2005 CHRYSLER CARAVAN tow

Fig. 135 INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL
Fig. 136 STRUT TOWER BRACKET AND COWL PLENUM
23 - 282 BODY STRUCTURERS
WELD LOCATIONS (Continued)

Fig. 210 STRUT TOWER, COWL SIDE PANEL - RIGHT HAND DRIVE
RSBODY STRUCTURE23 - 347
WELD LOCATIONS (Continued)

mance and to protect the system components from
damage. The A/C pressure transducer input to the
PCM will also prevent the A/C compressor clutch
from engaging when ambient temperatures are below
about 4.5É C (40É F) due to the pressure/temperature
relationship of the refrigerant. The Schrader-type
valve in the liquid line fitting permits the A/C pres-
sure transducer to be removed or installed without
disturbing the refrigerant in the system. The A/C
pressure transducer is diagnosed using a DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER
The A/C pressure transducer is tested using a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information. Before testing the A/C pressure
transducer, be certain that the transducer wire har-
ness connection is clean of corrosion and properly
connected. For the A/C to operate, an A/C pressure
transducer voltage reading between 0.451 and 4.519
volts is required. Voltages outside this range indicate
a low or high refrigerant system pressure condition
to the powertrain control module (PCM). The PCM is
programmed to respond to a low or high refrigerant
system pressure by suppressing operation of the A/C
compressor. Refer to the A/C Pressure Transducer
Voltage chart for the possible conditions indicated by
the transducer voltage reading.
A/C PRESSURE TRANSDUCER VOLTAGE
Voltage Possible Indication
0.0 1. No sensor supply voltage from
PCM.
2. Shorted sensor circuit.
3. Faulty transducer.
0.150 TO 0.450 1. Ambient temperature below
10É C (50É F).
2. Low refrigerant system
pressure.
0.451 TO 4.519 1. Normal refrigerant system
pressure.
4.520 TO 4.850 1. High refrigerant system
pressure.
5.0 1. Open sensor circuit.
2. Faulty transducer.
REMOVAL
NOTE: Note: It is not necessary to discharge the
refrigerant system to replace the A/C pressure
transducer.
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the wire harness connector from the
A/C pressure transducer (Fig. 10).
(3) Remove the A/C pressure transducer from the
fitting on the liquid line.
(4) Remove the O-ring seal from the A/C pressure
transducer fitting and discard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C pressure transducer.
(1) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the A/C pressure
transducer fitting. Use only the specified O-rings as
they are made of a special material for the R-134a
system. Use only refrigerant oil of the type recom-
mended for the A/C compressor in the vehicle.
(2) Install and tighten the A/C pressure transducer
onto the fitting onto the liquid line fitting.
(3) Connect the wire harness connector to the A/C
pressure transducer.
(4) Reconnect the battery negative cable.
Fig. 10 A/C Pressure Transducer - Typical
1 - RIGHT FRONT STRUT TOWER
2 - WIRE HARNESS CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
RSCONTROLS - FRONT24-21
A/C PRESSURE TRANSDUCER (Continued)

