2002 CHRYSLER CARAVAN hood open

DESCRIPTION FIGURE
ROOF TOP JOINT & UPPER FRONT SLIDING DOOR - LEFT AND RIGHT SIDES 39
ROOF TOP JOINT & UPPER REAR SLIDING DOOR - LEFT AND RIGHT SIDES 40
ROOF TOP JOINT & WINDSHIELD OPENING - LEFT AND RIGHT SIDES 41
LIFT GATE ROOF COACH JOINT - LEFT AND RIGHT SIDES 42
ROOF RAP JOINT - LEFT AND RIGHT SIDES 43
DRAIN HOLE PATCHES 44
WHEELHOUSE VENT HOLE - LEFT SIDE SHOWN - RIGHT SIDE TYPICAL 45
FLOOR PAN HOLES - LEFT AND RIDE SIDES 46
HOOD FRONT HEM FLANGE & SIDES 47
FRONT DOOR LOWER FLANGE 48
LIFTGATE HEM FLANGE AND LATCH COVER SEAMS 49
FRONT DOOR BELT DOOR BELT SEAMS (FRONT) 50
FRONT DOOR BELT DOOR BELT SEAMS (REAR) 51
23 - 122 BODY STRUCTURERS
SEALER LOCATIONS (Continued)
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FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install and tighten the four screws that secure
the compressor mounting bracket to the engine.
Tighten the screws to 54 N´m (40 ft. lbs.).
(3) Reinstall the compressor onto the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - INSTALLA-
TION).
CONDENSER
DESCRIPTION
The condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The condenser cannot be
repaired or adjusted and, if faulty or damaged, it
must be replaced. The condenser may be removed
from the cooling module for service without removing
the cooling module from the vehicle.
OPERATION
The condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
compressor to give up its heat to the air passing over
the condenser fins. When the refrigerant gas gives up
its heat, it condenses. When the refrigerant leaves
the condenser, it has become a high-pressure liquid
refrigerant. The volume of air flowing over the con-
denser fins is critical to the proper cooling perfor-
mance of the air conditioning system. Therefore, it is
important that there are no objects placed in front of
the radiator grille openings in the front of the vehicle
or foreign material on the condenser fins that might
obstruct air flow. Also, any factory-installed air seals
or shrouds must be properly reinstalled following
radiator or condenser service.
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)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).NOTE: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 4).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the two screws that secure the hood
latch unit to the front of the radiator closure panel
crossmember and move the latch out of the way over
the top of the crossmember. Mark the location of
latch for reinstallation.
(6) Disconnect the hoses from the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - REMOVAL).
(7) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module.
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-65
COMPRESSOR (Continued)
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(10) Install and tighten the nut that secures the
liquid line fitting to the condenser. Tighten the nut to
23 N´m (17 ft. lbs.).
(11) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
(12) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the discharge line fit-
ting.
(13) Reconnect the discharge line fitting to the
condenser inlet port on the right side of the cooling
module.
(14) Install and tighten the nut that secures the
discharge line fitting to the condenser. Tighten the
nut to 23 N´m (17 ft. lbs.).
(15) Reconnect the hoses to the transmission oil
cooler fittings on the left side of the cooling module.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER LINES - INSTALLATION).
(16) Reposition the hood latch unit to the front of
the radiator closure panel crossmember.
(17) Install and tighten the two screws that secure
the hood latch unit to the front of the radiator clo-
sure panel crossmember. Check and adjust the hood
latch as needed. Tighten the screws to 14 N´m (123
in. lbs.).
(18) Position the radiator sight shield onto the
radiator closure panel crossmember.
(19) Install and tighten the five small screws that
secure the front fascia grille inserts to the radiator
sight shield. Tighten the screws to 2 N´m (18 in. lbs.).
(20) Install and tighten the two large screws that
secure the front fascia and the outboard ends of the
radiator sight shield to the radiator closure panel
crossmember. Tighten the screws to 6 N´m (53 in.
lbs.).
(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).
DISCHARGE LINE
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)
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) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 6).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the nut that secures the discharge line
fitting to the condenser on the right side of the cool-
ing module (Fig. 7).
(6) Disconnect the discharge line fitting from the
condenser inlet port.
(7) Remove the seal from the discharge line fitting
and discard.
(8) Install plugs in, or tape over the opened dis-
charge line fitting and the condenser inlet port.
(9) Remove the nut that secures the discharge line
fitting to the top of the compressor (Fig. 8).
(10) Disconnect the discharge line fitting from the
compressor discharge port.
(11) Remove the seal from the discharge line fit-
ting and discard.
(12) Install plugs in, or tape over the opened dis-
charge line fitting and the compressor discharge port.
(13) Remove the discharge line from the engine
compartment.
Fig. 6 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
RSPLUMBING - FRONT24-67
CONDENSER (Continued)
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HEATER HOSES - DIESEL
SUPPLEMENTAL HEATER -
BUX
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Lower heater unit from vehicle(Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/HEATER UNIT - REMOVAL).
NOTE: Complete removal of cabin heater from vehi-
cle is not required, lowering unit allows easier
access to coolant line clamps.
(4) Remove clamps from both flexible coolant line
ends.
(5) Remove both lines from vehicle.
NOTE: If either line is damaged it is recommended
that both flexible lines be replaced.
INSTALLATION
(1) Install both flexible coolant lines to the heater
unit and install clamps.
(2) Install flexible coolant lines to the coolant pipes
and install clamps.
(3) Install heater unit into vehicle(Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/HEATER UNIT - INSTALLATION).
(4) Lower vehicle.
(5) Refill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(6) Verify operation of heater unit.
HEATER PIPES - DIESEL
SUPPLEMENTAL HEATER -
BUX
REMOVAL
CAUTION: Allow cooling system to cool completely
before removing radiator cap or draining cooling
system. Injury could result is system is opened
while system coolant is hot and under pressure.
NOTE: Steel heater lines from engine compartment
to heater unit are part of an assembly that includes
the air intake pipe. If the heater lines or air intake
pipe require removal or replacement the entire
assembly must be removed or replaced.
(1) Open hood.
(2) Drain the cooling system(Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove clamps from both the EGR cooler and
the lower heater port. Separate hoses from the mat-
ing plumbing port. (Fig. 26).
(4) Remove retaining nut from heater line under
hood bracket.
(5) Elevate vehicle on a lift.
NOTE: When supporting vehicle care should be
taken not to damage the heater exhaust tube.
(6) Remove clamps from heater lines to the rubber
connection nearest the tubes. Separate the hoses
from the tube assembly leaving the rubber hose
attached to the supplemental heater.
(7) Remove heater unit intake pipe from heater-
(Refer to 24 - HEATING & AIR CONDITIONING/
CABIN HEATER/INLET HOSE - REMOVAL) (Fig.
27).
(8) Remove heater pipe assembly retaining screws
and remove assembly from vehicle.
24 - 80 PLUMBING - FRONTRS
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