Chrysler Voyager 2020-present HVAC System Bolt Torque Specifications
Chrysler Voyager 2020-present

Chrysler Voyager 2020-present HVAC System Bolt Torque Specifications

This page provides detailed torque specifications for bolts related to the HVAC (Heating, Ventilation, and Air Conditioning) system of the 2020-Present Chrysler Voyager. Includes compressor, condenser, evaporator, and associated component bolt torques.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Ac Compressor

Specifications for mounting the A/C compressor to the engine bracket. Proper torque is essential for secure mounting and preventing vibration.

1

A/C Compressor Mounting Bolts

M8 x 1.25
Torque Value
25 ft-lbs (34 N·m)
Important Notes
Ensure bolts are clean and threads are in good condition. Over-torquing can damage the compressor housing.

Ac Lines

Specifications for A/C line fittings, including refrigerant lines to the compressor, condenser, evaporator and expansion valve. Precise torque is crucial to ensure leak-proof seals.

1

A/C Line Fittings

Varying, typically M10 x 1.5 or M12 x 1.75
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Use a backup wrench to prevent twisting of the lines. Over-tightening can damage O-rings and cause leaks. Verify proper seating of the sealing surfaces and O-rings before tightening.

Ac Condenser

Specifications for securing the A/C condenser to the vehicle structure. These bolts/screws must secure the condenser without damaging the thin-walled tubing.

1

A/C Condenser Mounting Bolts/Screws

M6 x 1.0
Torque Value
8 ft-lbs (11 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Do not over-tighten, as the condenser is made of thin material.

Ac Evaporator

Specifications for mounting the A/C evaporator housing inside the dashboard. Secure mounting prevents air leaks.

1

A/C Evaporator Housing Mounting Bolts/Screws

M5 x 0.8
Torque Value
5.8 ft-lbs (8 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Do not over-tighten, as the housing is typically made of plastic. Torque should be checked using an inch pound wrench.

Blower Motor

Specifications for securing the blower motor to the HVAC housing. Correct torque avoids vibration and noise.

1

HVAC Blower Motor Mounting Bolts/Screws

M5 x 0.8
Torque Value
5.8 ft-lbs (8 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Do not over-tighten, as the motor is typically mounted into a plastic housing.

Blend Door Actuator

Specifications for mounting the blend door actuator. These are low torque values to prevent damage to the plastic actuator or housing.

1

Blend Door Actuator Mounting Screws

M4 x 0.7
Torque Value
2.6 ft-lbs (4 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Screws typically mount to a plastic housing. Use an inch-pound wrench for accuracy.

Mode Door Actuator

Specifications for mounting the mode door actuator. These are low torque values to prevent damage to the plastic actuator or housing.

1

Mode Door Actuator Mounting Screws

M4 x 0.7
Torque Value
2.6 ft-lbs (4 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Screws typically mount to a plastic housing. Use an inch-pound wrench for accuracy.

Recirculation Door Actuator

Specifications for mounting the recirculation door actuator. These are low torque values to prevent damage to the plastic actuator or housing.

1

Recirculation Door Actuator Mounting Screws

M4 x 0.7
Torque Value
2.6 ft-lbs (4 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Screws typically mount to a plastic housing. Use an inch-pound wrench for accuracy.

Expansion Valve

Specifications for securing the expansion valve to the evaporator. Proper torque ensures a leak-free seal.

1

Expansion Valve Mounting Bolts

M6 x 1.0
Torque Value
8 ft-lbs (11 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. These bolts are often aluminum and easily damaged.

Heater Core

Specifications for mounting the heater core. This ensures proper sealing and no damage to the plastic housing.

1

Heater Core Mounting Screws/Bolts

M5 x 0.8
Torque Value
5.8 ft-lbs (8 N·m)
Important Notes
This is an estimated value, confirm with specific service manual. Do not over-tighten as they typically mount into plastic. Use an inch-pound wrench for accuracy.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why are torque specifications important for HVAC components?

Correct torque ensures proper clamping force, preventing leaks and component damage. Under-tightening can lead to refrigerant leaks and loose connections, while over-tightening can damage threads, gaskets, and fragile parts like plastic housings. For example, over-tightening an evaporator case bolt can crack the plastic housing.

Q2

What happens if I don't have a torque wrench?

While it's highly recommended to use a torque wrench, especially for critical HVAC components, you may be able to estimate using a wrench with careful hand tightening. However, this is highly risky. Without a torque wrench, you risk leaks from under-torqued connections, or damage from over-torquing which could be quite expensive to repair. Always refer to the vehicle's service manual for correct torque specs. If you lack a torque wrench, consider borrowing one from a tool lending program, or going to a professional repair facility.

Q3

Can I reuse HVAC system bolts?

In most cases, it is acceptable to reuse bolts provided they are not damaged (e.g., stretched threads, corrosion). However, for critical components like compressor mounting bolts or those that hold refrigerant lines, it is highly advisable to replace them with new ones. They are designed to maintain a specific clamping force with proper torque. Reusing stretched or damaged bolts can result in failure, creating a dangerous situation, and potentially causing serious injury. Always examine bolts for damage and consult the service manual.

Q4

Do torque specs vary depending on the specific HVAC component?