The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The evaporator temperature sensor monitors the
temperature of the conditioned air once it passes
through the A/C evaporator. The evaporator temper-
ature sensor will change its internal resistance in
response to the air temperatures it monitors and is
connected to the A/C-heater control through sensor
ground and signal circuits. As the conditioned air
temperature increases, the resistance of the evapora-
tor temperature sensor decreases and the voltage
monitored by the A/C-heater control decreases. The
external location of the evaporator temperature sen-
sor allows the sensor to be removed or installed with-
out disturbing the refrigerant in the A/C system.
The A/C-heater control uses this monitored voltage
reading as an indication of the evaporator tempera-
ture. The A/C-heater control is programmed to
respond to this input by sending electronic messages
to the powertrain control module (PCM) over the con-
troller area network (CAN) data bus. The PCM then
cycles the A/C compressor clutch as necessary to opti-
mize A/C system performance and to protect the A/C
system from evaporator freezing.
The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
The evaporator temperature sensor is diagnosed
using the DRBIIItscan tool. Refer to Body Diagnos-
tic Procedures.
REMOVAL
RG MODELS
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the windshield wiper assembly from
the vehicle (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Remove the temperature sensor retainer from
the expansion valve (Fig. 17).
(5) Pull the evaporator temperature sensor away
from the expansion valve far enough to access the
red release ring on the wiring connector. Push the
red ring toward the connector to release the lock and
disconnect the wire harness connector from the tem-
perature sensor.
(6) Remove the evaporator temperature sensor
from the engine compartment.
RS MODELS
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the wire harness connector from the
evaporator temperature sensor located on the top of
the HVAC housing (Fig. 18).
(4) Remove the evaporator temperature sensor
from the HVAC housing.
INSTALLATION
RG MODELS
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) Position the evaporator temperature sensor
into the right rear corner of the engine compartment.
(2) Reconnect the wire harness connector to the
evaporator temperature sensor.
(3) Position the evaporator temperature sensor
onto the top of the expansion valve with the sensor
probe inserted into the well in the expansion valve.
(4) Install the temperature sensor retainer.
(5) Install the window wiper module (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(6) Reinstall the air cleaner housing into the right
side of the engine compartment.
(7) Reconnect the battery negative cable.
Fig. 17 Evaporator Temperature Sensor - RG Models
1 - RIGHT FRONT STRUT TOWER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - DASH PANEL
5 - RETAINER
RSCONTROLS - FRONT24-27
EVAPORATOR TEMPERATURE SENSOR (Continued)

DISTRIBUTION - FRONT
TABLE OF CONTENTS
page page
AIR FILTER
DESCRIPTION.........................42
REMOVAL.............................42
INSTALLATION.........................43
AIR OUTLETS
DESCRIPTION.........................43
REMOVAL
FRONT CENTER BEZEL OUTLETS........44
FRONT DEMISTER OUTLETS............44
INSTRUMENT PANEL OUTLETS..........45
INSTALLATION
FRONT CENTER BEZEL OUTLETS........45
FRONT DEMISTER OUTLETS............45
INSTRUMENT PANEL OUTLETS..........45
BLOWER MOTOR
DESCRIPTION.........................45
OPERATION...........................45
DIAGNOSIS AND TESTING
FRONT BLOWER MOTOR...............46
REMOVAL.............................48INSTALLATION.........................49
DEFROSTER DUCT
REMOVAL.............................49
INSTALLATION.........................50
FLOOR DISTRIBUTION DUCTS
REMOVAL.............................50
INSTALLATION.........................50
HVAC HOUSING
REMOVAL
REMOVAL...........................50
DISSASEMBLY.......................51
INSTALLATION
ASSEMBLY..........................53
INSTALLATION.......................53
INSTRUMENT PANEL DEMISTER DUCTS
REMOVAL.............................54
INSTALLATION.........................54
INSTRUMENT PANEL DUCTS
REMOVAL.............................55
INSTALLATION.........................55
AIR FILTER
DESCRIPTION
A dust and odor air filter is standard equipment on
models equipped with the three zone temperature
control systems (Fig. 1). The filter element is the
same size as the front air conditioner evaporator to
ensure ample filtering capacity. A removable door on
the bottom of the front HVAC housing below the
glove box provides easy access to the filter element
for replacement. The filter should be checked and
replaced at least once every 24,000 km (15,000 miles)
and checked if heater-A/C system performance seems
lower than expected.
REMOVAL
(1) Locate the air filter door on the bottom of the
lower HVAC housing just outboard of the passenger
side of the instrument panel center stack (Fig. 2).
(2) Slide the air filter door latch toward the rear of
the vehicle until it engages the opened stop on the
door.Fig. 1 Air Filter - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - LOWER EDGE OF INSTRUMENT PANEL
3 - AIR FILTER (IF EQUIPPED)
4 - CENTER FLOOR BRACKET COVER
5 - FILTER SEALING EDGES (IF EQUIPPED)
6 - AIR FILTER OPENING (IF EQUIPPED)
24 - 42 DISTRIBUTION - FRONTRS

