2002 CHRYSLER CARAVAN Service Manual

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Page 2297 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 4 Blower Motor Noise/Vibration Diagnosis
24 - 54 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)
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Page 2298 of 2399

CHRYSLER CARAVAN 2002 Service Manual INSTALLATION
(1) Position the blower motor and blower wheel
onto the outboard side of the rear heater-A/C unit
housing.
(2) Install and tighten the three screws that secure
the blower motor to the rea

INSTALLATION
(1) Position the blower motor and blower wheel
onto the outboard side of the rear heater-A/C unit
housing.
(2) Install and tighten the three screws that secure
the blower motor to the rear heater-A/C unit housing.
Tighten the screws to 2 N´m (18 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(4) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
REAR HEATER-A/C HOUSING
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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Raise and support the vehicle.
(5) Disconnect the underbody refrigerant line seal-
ing plate from the rear heater-A/C unit evaporator
extension line sealing plate that extends through the
rear floor panel behind the right rear wheel housing
(Fig. 6).
(6) Remove the seals from the liquid line and suc-
tion line fittings and discard.
(7) Install plugs in, or tape over the opened liquid
line and suction line fittings and both ports in the
evaporator extension line sealing plate.
Fig. 5 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
Fig. 6 Refrigerant Lines
1 - UNDERBODY REFRIGERANT LINE SEALING PLATE
RSDISTRIBUTION - REAR24-55
BLOWER MOTOR (Continued)
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Page 2299 of 2399

CHRYSLER CARAVAN 2002 Service Manual (8) Remove the three nuts that secure the rear
heater-A/C unit mounting studs to the rear floor
panel behind the right rear wheel housing (Fig. 7).
(9) Lower the vehicle.
(10) Remove the right quarter

(8) Remove the three nuts that secure the rear
heater-A/C unit mounting studs to the rear floor
panel behind the right rear wheel housing (Fig. 7).
(9) Lower the vehicle.
(10) 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).
(11) Remove the rear A/C distribution duct from
the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear heater-A/C unit housing from the rear
HVAC wire harness connector located near the
expansion valve at the back of the unit.
(13) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(14) Remove the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear heater-A/C unit housing.
(15) 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).
(16) Take the proper precautions to protect the
carpeting below the rear heater core from spilled
engine coolant and have absorbent toweling readily
available to clean up any spills.
(17) Disconnect the heater hoses at the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - REMOV-
AL).(18) Install plugs in, or tape over the opened
heater core fittings and both heater hoses.
(19) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(20) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar
(Fig. 8).
(21) Remove the screw that secures the front of
the rear heater-A/C unit housing to the right quarter
inner panel.
(22) Lift the rear heater-A/C unit housing up far
enough for the lower mounting studs and the evapo-
rator extension lines to clear the mounting holes in
the rear floor panel.
(23) Remove the rear heater-A/C unit housing from
the vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
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) Position the rear heater-A/C unit housing into
the vehicle with the evaporator extension line sealing
plate inserted into the rectangular hole in the rear
floor panel behind the right rear wheel house.
(2) Align the rear heater-A/C unit housing lower
mounting studs with the mounting holes in the rear
floor panel and lower the unit to the floor.
(3) 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.).
(4) 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.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(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).
Fig. 7 Rear Heater-A/C Unit Mounting Studs
1 - REAR HEATER-A/C UNIT MOUNTING STUDS
24 - 56 DISTRIBUTION - REARRS
REAR HEATER-A/C HOUSING (Continued)
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Page 2300 of 2399

CHRYSLER CARAVAN 2002 Service Manual (8) Install and tighten the two screws that secure
the bottom of the quarter trim panel attaching
bracket to the rear heater-A/C unit housing. Tighten
the screws to 1.7 N´m (15 in. lbs.).
(9) Install

