2002 CHRYSLER CARAVAN Service Manual

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CHRYSLER CARAVAN 2002 Service Manual Fig. 175 LOWER LIFTGATE OPENING - SHORT WHEEL BASE ONLY
23 - 258 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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CHRYSLER CARAVAN 2002 Service Manual Fig. 176 ROOF PANEL/ROOF RAIL - SHORT WHEEL BASE ONLY
RSBODY STRUCTURE23 - 259
WELD LOCATIONS (Continued)
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CHRYSLER CARAVAN 2002 Service Manual ProCarManuals.com

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CHRYSLER CARAVAN 2002 Service Manual HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE...........1
DESCRIPTION - DUAL ZONE.............1
DESCRIPTION - MANUAL THREE ZON

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE...........1
DESCRIPTION - DUAL ZONE.............1
DESCRIPTION - MANUAL THREE ZONE.....1
DESCRIPTION - THREE ZONE AUTOMATIC
TEMPERATURE CONTROL...............2
OPERATION
OPERATION - DUAL ZONE...............3
OPERATION - MANUAL THREE ZONE......3
OPERATION - THREE ZONE ATC..........4
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL
DOWN TEST..........................5DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST..................5
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST..................6
SPECIFICATIONS - HEATER-A/C SYSTEM.....7
CONTROLS - FRONT......................8
CONTROLS - REAR......................29
DISTRIBUTION - FRONT...................39
DISTRIBUTION - REAR....................51
PLUMBING - FRONT.....................59
PLUMBING - REAR......................97
DIESEL SUPPLEMENTAL HEATER - DCHA -
BUX.................................109
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - SINGLE ZONE
A single zone heating and air conditioning system
allows one temperature setting for the entire vehicle.
The full range of temperatures that the system can
produce are available by rotating the temperature
control located in control panel.
The control panel and integral computer is
mounted in the instrument panel.
DESCRIPTION - DUAL ZONE
A manual Dual Zone Heating and Air Conditioning
system allows completely independent side-to-side
tempeture control of the discharge air.
The Dual Zone Heating and Air Conditioning sys-
tem includes a dust and odor air filter. The filter ele-
ment is the same size as the air conditioning
evaporator to ensure ample capacity. A door at the
base of the heating and air conditioning housing
below the glove box provides easy access to the filter
element.
The control panel and integral computer is located
in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off. Contains an LED that illumi-
nates to show when the function is operational.²rear window defogger on/off switch. Contains an
LED that illuminates to show when the function is
operational.
²slide controls for completely independent side-to-
side temperature control of the discharged air. The
full range of temperature that the system can pro-
duce in any mode is available on either side of the
vehicle by independently positioning the slide con-
trols on the instrument panel.
²air recirculation on/off switch. The Recirculate
button contains an LED that illuminates to show
when the function is in operation.
²air conditioning on/off switch. The Snowflake
button contains an LED that illuminates to shown
when the function is in operation.
²rotary knob for fan speed selection.
²a rotary knob for mode control.
DESCRIPTION - MANUAL THREE ZONE
The fully adjustable Three-Zone front and rear
heating and air conditioning system allows interme-
diate seat passengers the ability to regulate air tem-
perature as well as fan speed. All controls are
identified by ISO graphic symbols.
The Three Zone Heating and Air Conditioning sys-
tem includes a dust and odor air filter. The filter ele-
ment is the same size as the air conditioning
evaporator to ensure ample capacity. A door at the
base of the heating and air conditioning housing
below the glove box provides easy access to the filter
element.
RSHEATING & AIR CONDITIONING24-1
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CHRYSLER CARAVAN 2002 Service Manual FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allo

FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off.
²rear window defogger on/off switch.
²slide controls for completely independent side-to-
side temperature control of the discharge air. The full
range of temperature that the system can produce in
any mode is available on either side of the vehicle by
independently positioning the slide controls on the
instrument panel.
²air recirculation button. The Recirculate button
contains an LED that illuminates to show when the
function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²rotary knobs for front and rear fan speed selec-
tion.
²a rotary knob for mode control.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner has a rotary adjustment for temperature
and fan speed control of the rear unit by intermedi-
ate seat passengers when the front control rear knob
is set to the rear position.
DESCRIPTION - THREE ZONE AUTOMATIC
TEMPERATURE CONTROL
The Three-Zone Automatic Temperature Control
(ATC) allows occupants to select a comfort tempera-
ture, which is the perceived temperature level not
the actual passenger compartment air temperature.
The Three Zone Automatic Temperature Control
system includes a dust and odor air filter. The filter
element is the same size as the air conditioning evap-
orator to ensure ample capacity. A door at the base of
the heater and air conditioning housing below the
glove box provides easy access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the Programmable Communi-
cations Interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine RPM, vehicle speed and Man-
ifold Absolute Pressure information from the PCM.²Coolant Temperature± ATC computer moni-
tors Coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors Ambient temperature from the Compass Mini
Trip Computer (CMTC) and converts it to degrees
Fahrenheit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors Barometric Pressure, Intake Air Temperature,
High Side Pressure and Methanol Content as broad-
cast by the PCM.
²Door Ajar Status± The ATC computer moni-
tors Driver Front Door, Passenger Front Door, Left
Rear Door, Right Rear Door and Liftgate ajar infor-
mation, as identified by the Body Control Module
(BCM), to determine if all in-car temperatures should
be maintained.
²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the VF tube icons if the manual
motor calibration or manual cool down tests have
failed. Flashing of the display icons will cease when
the vehicle odometer is greater than 3 miles.
²English Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for Evaporator Temperature too
Low, Fan Blower Relay status, Evaporator Sensor
Failure, Rear Window Defogger Relay and A/C Select.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²A power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²Three rocker switches that select comfort tem-
peratures from 15É to 30É C (59É to 85É F), which are
shown in the vacuum-fluorescent digital control dis-
play. If the set temp is 59 and the down button is
24 - 2 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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Page 2246 of 2399

CHRYSLER CARAVAN 2002 Service Manual pressed, the set temp value will become 55 but the
display will show LO. If the set temp is 85 and the
up button is pressed, the set temp value will become
90 but the display will show HIGH. Temperatu

pressed, the set temp value will become 55 but the
display will show LO. If the set temp is 85 and the
up button is pressed, the set temp value will become
90 but the display will show HIGH. Temperatures
can be displayed in either metric or Fahrenheit,
which is controlled from the overhead console.
²A rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²A defroster button which turns on the defroster
independently during full automatic control. A
defroster symbol illuminates in the display when the
button is pressed.
²Air recirculation button. A Recirculation symbol
appears in the display when the button is pressed, or
when the system exceeds 80 percent circulated air
under automatic control due to high air conditioning
demand.
²Rear window defogger on/off switch. A graphic
symbol shows when the defroster is on.
²An air conditioning button that allows the com-
pressor to be turned off. A Snowflake symbol is illu-
minated when air conditioning is on, whether under
manual or automatic control.
²Rotary knob for front fan speed selection can
override the automatic controls. LEDs surrounding
the knob show the current setting.
²Rotary knob for control of the Rear system.
²A rotary knob for mode control can override the
automatic controls. LEDs surrounding the knob show
the current setting.
²Computer logic remembers the settings of the
controls when the ignition is turned off and retains
those settings after a restart. If the system is off
when the ignition is turned off it will be off when the
engine is restarted, etc.
²Computer logic provides variable air recircula-
tion under high temperature and humidity condi-
tions. Because recirculation is generally accompanied
by increased fan noise, the proportion of recirculated
to outside air gradually approaches full recirculation
over a broad temperature range.
²A graphic symbol of the windshield that illumi-
nates when the windshield wiper deicer is active.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner includes a vacuum-flourescent digital dis-
play, a rocker control for temperature and rotary con-
trols for adjustment of mode and fan speed control of
the rear unit by intermediate seat passengers.
OPERATION
OPERATION - DUAL ZONE
²The mode control knob enables continously vari-
able proportioning of air flow between modes but has
detents adjacent to each icon.
²The blower control provides five separate speeds.
²When the fan is off, the HVAC computer closes
the recirculation door to prevent outside air from
entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
OPERATION - MANUAL THREE ZONE
FRONT CONTROL PANEL
²Primary control of the rear compartment unit is
on the instrument panel. This control allows the
driver to set the rear compartment fan speed, to turn
the rear unit off, or to give control to the intermedi-
ate seat occupants by switching to the REAR posi-
tion. When the rear unit is controlled from the
instrument panel, rear air temperature is based on
the driver-side temperature control position, and the
mode (floor or overhead air) is based on the front
control's mode position.
²The mode control knob enables continously vari-
able proportioning of air flow between modes but has
detents adjacent to each icon.
²The blower control provides five separate speeds
and Off. When the fan is off, the HVAC computer
closes the recirculation door to prevent outside air
from entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes exccept defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
RSHEATING & AIR CONDITIONING24-3
HEATING & AIR CONDITIONING (Continued)
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CHRYSLER CARAVAN 2002 Service Manual REAR CONTROL PANEL
With the rear control active, temperature selection
dictates indirectly the mode (floor or overhead air) of
the rear unit: a low temperature setting directs flow
to the overhead out

