a/c had a mess on their hands when that line leaked all over. They kindly removed the leaky line and installed a properly sized o-ring which cured it.

- The instructions provided covered EVERYTHING that was needed... Bolt sizes, counts, photos, etc all matched up perfectly with my 99 base model voyager 2.4L. No steps missing that I can recall. Took me about 12 hours on a Saturday, start to finish. a/c blowing ice-cold now and everything checks out!

Thanks again guys... Note I did a blend door replacement on a 1999 Ford Expedition I owned a few years back (and posted similar article on that repair at that time, before any real internet instructions existed for that repair), that job was extremely similar but I must say your instructions really made this one a breeze... Just time consuming, but no surprises at all.

Appreciate your time and effort!

Best Regards
Scott

 

Note the expansion valve in this pic:
http://www2.scsc.k12.in.us/mahoney/v...ictures/22.JPG

The two bolts under the treaded stud need removed so the valve can come off of the evap core.

Here is another pic:


The holes show where the two bolts go. Be sure to place on new o-rings.

 

Complete photos can be found here:

http://www2.scsc.k12.in.us/mahoney/vanfix/

 

how well will these awesome instructions work on my 2007? anybody have anything to add??

Thanks, David

 

I doubt these instructions will be of much use to you. Your van is 5 years newer than the models posted here. There may be some similarities but there will likely be significant differences too. Therefore, I'd advise you to look elsewhere for instructions for your model year.

 

It really is delicious thought. I wish i was a part of it!

 

Late to the party, but facing the same repair. But few of the links in this old thread are working for me!

The "Gear Head Gospel" page, with pics, will sure be helpful. But I was wondering if anyone had a working link to a copy of CaravanHomer's word/pdf document with his pictures, too?

I have a 2000 CG "donor" van with a good HVAC unit, I need to pull that out and install it in another 2000 CG.

The "donor" unit passes calibration but does not get cold. The "recipient" unit does not pass calibration but gets nice and cold. Both units produce heat. So I'm planning on swapping the evaporators before installing the HVAC unit.

 

https://skydrive.live.com/?cid=dd8cb...A29CBE4A%21103

This link doesn't work? It worked for me just now.

 

Not working for me...it comes up with a Skydrive web page saying:

"This item might not exist or is no longer available. this item may have been deleted, expired, or you might not have permission to view it. Contact the owner of this item for more information."

 

Works for me as well. Maybe try another computer.