(3) Pull the air filter door straight downward to
disengage it from the air filter opening of the lower
HVAC housing.
(4) Use your fingers to reach through the air filter
opening of the lower HVAC housing far enough to
grasp the air filter.
(5) Pull the air filter straight down and out of the
HVAC housing.
INSTALLATION
(1) Note the ªAirflowº directional arrow imprinted
on the foam seal around the frame of the air filter.
This arrow should always be oriented towards the
center of the vehicle.
(2) With the air filter ªAirflowº arrow properly ori-
ented, carefully slide the filter fully upward into the
HVAC housing through the air filter opening.
(3) With the latch still positioned against its
opened stop, reinstall the air filter door onto the
lower HVAC housing air filter opening.
(4) Slide the air filter door latch toward the front
of the vehicle until it hits the closed stop on the door.
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the front HVAC housing through one or a
combination of the four main housing outlets: defrost,
demist, panel, or floor. Once the conditioned air exits
the unit housing, it is directed through molded plas-
tic ducts to the various outlets in the vehicle interior.
These outlets and their locations are as follows:²Defroster Outlet- A single, centrally mounted
outlet delivers air for defrosting the large windshield.
Because outlet vanes are not needed to direct flow, a
simple, integral grid is molded into the center of the
instrument panel top cover to prevent objects from
falling into the duct. If the defroster outlet is faulty
or damaged, the instrument panel top cover must be
replaced.
²Demister Outlets- There are two side window
demisters that aid in defogging and defrosting the
front door windows. One demister outlet is located at
each outboard end of the instrument panel top pad,
near the belt line at the A-pillars. The demister out-
lets can be removed from the top pad individually for
service replacement.
²Instrument Panel Outlets- There are five
panel outlets in the instrument panel, one located
near each outboard end of the instrument panel fac-
ing the rear of the vehicle, and three located near the
top of the instrument panel center bezel. On models
with manual temperature control, all five of these
outlets are fully adjustable. On models with Auto-
matic Temperature Control (ATC) system, the center
outlet in the center bezel has fixed vanes because it
also houses the remote infrared temperature sensors
for the front seat positions. The outboard outlets can
be removed individually for service replacement. The
center bezel outlets are serviced as a gang of three
outlets and, on models with ATC, also includes the
infrared sensors.
²Front Door Rear Outlets- A fully adjustable
outlet located at the rear of each front door trim
panel supplies only cooled air to the intermediate
seat passengers. Air is supplied to these outlets from
the instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. The door ducts are integral to the front
door trim panels. These outlets also incorporate a red
reflector to improve the safety and visibility of an
opened front door to traffic approaching the vehicle
from the rear at night. These outlets can be removed
from the door trim panels for service replacement.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel below the instrument panel. These out-
lets are integral to the front HVAC distribution hous-
ing.
²Rear Floor Outlets- Wide rear floor outlets
located under each front seat have integral, fixed
directional dividers to distribute heated air across
the floor for intermediate seat passengers. These out-
lets are integral to the floor distribution ducts routed
under the front floor carpet from an outlet nozzle on
the bottom of the front HVAC distribution housing.
Fig. 2 Air Filter Door - Typical
1 - AIR FILTER DOOR
2-LATCH
3 - CLOSED STOP
4 - LOWER HVAC HOUSING
5 - OPENED STOP
RSDISTRIBUTION - FRONT24-43
AIR FILTER (Continued)

