2002 CHRYSLER CARAVAN service

(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the demister
ducts to the instrument panel armature.
(5) Disengage the demister ducts from the demis-
ter outlets.
(6) Remove the demister ducts from the instru-
ment panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the demister ducts to the instrument
panel.
(2) Engage the demister ducts to the demister out-
lets.
(3) Install the fasteners that secure the demister
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 12).
(3) Pull the floor distribution duct assembly rear-
ward far enough to disengage the center floor distri-bution duct from the outlet on the bottom of the
heater-A/C housing unit.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required.
(2) Slide the floor distribution duct assembly
under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.
(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
Fig. 12 Floor Distribution Ducts
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
24 - 48 DISTRIBUTION - FRONTRS
DEMISTER DUCTS (Continued)
ProCarManuals.com

HVAC 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).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(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) Disconnect the liquid line and suction line from
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(5) Disconnect the heater hoses from the heater
core tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(6) Remove the four nuts that secure the heater-
A/C unit housing studs to the engine compartment
side of the dash panel (Fig. 13).
(7) Remove the instrument panel from the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(8) Remove the floor distribution duct from the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - REMOVAL).
(9) Remove the one screw that secures the heater-
A/C unit housing bracket to the passenger compart-
ment side of the dash panel (Fig. 14).
Fig. 13 Heater-A/C Unit Housing Studs
1 - HEATER-A/C UNIT HOUSING
2 - DASH PANEL
3 - NUT (4)
4 - STUD (4)
Fig. 14 Heater-A/C Unit Housing
1 - HEATER-A/C UNIT HOUSING
2 - SCREW
3 - BRACKET
4 - DASH PANEL
RSDISTRIBUTION - FRONT24-49
ProCarManuals.com

(10) Pull the heater-A/C unit housing rearward far
enough for the mounting studs to clear the dash
panel and remove the unit from the passenger com-
partment.
INSTALLATION
(1) Position the heater-A/C unit housing against
the dash panel in the passenger compartment with
the four mounting studs located in their proper
mounting holes in the dash panel.
(2) Install and tighten the one screw that secures
the heater-A/C unit housing bracket to the passenger
compartment side of the dash panel. Tighten the
screw to 3 N´m (26 in. lbs.).
(3) Install and tighten the four nuts that secure
the heater-A/C unit housing studs to the engine com-
partment side of the dash panel. Tighten the nuts to
7 N´m (62 in. lbs.).
(4) Reinstall the floor distribution duct onto the
heater-A/C unit housing. (Refer to 24 - HEATING &
AIR CONDITIONING/DISTRIBUTION - FRONT/
FLOOR DISTRIBUTION DUCTS - INSTALLATION).
(5) Reinstall the instrument panel into the passen-
ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
INSTALLATION).
(6) Reconnect the heater hoses to the heater core
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(7) Reconnect the suction line and liquid line to
the expansion valve. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(8) Reconnect the battery negative cable.
(9) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(10) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(11) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
PANEL DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the panel
ducts to the instrument panel armature.
(5) Disengage the panel ducts from the panel out-
lets.
(6) Remove the panel ducts from the instrument
panel.
INSTALLATION
(1) Position the panel ducts to the instrument
panel.
(2) Engage the panel ducts to the panel outlets.
(3) Install the fasteners that secure the panel
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
24 - 50 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)
ProCarManuals.com

DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION.........................51
REMOVAL.............................51
INSTALLATION.........................51
A/C DISTRIBUTION DUCT
REMOVAL.............................52
INSTALLATION.........................52
BLOWER MOTOR
DESCRIPTION.........................52
OPERATION...........................52DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................53
REMOVAL.............................53
INSTALLATION.........................55
REAR HEATER-A/C HOUSING
REMOVAL.............................55
INSTALLATION.........................56
REAR HEATER DISTRIBUTION DUCT
REMOVAL.............................58
INSTALLATION.........................58
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear heater-A/C unit housing through
one or a combination of the two main housing out-
lets: air conditioner, or heater. Once the conditioned
air exits the unit housing, it is directed through
molded plastic ducts to the various outlets in the
vehicle interior. These outlets and their locations are
as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear heater distribution duct to the intermediate and
rear seat occupants. The floor outlets are integral to
the right quarter trim panel and, if faulty or dam-
aged, the quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear A/C distribution
duct and the headliner ducts to the intermediate and
rear seat occupants. The headliner ducts are integral
to the headliner panel. Each overhead outlet is
housed in a headliner bezel. The two forward head-
liner bezels also feature a courtesy lamp, a fold-away
coat hook, and a fold-away assist handle. The over-
head outlets can be removed from the headliner
bezels individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel.
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
RSDISTRIBUTION - REAR24-51
ProCarManuals.com

A/C DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear air conditioning distribution duct
upwards far enough to disengage it from the outlet at
the top of the rear heater-A/C unit housing (Fig. 2).
(3) While pulling the lower end of the auxiliary air
conditioning distribution duct away from the rear
heater-A/C unit outlet, disengage the upper end of
the distribution duct from the headliner duct.
(4) Remove the auxiliary air conditioning distribu-
tion duct from the vehicle.
INSTALLATION
(1) Align the upper end of the rear air conditioning
distribution duct to the headliner duct.
(2) Slide the upper end of the rear air conditioning
distribution duct onto the headliner duct far enough
to align the lower end of the duct with the outlet at
the top of the rear heater-A/C unit housing.
(3) Slide the rear air conditioning distribution duct
downwards far enough to engage it onto the outlet at
the top of the rear heater-A/C unit housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 3). The
blower motor and wheel are located in a housing
near the top of the rear heater-A/C unit in the pas-
senger compartment behind the right rear wheel
house. The rear heater-A/C unit housing must be
removed from the vehicle to access the blower motor
and blower wheel for service. The blower motor and
blower motor wheel are a factory balanced unit and
cannot be adjusted or repaired. If faulty or damaged,
the blower motor and blower wheel must be replaced
as a unit.
OPERATION
The rear blower motor will operate whenever the
ignition switch is in the On position, the heater-A/C
control power is turned on, and the rear heater-A/C
Fig. 2 Rear A/C Distribution Duct
1 - HEADLINER DUCT
2 - REAR A/C DISTRIBUTION DUCT
3 - REAR HEATER-A/C UNIT OUTLET
Fig. 3 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
24 - 52 DISTRIBUTION - REARRS
ProCarManuals.com

(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)
ProCarManuals.com

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
ProCarManuals.com

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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