Auxiliary Rear Heater Line - Coolant Seepage
NO: 24-02-97GROUP: Heater & A/C
EFFECTIVE DATE: Mar. 21, 1997
SUBJECT:
Coolant Seepage At Underbody
Auxiliary Rear Heater Line
Hose Connection(s)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-04-96 REV. A, DATED DEC. 20, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). REVISION INCLUDES ADDITION OF PART NUMBER FOR 15 mm HOSE AND CLAMP ASSEMBLY.
MODELS:
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1996 - 1997 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR AUXILIARY HEATER.
SYMPTOM/CONDITION:
Coolant seepage at rubber hose crimp connection(s) and/or the quick-connect fitting(s) of the underbody auxiliary rear heater coolant line hoses.
DIAGNOSIS:
Raise the vehicle on an appropriate hoist and inspect the crimp and quick-connect fittings of the underbody auxiliary rear heater coolant line hoses. If coolant is evident, perform the Repair Procedure.
PARTS REQUIRED:
2 04882938AB Hose Assembly, Heater Aux. Rear, with Quick Connect
**2 04897046AA Hose & Clamp Assembly, 15 mm Heater**
NOTE:
DO NOT USE ANY OTHER CLAMPS FOR THIS APPLICATION. IF SCREW TYPE CLAMPS ARE USED THE LEAK WILL REOCCUR OVER TIME BECAUSE OF SHRINKAGE OF THE HOSE MATERIAL AND RESULTANT LOSS OF TENSION APPLIED BY THE CLAMP TO THE HOSE.
REPAIR PROCEDURE:
This bulletin involves replacing underbody auxiliary rear heater coolant line hoses.
1. With the vehicle raised on an appropriate hoist, install clamp-off pliers on the rear hose of the underbody auxiliary rear heater coolant line opposite the hose to be replaced. Also install clamp-off pliers on the front hose of the underbody auxiliary rear heater coolant line that is being repaired.
2. With proper safety glasses on, use a die grinder or other appropriate tool to cut off the metal crimp on the end of the hose where it connects to the auxiliary rear heater tube. Be careful not to damage the tube under the metal crimp.
3. Position a clean drain pan under the hose and pull the end of the hose from the tube. Let the coolant drain into the pan for reuse.
4. Break the plastic quick-connect fitting at the area shown in Figure 1 on both sides of the quick-connect fitting using a screwdriver.
5. Remove the hose from the vehicle. Also remove plastic insert which may have remained on the auxiliary rear heater tube.
NOTE:
TRANSFER ANY CONVOLUTE ON THE ORIGINAL HOSE TO THE REPLACEMENT HOSE.
6. Install replacement hose assembly (p/n 04882938AB). Be sure the quick connect is fully engaged by trying to pull it off.
7. Repeat steps 2 thru 6 for the other rear hose of the underbody auxiliary rear heater coolant line.
8. Install clamp-off pliers on the heater hoses above and to the left of the catalytic convertor.
9. Use a die grinder or other appropriate tool to cut off the metal crimp on the hoses at the front of the underbody auxiliary rear heater tubes. Be careful not to damage the tube under the metal crimp.
10. Remove the clamps from the front hoses of the underbody auxiliary rear heater tubes and slide them onto the tubes leading to the front of the vehicle.
11. Position a clean drain pan under the hoses and pull one end of the hoses from the tubes. Let the coolant drain into the pan for reuse, then remove the hoses and clamps from the vehicle and discard.
12. **Install two 15 mm hose and clamp assemblies (p/n 04897046AA)** onto the underbody auxiliary rear heater coolant line tubes and the coolant tubes coming from the front of the vehicle. Position the spring clamps to secure the hoses to the tubes.
13. Remove all clamp-off pliers.
14. Lower the vehicle. Poor the coolant from the drain pan into the coolant recovery tank.
15. Start and run the engine until the cooling fans cycle. Check the coolant level in the coolant recovery tank and add coolant if necessary.
16. With the front heater "OFF", the temperature slide(s) to the full "HOT" position, the rear blower on "HIGH", the engine at normal operating temperature and idling, check the air discharge temperature at the base of the right "C"-pillar. If the discharge air temperature is less than 135°F (57°C), shut off the engine and allow it to cool to ambient temperature. Check the coolant level in the coolant recovery tank and add coolant as necessary. Repeat the "C"-pillar air discharge temperature check. Repeat cool down and warm up until the "C"-pillar air discharge temperature is 135°F (57°C) or greater. This process bleeds the air out of the cooling system.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-46-18-90 1.0 Hrs.
FAILURE CODE: P8 - New Part