2002 CHRYSLER CARAVAN cooling

(4) Carefully pour the proper pre-mixed engine
coolant solution into the rear heater core through a
funnel until coolant begins to appear at the lower
hose fitting of the heater core.
(5) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(6) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
THERMAL CYCLING
If the rear heater core was emptied and was not
pre-filled, it will be necessary to thermal cycle the
vehicle at least two times to ensure that the rear
heater core is properly filled.
(1) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(2) Start the engine and allow it to operate until
the thermostat opens.
(3) Turn the engine off and allow it to cool.
(4) With the engine cold and not running, check
and top off the engine coolant level as necessary.
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(5) Start the engine and allow it to operate until
the thermostat opens again.
(6) Turn the engine off and allow it to cool down
again.
(7) With the engine cold and not running, check
and top off the engine coolant level as necessary.
(Refer to 7 - COOLING - STANDARD PROCEDURE
- COOLANT LEVEL CHECK) and (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLANT
- ADDING).
(8) Check the performance of the rear heater.
Refer to REAR HEATER PERFORMANCE CHECK .
REAR HEATER PERFORMANCE CHECK
Successful completion of the rear heater perfor-
mance check will confirm that the rear heater core is
properly filled with engine coolant. If the check is not
successful, either there is still air trapped in the rear
heater core or the rear heater plumbing is restricted.
This check should be performed with the vehicle in a
shop where the ambient temperature is about 21É C
(70É F).
(1) Start the engine and allow it to idle until it
warms up to normal operating temperature.(2) Adjust the heater-A/C controls so that the front
heater is turned Off, the rear heater is set for full
Heat, and the rear blower motor is at its highest
speed setting.
(3) Use an accurate test thermometer to measure
the temperature of the air being discharged from the
rear heater outlet located at the base of the right
C-pillar.
(4) Proper discharge air temperature readings
should be from 57É to 63É C (135É to 145É F).
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the rear heater distribution duct from
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
REMOVAL).
(4) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar.
(5) Remove the screw that secures the front of the
rear heater-A/C unit housing to the right quarter
inner panel.
(6) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(7) Disconnect the heater hoses at the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - REMOV-
AL).
(8) Install plugs in, or tape over the opened heater
core fittings and both heater hoses (Fig. 5).
(9) Use absorbent toweling to clean up any engine
coolant spills from the preceding operation.
(10) Release the four latch tabs that secure the
heater core in the rear heater-A/C unit housing.
(11) Carefully pull the heater core straight out of
the rear heater-A/C unit housing.
(12) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
24 - 102 PLUMBING - REARRS
HEATER CORE (Continued)
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INSTALLATION
NOTE: If the rear heater core or the rear heater-A/C
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Carefully slide the heater core into the rear
heater-A/C unit housing.
(2) Using hand pressure, press firmly and evenly
on the heater core end plate until the four latch tabs
that secure the heater core in the rear heater-A/C
unit housing are fully engaged (Fig. 5).
(3) Remove the plugs or tape from the heater core
fittings and both heater hoses.
(4) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(5) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).
(6) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(7) Reinstall the rear heater distribution duct onto
the right quarter inner panel. (Refer to 24 - HEAT-ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
INSTALLATION).
(8) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - INSTALLATION).
(9) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
HEATER HOSE
REMOVAL
REFER TO THE APPLICABLE WARNINGS AND
CAUTIONS FOR THIS SYSTEM BEFORE PER-
FORMING THE FOLLOWING OPERATION. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING FRONT - WARNING - HEATER PLUMBING).
(1) Partially drain engine cooling system. Refer to
Group 7, Engine Cooling.
(2) Loosen clamp at the front end of the hose
located at the right, outboard side of the underbody,
rearward of the front crossmember. (Fig. 9)
(3) Carefully rotate hose back and forth while tug-
ging slightly away from connector nipple. If the hose
will not come off, slice the hose at the connector nip-
ple and peel off heater hose. This method will require
heater hose replacement.
CAUTION:
When removing hoses from outlet nipples, do not
use excessive force. Outlet nipples may become
damaged and leak engine coolant.
(4) Compress insert in rear heater hose quick con-
nection and pull downward on hose. (Fig. 11)
(5) Remove (3) straps securing underbody lines.
(Fig. 8)
(6) Separate and remove rear heater lines from
vehicle.
INSTALLATION
There are several heater core plumbing configura-
tions used on this model, depending upon the engine
size and other optional equipment. One plumbing
configuration is used for all 2.4L engines, while the
3.3L and 3.8L engines have unique heater return
plumbing on the engine for models with or without
an optional engine oil cooler. There are also unique
plumbing configurations at the heater core for mod-
els with or without the optional rear heater and air
conditioner. All models use a combination of formed
steel tubing and rubber hoses. In most cases, the
rubber hose is secured to the steel tubing with a
spring tension clamp.
