Q: How to Service and Repair an A/C Hose in the HVAC System on 2005 Dodge Grand Caravan?
A: Begin with recovering the refrigerant from the HVAC system and then take off the negative battery cable. Open the end cap of the air cleaner on the right side of the engine bay, remove the air cleaner top and snorkel and loosen the tube from the wiper module drain. Remove the nut holding the suction line fitting to the A/C compressor, pull the fitting from the compressor's suction port and remove the O-ring seal. Tape or plug the suction line fitting as well as the compressor suction port after opening them. After that, take out the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the right front strut tower and unbolt the nut attaching both liquid line and suction line fittings to the expansion valve. Unscrew these fittings from the expansion valve and throw away the seals, then seal or tape the open fittings and the expansion valve's two ports. Separate the suction line from the retaining bracket fixed to the top of the dash board. When the vehicle has a rear heating-A/C system, lift and prop it up on stands, remove the screw at the tie strap's underbody plumbing connection, disconnect the suction line extension from the underbody fitting, eliminate the O-ring at that spot and then plug or tape the opens fittings. Slide the jack in and move the vehicle down until the suction line is out of the compartment. To install the AC system, place the suction tube into the engine compartment, remove all tape and plugs from both types of fitting and both ports on the expansion valve, coat the new O-rings with clean oil and attach each O-ring to its fitting. Restore the liquid line and suction line fittings to the expansion valve and screw the nut on them till it reaches 23 N.m (17 ft. lbs.) and then fix the retainer for the suction line routing clip. Take out the plug or tape from the compressor suction port and the suction line fitting, apply refrigerant oil to a new O-ring seal, install it on the fitting and then attach the fitting to the port with a new dual plan seal, tightening the nut at 23 N.m (17 ft. lbs.). Attach the drain tube once more, secure the air cleaner top and snorkel and on RHD cars, slide the suction line into the bracket sitting atop the dash panel. When the rear A/C is present, raise the car, take out the tape or plugs at the suction line extensions and the underbody suction line fittings, add the new lubricated O-ring and rejoin everything, finger-tightening for now. Put a new tie strap by the location of the underbody plumbing connections, lower the vehicle, connect the negative battery cable, let out the refrigerant and flush and recharge the cooling system.