REMOVAL
FRONT CENTER BEZEL OUTLETS
The three outlets located near the top of the
instrument panel center bezel are serviced only as a
set of all three outlets. If the vehicle is equipped with
the optional automatic temperature control (ATC)
system, the center outlet of the three has fixed vanes
and also houses the remote front infrared tempera-
ture sensors.
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 negative battery
cable.
(2) Remove the center bezel from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(3) Place the center bezel face down on a suitable
work surface. Be certain to take the proper precau-
tions to protect the face of the center bezel from cos-
metic damage.
(4) If the vehicle is equipped with the optional
ATC system, disconnect the ATC remote infrared
temperature sensor jumper harness from the sensor
connector receptacle located on the bottom of the cen-
ter outlet housing (Fig. 3).
(5) Remove the three screws that secure the bot-
tom of the outlet housing to the center bezel.
(6) Roll the bottom of the outlet housing upwards
towards the top of the center bezel far enough to dis-
engage the retainer features on the top of the outlet
housing from their receptacles at the top of the cen-
ter bezel.
(7) Remove the center bezel outlets and housing
from the center bezel as a unit.
FRONT DEMISTER OUTLETS
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
demister outlet away from the instrument panel top
pad until the snap features on the outlet are released
(Fig. 4).
(2) Remove the demister outlet from the demister
duct opening in the instrument panel top pad.
Fig. 3 Center Air Outlets
1 - CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - SCREW (3)
4 - INSTRUMENT PANEL SWITCH BANK
5 - CONNECTOR (ATC ONLY)
6 - JUMPER HARHESS (ATC ONLY)
Fig. 4 Demister Outlet
1 - DEMISTER OUTLET
2 - INSTRUMENT PANEL TOP PAD
3 - TRIM STICK
24 - 44 DISTRIBUTION - FRONTRS
AIR OUTLETS (Continued)

INSTRUMENT PANEL OUTLETS
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
instrument panel outlet away from the instrument
panel top pad until the snap features on the outlet
are released (Fig. 5).
(2) Remove the instrument panel outlet from the
panel duct opening in the instrument panel top pad.
INSTALLATION
FRONT CENTER BEZEL OUTLETS
(1) Position the center bezel outlets and housing
onto the center bezel as a unit.
(2) Engage the retainer features on the top of the
outlet housing with their receptacles at the top of the
center bezel, then roll the bottom of the outlet hous-
ing downwards towards the center bezel.
(3) Install the three screws that secure the bottom
of the outlet housing to the center bezel. Tighten the
screws to 2 N´m (17 in. lbs.).
(4) If the vehicle is equipped with the optional
ATC system, reconnect the ATC remote infrared tem-
perature sensor jumper harness to the sensor connec-
tor receptacle located on the bottom of the center
outlet housing.
(5) Reinstall the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(6) Reconnect the battery negative cable.
FRONT DEMISTER OUTLETS
(1) Position the demister outlet over the demister
duct opening in the instrument panel top pad.(2) Using hand pressure, press the demister outlet
firmly and evenly into the instrument panel top pad
opening until the snap features on the outlet are
fully engaged.
INSTRUMENT PANEL OUTLETS
(1) Position the instrument panel outlet into the
panel duct opening in the instrument panel top pad.
(2) Using hand pressure, press the instrument
panel outlet firmly and evenly into the instrument
panel top pad opening until the snap features on the
outlet are fully engaged.
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. 6). The
blower motor and wheel are located near the passen-
ger side end of the HVAC housing in the passenger
compartment below the instrument panel. The
blower motor and blower motor wheel are factory bal-
anced and cannot be adjusted or repaired. If faulty or
damaged, the blower motor and blower wheel must
be replaced as an assembly.
OPERATION
On models equipped with the manual heater-A/C
system, the blower motor will operate whenever the
ignition switch is in the On position and the blower
control switch is in any position except Off. On mod-
els equipped with the Automatic Temperature Con-
trol (ATC) system, the blower motor will operate
Fig. 5 Instrument Panel Outlet - Left Side Shown
1 - INSTRUMENT PANEL TOP PAD
2 - INSTRUMENT PANEL OUTLET
3 - TRIM STICK
Fig. 6 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-45
AIR OUTLETS (Continued)