(8) Install and tighten the two screws that secure
the bottom of the quarter trim panel attaching
bracket to the rear heater-A/C unit housing. Tighten
the screws to 1.7 N´m (15 in. lbs.).
(9) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel.
(10) Reconnect the body wire harness connector for
the rear heater-A/C unit housing to the rear HVAC
wire harness connector located near the expansion
valve at the back of the unit.
(11) Reinstall the auxiliary A/C distribution duct
onto the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - INSTALLATION).
(12) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(13) Raise and support the vehicle.(14) Install and tighten the three nuts that secure
the rear heater-A/C unit mounting studs to the rear
floor panel behind the right rear wheel housing.
Tighten the nuts to 9 N´m (80 in. lbs.).
(15) Remove the tape or plugs from the underbody
liquid line and suction line fittings and both ports in
the rear heater-A/C unit evaporator extension line
sealing plate that extends through the rear floor
panel behind the right rear wheel housing.
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line and
suction line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line sealing
plate.
(18) Install and tighten the screw that secures the
underbody refrigerant line sealing plate to the evap-
orator extension line sealing plate. Tighten the screw
to 23 N´m (17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
Fig. 8 Rear Heater-A/C Housing
1 - U-NUT (3)
2 - REAR HEATER-A/C HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
RSDISTRIBUTION - REAR24-57
REAR HEATER-A/C HOUSING (Continued)
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Page 2301 of 2399

CHRYSLER CARAVAN 2002 Service Manual (21) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
F

Page 2302 of 2399

CHRYSLER CARAVAN 2002 Service Manual PLUMBING - FRONT
TABLE OF CONTENTS
page page
PLUMBING - FRONT
WARNING
WARNING...........................60
WARNING...........................60
WARNING - A/C PLUMBING.............60
CAUTION - A/C PLUM

PLUMBING - FRONT
TABLE OF CONTENTS
page page
PLUMBING - FRONT
WARNING
WARNING...........................60
WARNING...........................60
WARNING - A/C PLUMBING.............60
CAUTION - A/C PLUMBING...............61
COMPRESSOR
DESCRIPTION.........................62
OPERATION...........................62
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS....................62
REMOVAL
REMOVAL - COMPRESSOR.............63
REMOVAL - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE...............64
INSTALLATION
INSTALLATION - COMPRESSOR..........64
INSTALLATION - COMPRESSOR
MOUNTING BRACKET - 2.4L ENGINE......65
CONDENSER
DESCRIPTION.........................65
OPERATION...........................65
REMOVAL.............................65
INSTALLATION.........................66
DISCHARGE LINE
REMOVAL.............................67
INSTALLATION.........................68
EVAPORATOR
DESCRIPTION.........................68
OPERATION...........................68
REMOVAL.............................69
INSTALLATION.........................70
EXPANSION VALVE
DESCRIPTION.........................71
OPERATION...........................71
DIAGNOSIS AND TESTING - EXPANSION
VALVE ..............................71
REMOVAL.............................72
INSTALLATION.........................73
HEATER CORE
DESCRIPTION.........................73
OPERATION...........................73
REMOVAL
REMOVAL- HEATER CORE EXTENSION
TUBES.............................74
REMOVAL - HEATER CORE.............75
INSTALLATION
INSTALLATION- HEATER CORE
EXTENSION TUBES...................76
INSTALLATION - HEATER CORE..........77HEATER HOSE
REMOVAL.............................78
INSTALLATION.........................79
HEATER HOSES - DIESEL SUPPLEMENTAL
HEATER - BUX
REMOVAL.............................80
INSTALLATION.........................80
HEATER PIPES - DIESEL SUPPLEMENTAL
HEATER - BUX
REMOVAL.............................80
INSTALLATION.........................82
LIQUID LINE
REMOVAL.............................82
INSTALLATION.........................84
RECEIVER/DRIER
DESCRIPTION.........................85
OPERATION...........................85
REMOVAL.............................85
INSTALLATION.........................86
REFRIGERANT
DESCRIPTION.........................87
OPERATION...........................87
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL...............87
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS......................88
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL 2.5L DIESEL.....89
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........90
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................91
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................92
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................93
REFRIGERANT OIL
DESCRIPTION.........................93
OPERATION...........................93
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................93
SUCTION LINE
REMOVAL.............................94
INSTALLATION.........................95
SERVICE PORTS
REMOVAL.............................95
INSTALLATION.........................96
RSPLUMBING - FRONT24-59
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Page 2303 of 2399