Yes, torque specifications are component-specific. For example, the torque required for a blower motor mounting screw will be significantly different than the torque required for a high pressure refrigerant line fitting. Always refer to the Chrysler Voyager service manual for the precise torque specifications for each specific component. Using the incorrect torque can result in leaks, damage, or system failure.

Q5

How do I know what type of thread sealant to use on HVAC components?

When a thread sealant is specified in your Chrysler Voyager service manual, you must use the recommended type of sealant or similar. Using the wrong type could cause a blockage in the system or otherwise cause system failure. Also, remember that a sealant is not a replacement for proper torquing. Do not use sealant as a substitute for using a torque wrench.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/4" Drive)

A 1/4" drive torque wrench is essential for accurately tightening smaller HVAC system fasteners to the specified torque values.

  • Accurate torque settings
  • Click-type mechanism
  • Low torque range (5-50 inch-lbs recommended)
Learn more

Torque Wrench (3/8" Drive)

A 3/8" drive torque wrench is needed for larger fasteners found within the HVAC system that require higher torque values.

  • Accurate torque settings
  • Click-type mechanism
  • Medium torque range (10-100 ft-lbs recommended)
Learn more

Socket Set (1/4" & 3/8" Drive)

A comprehensive socket set is required to accommodate various bolt and nut sizes within the HVAC system.

  • Metric sizes (7mm - 19mm typically)
  • Standard sizes (where applicable)
  • Shallow and deep sockets
Learn more

Extension Bars (1/4" & 3/8" Drive)

Extension bars are necessary to reach fasteners in tight and recessed areas of the HVAC system.

  • Various lengths (3", 6", 12" recommended)
  • Durable construction
  • Secure connection to sockets
Learn more
Service Procedures

HVAC Control Module Bolt Torque Check

This procedure details how to check the torque specifications on the HVAC control module mounting bolts. Ensure proper module function and prevent vibration issues.

  • Locate the HVAC control module within the dashboard.
  • Identify the mounting bolts securing the module.
  • Using the correct socket and torque wrench, verify each bolt's torque is set to the specified value (typically 70-80 inch-lbs, consult service manual for exact value).
  • If any bolt is undertorqued or overtorqued, adjust accordingly and re-check.
View full procedure

Evaporator Core Housing Bolt Torque

This procedure outlines checking the torque on the evaporator core housing bolts to ensure an airtight seal. Failure to do this may result in system performance issues.

  • Locate the evaporator core housing, typically located behind the dashboard.
  • Identify all housing bolts around the perimeter.
  • Using the appropriate socket and torque wrench, check the torque of each bolt to the specified value (typically 80-90 inch-lbs, consult service manual for exact value).
  • Adjust any bolts that are not within the torque specification and re-check.
View full procedure

A/C Compressor Mounting Bolt Torque

This procedure details tightening the mounting bolts for the air conditioning compressor. Improper torque could result in compressor damage or improper mounting.

  • Locate the A/C compressor in the engine bay.
  • Identify all compressor mounting bolts.
  • Using the proper socket and torque wrench, tighten the bolts in a cross-pattern to the specified torque values (typically 18-22 ft-lbs, consult service manual for exact value).
  • Double-check each bolt to ensure proper torque is achieved.
View full procedure

Condenser Mounting Bolt Torque

This procedure details checking the torque on the condenser mounting bolts, which need to be tightened properly to maintain condenser integrity.

  • Locate the A/C condenser at the front of the vehicle, typically in front of the radiator.
  • Identify the mounting bolts holding the condenser in place.
  • Using a proper socket and torque wrench, check the torque of each bolt to the specified value (typically 100-120 inch-lbs, consult service manual for exact value).
  • Adjust any bolts that are under or over the torque specification and recheck.
View full procedure
Technical Service Bulletins

HVAC Control Module Mounting Bolt Loosening

2021-05-15

Some 2020-2021 Voyager models have experienced issues with the HVAC control module mounting bolts loosening over time due to vibration. This can lead to intermittent HVAC function.

2020-2021

Resolution: Apply thread-locking compound (Loctite 242 or equivalent) to the mounting bolts and re-torque to the specified value (70-80 inch-lbs) to prevent future loosening.

Evaporator Core Housing Leak Due to Incorrect Torque

2022-03-20

A small percentage of 2020-2022 Voyager models exhibit leaks at the evaporator core housing due to inconsistent torque application during assembly. This can result in reduced A/C performance.

2020-2022

Resolution: Inspect the evaporator core housing for any leaks. If leakage is detected, remove the housing bolts, apply a new sealant gasket (if applicable), and retorque all bolts in a star pattern to the specified value (80-90 inch-lbs) to ensure a proper seal.

A/C Compressor Mounting Bolt Failure

2023-11-10

A small number of A/C compressors have been reported with failed mounting bolts, due to improper torque application or material failure. Ensure proper torque for proper operation and to avoid premature component failure.

2020-2023

Resolution: When replacing an A/C compressor or mounting bolts, inspect bolts for damage. Mount new bolts and tighten in a cross pattern to the specified value (18-22 ft-lbs). Ensure no over or under torquing occurs.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

Automotive Technical Specialist

ASE Master Certified Technician with over a decade of hands-on experience in automotive repair and diagnostics.

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