airbag CHRYSLER CARAVAN 2002 Owners Manual

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
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(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)
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REMOVAL
REMOVAL- HEATER CORE EXTENSION TUBES
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 - 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) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the heater hoses from the heater
hose tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(5) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 15).
(6) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.
(7) Remove the heater core shield from the distri-
bution housing.
(8) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-
ant and have absorbent toweling readily available to
clean up any spills.
(9) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 16).(10) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(11) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
(12) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(13) Pull both heater core tubes simultaneously
slightly away from the distribution housing and rear-
Fig. 15 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 16 Heater Core Tubes
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
24 - 74 PLUMBING - FRONTRS
HEATER CORE (Continued)
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ward far enough to disengage the engine compart-
ment ends of the tubes from the dash panel seal.
(14) Remove the heater core tubes and sealing
plate as a unit from beneath the instrument panel.
(15) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
REMOVAL - HEATER CORE
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 - 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) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(4) Remove the brake lamp switch from its mount-
ing bracket. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(5) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm.
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER - REMOV-
AL).
(6) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 17).
(7) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.(8) Remove the heater core shield from the distri-
bution housing.
(9) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-
ant and have absorbent toweling readily available to
mop up any spills.
(10) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 18).
Fig. 17 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 18 Heater Core
1 - SEALING PLATE
2 - SCREW
3 - SCREWS (2)
4 - HEATER CORE
5 - HEATER CORE TUBES
RSPLUMBING - FRONT24-75
HEATER CORE (Continued)
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(11) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(12) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
(13) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(14) Remove the two screws that secure the heater
core mounting plate to the distribution housing.
(15) While pulling the accelerator pedal upward
(Fig. 19) and pushing the brake pedal downward
(Fig. 20) far enough for clearance, pull the heater
core out of the distribution housing.(16) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation. Also, if
the heater core was leaking, use absorbent toweling
and reach into the heater core opening to mop up
any residual engine coolant within the distribution
housing.
INSTALLATION
INSTALLATION- HEATER CORE EXTENSION
TUBES
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 - 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) Remove the plugs or tape from both heater core
tube fittings and both heater core ports.
(2) Position the heater core tubes and sealing plate
as a unit beneath the instrument panel.
(3) Align the engine compartment ends of both
heater core tubes with the openings in the dash
panel seal and push them simultaneously forward
through the seal far enough to engage the heater
core ends of the tubes with the heater core supply
and return ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
Fig. 19 Accelerator Pedal
1 - SLIDE HEATER CORE PAST ACCELERATOR PEDAL
Fig. 20 Brake Pedal
1 - SLIDE HEATER CORE PAST BRAKE PEDAL
2 - DEPRESS BRAKE PEDAL
24 - 76 PLUMBING - FRONTRS
HEATER CORE (Continued)
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(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel.
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(10) Reconnect the heater hoses to the heater hose
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(11) Reconnect the battery negative cable.
(12) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
INSTALLATION - HEATER CORE
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 - 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) While pushing the brake pedal downward and
pulling the accelerator pedal upward far enough for
clearance, slide the heater core into the distribution
housing.
(2) Install and tighten the two screws that secure
the heater core mounting plate to the distribution
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Remove the plugs or tape from the heater core
tube fittings and both heater core ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel.
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm(Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - INSTALLATION).
(10) Reinstall the brake lamp switch into its
mounting bracket(Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION).
(11) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(12) Reconnect the battery negative cable.
(13) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(14) Operate system for two thermostat cycles to
assure elimination of air in the system.
RSPLUMBING - FRONT24-77
HEATER CORE (Continued)
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