CHRYSLER CARAVAN 2002 Service Manual PLUMBING - FRONT
WARNING
WARNING
WARNING: DO NOT OPERATE DCHA IN AN
ENCLOSED AREA SUCH AS A GARAGE THAT
DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHAS EXHAUST WHEN
OPERATING TH

PLUMBING - FRONT
WARNING
WARNING
WARNING: DO NOT OPERATE DCHA IN AN
ENCLOSED AREA SUCH AS A GARAGE THAT
DOES NOT HAVE EXHAUST VENTILATION FACILI-
TIES. ALWAYS VENT THE DCHA'S EXHAUST WHEN
OPERATING THE DCHA. FAILURE TO FOLLOW
THESE INSTRUCTION MAY RESULT IN PERSONAL
INJURY OR DEATH.
ALLOW THE DCHA ASSEMBLY TO COOL BEFORE
PERFORMING A COMPONENT INSPECTION/RE-
PAIR/REPLACEMENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MY RESULT IN PERSONAL INJURY.
VERIFY THAT ALL DCHA FUEL LINES ARE
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE THIS PROCEDURE.
WARNING
WARNING:: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE SYSTEM IS HOT AND UNDER
PRESSURE. FAILURE TO OBSERVE THIS WARNING
CAN RESULT IN SERIOUS BURNS FROM THE
HEATED ENGINE COOLANT. ALLOW THE VEHICLE
TO COOL FOR A MINIMUM OF 15 MINUTES
BEFORE OPENING THE COOLING SYSTEM FOR
SERVICE.
WARNING: THE ENGINE COOLING SYSTEM CON-
TAINS ANTIFREEZE. ANTIFREEZE IS AN ETHYLENE
GLYCOL BASED COOLANT AND IS HARMFUL IF
SWALLOWED OR IF THE VAPORS ARE INHALED. IF
SWALLOWED, DRINK TWO GLASSES OF WATER
AND INDUCE VOMITING. IF VAPORS ARE INHALED,
MOVE TO AN AREA FOR FRESH AIR. SEEK MEDI-
CAL ATTENTION IMMEDIATELY. DO NOT STORE IN
OPEN OR UNMARKED CONTAINERS. WASH SKIN
AND CLOTHING THOROUGHLY AFTER COMING IN
CONTACT WITH ETHYLENE GLYCOL. KEEP OUT
OF REACH OF CHILDREN.
WARNING: DISPOSE OF ETHYLENE GLYCOL
BASED COOLANT PROPERLY. CONTACT YOURDEALER OR A LOCAL GOVERNMENT AGENCY FOR
THE LOCATION OF AN APPROVED ETHYLENE GLY-
COL COLLECTION AND/OR RECYCLING CENTER IN
YOUR AREA.
WARNING - A/C PLUMBING
WARNING:: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
WARNING: AVOID BREATHING THE REFRIGERANT
AND REFRIGERANT OIL VAPOR OR MIST. EXPO-
SURE MAY IRRITATE THE EYES, NOSE, AND/OR
THROAT. WEAR EYE PROTECTION WHEN SERVIC-
ING THE AIR CONDITIONING REFRIGERANT SYS-
TEM. SERIOUS EYE INJURY CAN RESULT FROM
DIRECT CONTACT WITH THE REFRIGERANT. IF
EYE CONTACT OCCURS, SEEK MEDICAL ATTEN-
TION IMMEDIATELY.
WARNING: DO NOT EXPOSE THE REFRIGERANT
TO OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
WARNING: IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
WARNING: THE EVAPORATION RATE OF R-134a
REFRIGERANT AT AVERAGE TEMPERATURE AND
ALTITUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
WARNING: THE R-134a SERVICE EQUIPMENT OR
THE VEHICLE REFRIGERANT SYSTEM SHOULD
NOT BE PRESSURE TESTED OR LEAK TESTED
WITH COMPRESSED AIR. SOME MIXTURES OF AIR
AND R-134a HAVE BEEN SHOWN TO BE COMBUS-
TIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS, AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
24 - 60 PLUMBING - FRONTRS
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Page 2304 of 2399