Fig. 5 Heater Core
1 - REAR HEATER-A/C HOUSING OUTLET
2 - REAR HEATER-A/C UNIT HOUSING
3 - LATCH (4)
4 - HEATER CORE
5 - RIGHT REAR WHEEL HOUSE
6 - HEATER HOSES
RSPLUMBING - REAR24 - 103
HEATER CORE (Continued)
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WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
(1) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose toward the center of the hose being
installed. Release the clamp when it is near the cen-
ter of the hose.
(2) Grasp one end of the heater hose being
installed firmly and carefully twist the hose back and
forth while pushing it over from the barbed end of
the nipple. Repeat this procedure at the opposite end
of the hose being installed.
(3) Using spring tension clamp pliers, compress
and slide the clamps that secure each end of the
heater hose over the tube or nipple. Release the
clamp when it is over the tube or nipple.
(4) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
SUCTION LINE
REMOVAL
The front air conditioner suction line includes the
low side service port on a section of tubing located
near the compressor. On models equipped with the
optional rear air conditioner, the front air conditioner
suction line also includes a suction line hose and
tube extension that connects the front suction line to
the suction line for the rear air conditioner.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner top cover and snorkel
from the air cleaner housing located on the right side
of the engine compartment.(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Remove the nut that secures the suction line
fitting to the top of the compressor.
(6) Disconnect the suction line fitting from the
compressor suction port.
(7) Remove the seal from the suction line fitting
and discard.
(8) Install plugs in, or tape over the opened suc-
tion line fitting and the compressor suction port.
(9) Disengage the retainer that secures the suction
line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment (Fig. 6).
(10) Remove the nut that secures the suction line
and liquid line fittings to the expansion valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
Fig. 6 Suction Line
1 - EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - ROUTING CLIP
5 - SUCTION LINE
24 - 104 PLUMBING - REARRS
HEATER HOSE (Continued)
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(18) Reconnect the suction line extension fitting to
the underbody suction line fitting. Tighten the fit-
tings to 23 N´m (17 ft. lbs.).
(19) Install a new tie strap just forward of the con-
nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.
(20) Lower the vehicle.
(21) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(22) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
UNDERBODY LINES
DESCRIPTION
The rear heater-A/C unit plumbing is used only on
models with the optional rear heater-A/C unit. The
formed metal rear heater-A/C unit suction line, liquid
line, and heater lines are available for separate ser-
vice replacement. The molded and straight heater
hoses used on the rear heater-A/C unit can be ser-
viced in the vehicle. Refer to Group 7 - Cooling Sys-
tem for the heater hose service procedures.
OPERATION
The rear heater and A/C lines are all serviced as
individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any
contaminations that can get in to the system (Fig. 8),
(Fig. 9), (Fig. 11), (Fig. 10) and (Fig. 12).Any kinks or sharp bends in the rear heater-A/C
unit plumbing will reduce the capacity of the entire
heating and air conditioning system. Kinks and
sharp bends reduce the system flow. High pressures
are produced in the refrigerant system when the air
conditioning compressor is operating. High tempera-
ture coolant is present in the heater plumbing when
the engine is operating. Extreme care must be exer-
cised to make sure that each of the plumbing connec-
tions is pressure-tight and leak free.
Fig. 8 Rear Heater and A/C Lines
1 - HEATER CONNECTION
2 - REAR A/C LINE BLOCK CONNECTION
Fig. 9 Front Lines Connected to Rear Lines
24 - 106 PLUMBING - REARRS
SUCTION LINE (Continued)
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INSTALLATION
INSTALLATION - REAR HEATER LINES
(1) Install line into underbody straps.
(2) Install line into front hose and install hose
clamp.
(3) Connect quick fitting at rear of line.
(4) Lower vehicle.
(5) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
INSTALLATION - REAR AIR CONDITIONING
LINES
(1) Before installation, replace all O-rings and gas-
kets. Coat all sealing surfaces with approved wax-
free refrigerant oil.
(2) Install A/C line into rear block with nylon
wedge.
(3) Install A/C lines into five underbody brackets.
(4) Connect forward compression fittings.
(5) Install bolt at sealing block to rear A/C hous-
ing.
(6) Install ABS harness into clips.
(7) Install heater hoses into underbody brackets.
(8) Install lines into front hoses and install hose
clamps.
(9) Lower vehicle.
(10) Evacuate and recharge system.
(11) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Fig. 13 UNDERBODY LINE WEDGES
1 - O-RING
2 - DISCHARGE LINE
3 - NYLON WEDGE
4 - SEALING BLOCK
5 - VISE
6 - SUCTION LINE
24 - 108 PLUMBING - REARRS
UNDERBODY LINES (Continued)
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(7) With the DRBIIItin Cabin Heater, select Sys-
tem Tests and Dosing Pump Prime. Allow the Dosing
Pump to run for the full 45 second cycle time. When
the 45 second cycle is complete, press Page Back on
the DRBIIItkey pad to exit the Dosing Pump Prime.