REAR CONTROL PANEL
With the rear control active, temperature selection
dictates indirectly the mode (floor or overhead air) of
the rear unit: a low temperature setting directs flow
to the overhead outlets and a high temperature set-
ting to the floor.
OPERATION - THREE ZONE ATC
Comfort temperature or perceived temperature is
affected by air flow, sun impinging on exposed skin,
etc. The air temperature may be higher or lower than
the comfort temperature. Three infrared sensors, two
in the instrument panel center stack, and one in the
overhead-mounted rear control panel, independently
measure the temperature of the driver, front passen-
ger, and rear compartment occupants to determine
their comfort level relative to the selected comfort
temperature. The HVAC computer in the control
module adjusts the air flow rate and temperature to
maintain the customer-perceived comfort tempera-
ture. The air temperature in the passenger compart-
ment at any time may be slightly higher or lower
than the comfort temperature. For instance, on
sunny summer days the air flow will probably be
cooler than the comfort temperature; on cold or
cloudy days and at night it will probably be slightly
warmer. Infrared Three-Zone Temperature Control
provides side-to-side and front-to-rear variation in
comfort temperature settings. The Infrared Three-
Zone Automatic Temperature Control fan provides a
continuously variable air flow rate to meet occupant
comfort requirements.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DE-FROST± The front de-frost function is
active when the rear window defogger function is
active or when the defog/defrost mode is selected.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the Intelligent
Power Module which controls the Rear WindowDefogger and side view mirror (if equipped) circuitry.
The defogger function will be active for 10 minutes
and can be turned off by a switch press. The defogger
will function while the control is in the OFF mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that function alone manual for
as long as the ignition is on. If only one is changed
manually, the other remains under automatic control.
Pressing the HI-AUTO/LO-AUTO rocker switch
restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-
tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, Defrost mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
24 - 4 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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Page 2248 of 2399

CHRYSLER CARAVAN 2002 Service Manual control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and

control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the a/c system is
operating properly, or use a DRBIIItscan tool to
diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
MANUAL TEMPERATURE CONTROL
The front blower speed and rear blower speed (if
equipped with rear HVAC) must be set to High and
the evaporator temperature sensor must be greater
than 55É F or the test will fail immediately. The test
is activated by depressing the A/C and PWR buttons
simultaneously and holding them depressed for no
less than five seconds. The PWR and A/C LEDs will
blink on and off until the test is complete. If the
LEDs stop blinking before two minutes, then the cool
down test has been completed successfully. If the two
minutes expire without the expansion valve temper-
ature reaching 20É F less than the outside air tem-
perature, then the cool down test has been failed and
further A/C system diagnosis is required. If the test
is failed, the LEDs will continue to blink until the
vehicle has been driven for greater than (8 miles).
AUTOMATIC TEMPERATURE CONTROL
The ambient air temperature in the room where
the vehicle will be tested must be a minimum of 21É
C (70ÉF) for this test. The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking before two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-perature reaching 20É F less than the evaporator ini-
tial temperature, then the cool down test has been
failed and further A/C system diagnosis is required.
If the test is failed, the snowflake icon and the
DELAY text will continue to blink across ignition
cycles until the vehicle has been driven for greater
than (8 miles).
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
An air conditioning performance test is the best
way to determine whether the system is performing
up to standard. This test also provides valuable clues
as to the possible cause of trouble with the air con-
ditioning system. The ambient air temperature in the
location where the vehicle will be tested must be a
minimum of 21É C (70ÉF) for this test.
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).
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer to monitor the engine
speed.
(2) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set to
monitor the refrigerant system pressures.
(3) Set the heater-air conditioner controls so that
the compressor is engaged, the air within the vehicle
is being recirculated, the output air is directed
through the panel outlets, the temperature control is
in the full cool position, and the blower motor is oper-
ating at its highest speed.
(4) Start the engine and allow the engine to oper-
ate for about five minutes or until it reaches normal
operating temperature. Then hold the engine speed
at 1000 rpm with the compressor clutch engaged. If
the compressor clutch does not engage, proceed with
diagnosis of the compressor clutch coil. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH COIL - DIAGNO-
SIS AND TESTING).
(5) Close all the vehicle windows and doors.
(6) Insert a thermometer in the left center panel
outlet and operate the engine for five minutes.
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)
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