CHRYSLER CARAVAN 2002 Service Manual CAUTION - A/C PLUMBING
CAUTION:: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
CAUTION: Never add R-12 to a refri

CAUTION - A/C PLUMBING
CAUTION:: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
CAUTION: R-12 refrigerant oil must not be mixed
with R-134a refrigerant oil. They are not compatible.
CAUTION: Do not use R-12 equipment or parts on
the R-134a system. Damage to the system will
result. All parts, tools, and equipment must be
designed for R-134a refrigerant.
CAUTION: Do not discharge refrigerant into the
atmosphere. Use an R-134a refrigerant recovery/re-
cycling device that meets SAE Standard J2210.
CAUTION: The refrigerant must be recovered com-
pletely from the system before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. If any pres-
sure is noticed as a fitting is loosened, tighten the
fitting and recover the refrigerant from the system
again.
CAUTION: The refrigerant system must always be
evacuated before charging.
CAUTION: Do not overcharge the refrigerant sys-
tem. This will cause excessive compressor head
pressure and can cause noise and system failure.
CAUTION: Do not open the refrigerant system or
remove the sealing caps from a replacement com-
ponent until it is to be installed. This will prevent
contamination in the system.
CAUTION: Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.
CAUTION: When it is necessary to open the refrig-
erant system, have everything needed to service
the system ready. Immediately after disconnecting acomponent from the refrigerant system, seal the
open fittings with a cap or plug to prevent the
entrance of dirt and moisture. The refrigerant sys-
tem should not be left open to the atmosphere any
longer than necessary.
CAUTION: Before connecting an open refrigerant
fitting, always install a new seal or gasket. All fit-
tings with O-rings need to be coated with refriger-
ant oil before installation. Use only O-rings that are
the correct size and approved for use with R-134a
refrigerant. Failure to do so may result in a leak.
Coat the fitting and seal with clean refrigerant oil
before connecting. Unified plumbing connections
with gaskets cannot be serviced with O-rings. The
gaskets are not reusable and new gaskets do not
require lubrication before installing.
CAUTION: When installing a refrigerant line, avoid
sharp bends that may restrict refrigerant flow. A
good rule for the flexible hose refrigerant lines is to
keep the radius of all bends at least ten times the
diameter of the hose. Sharp bends will reduce the
flow of refrigerant.
CAUTION: Position the refrigerant lines away from
exhaust system components or any sharp edges,
which may damage the line. The flexible hose lines
should be routed so they are at least 80 millimeters
(3 inches) from the exhaust manifold. Inspect all
flexible refrigerant system hose lines at least once
a year to make sure they are in good condition and
properly routed.
CAUTION: High pressures are produced in the
refrigerant system when it is operating. Extreme
care must be exercised to make sure that all refrig-
erant system connections are pressure tight.
CAUTION: Tighten refrigerant fittings only to the
specified torque. The aluminum fittings used in the
refrigerant system will not tolerate overtightening.
CAUTION: When disconnecting a refrigerant fitting,
use a wrench on both halves of the fitting. This will
prevent twisting of the refrigerant lines or tubes.
CAUTION: Refrigerant oil will absorb moisture from
the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to
use it. Replace the cap on the oil container immedi-
ately after using. Store refrigerant oil only in a
clean, airtight, and moisture-free container.
RSPLUMBING - FRONT24-61
PLUMBING - FRONT (Continued)
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