The Dosing Pump priming procedure is now com-
plete.
HEATER UNIT
REMOVAL
WARNING: ALLOW THE DCHA TO COOL BEFORE
PERFORMING A COMPONENT INSPECTION/REPAIR
OR REPLACEMENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: ALLOW THE EXHAUST SYSTEM TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR OR REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
(1) Elevate the vehicle on a hoist/lift taking note of
heater exhaust tube flexible section.
(2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the heater and the hose and
tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board cross member at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe board cross member and
rail.
(7) Remove the wiring harness from the toe board
cross member(Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel fill cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(9) Loosen the two M8 fasteners at the rail. Take
care to notice that the exhaust tube bracket tab is on
top of the heater bracket.(10) Remove the heater exhaust tube flex section
from the exhaust tube by loosening the M6 bolt of
the clamp assembly. Remove the hose from the
exhaust tube. Removal of the rail tube assembly may
aid in this service operation.(Refer to 24 - HEATING
& AIR CONDITIONING/CABIN HEATER/EXHAUST
TUBE - REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to cross member.
(12) Loosen the remaining M6 and M8 fasteners
which mount the exhaust tube assembly to the vehi-
cle.
(a) Install a suitable cabin heater support device
under the cabin heater and secure the cabin heater
to the device.
(13) Loosen the remaining three M6 fasteners to
the cross members.
(14) Remove the loosened fasteners that support
the heater while supporting the weight of the heater.
(15) Swing the unit mounting bracket from
between the exhaust bracket and rail mounting loca-
tion. Drain any residual coolant from the heater unit.
(16) Lower the cabin heater and remove from the
supporting device and place on a suitable work area.
INSTALLATION
(1) Install the unit mounting bracket between the
exhaust bracket and the rail mounting location.
(2) Install the fasteners that support the heater
while supporting the weight of the heater.
(3) Install the three M6 fasteners to the cross
members. Tighten the M6 fasteners to 7 Nm (5 ft.
lbs.).
(4) Tighten the remaining M6 fasteners to 7 Nm (5
ft. lbs.) and the M8 fasteners to 23 Nm (17 ft. lbs.)
which mount the exhaust tube assembly to the vehi-
cle.
(5) Install the seat hex nut at the heater mounting
flange to the cross members. Tighten to 60 Nm (44 ft.
lbs.)
(6) Install the heater exhaust tube flex section to
the exhaust tube by tightening the M6 bolt of the
clamp assembly. Install the hose to the exhaust tube.
(7) Tighten the two M8 fasteners at the rail to 23
Nm (17 ft. lbs.). Taking care so that the exhaust tube
bracket tab is on the top of the heater bracket.
(8) Install the wiring harness(Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
(9) Tighten the hose and tube assembly to the toe-
board cross member at two locations.
(10) Install the second hose to the underbody hose
and tube assembly.
(11) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
24 - 114 DIESEL SUPPLEMENTAL HEATER - DCHA - BUXRS
FUEL LINE (Continued)
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(12) Remove the heater unit support device from
under the vehicle.
(13) Lower vehicle from lift.
(14) Refill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Verify function of the cabin heater.
SUPPLEMENTAL DIESEL
HEATER WIRING
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Unplug connector from vehicle wiring harness
to cabin heater harness.
(3) Unplug connector from cabin heater harness to
dosing pump connector.
(4) Unplug two connectors from cabin heater har-
ness to cabin heater controller connectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.
(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
AIR INTAKE PIPE
REMOVAL
NOTE: Heater air intake tube is part of an assembly
that includes the heater cooling intake and return
pipes. If heater air intake tube requires removal or
replacement the entire assembly will require remov-
al/replacement.
(1) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(2) Remove clamps from the heater tubes at the
lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the heater air
intake muffler connection(Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/INLET
MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 4).
Fig. 4 FLEXIBLE AIR INTAKE LINE
1 - HEATER UNIT AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
RSDIESEL SUPPLEMENTAL HEATER - DCHA - BUX24 - 115
HEATER UNIT (Continued)
ProCarManuals.com

(5) Remove the two retaining screws and remove
pipe assembly (Fig. 5).INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7 Nm
( 5 ft. lbs.).
(2) Attach the steel tube to the flexible tube and
position and then tighten the retaining clamp.
(3) Install the flexible tube to the heater air intake
muffler and install and tighten the retaining clamp.
(4) Install the heater tubes to the lower heater
connection and the lower EGR cooler connection and
tighten the retaining clamps.
(5) Lower the vehicle.
(6) Refill the cooling system(Refer to 7 - COOLING
- STANDARD PROCEDURE).
(7) Verify function of the heater unit.
Fig. 5 AIR INTAKE AND HEATER PIPE ASSEMBLY
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE
24 - 116 DIESEL SUPPLEMENTAL HEATER - DCHA - BUXRS
AIR INTAKE PIPE (Continued)
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