AUX CHRYSLER CARAVAN 2002 User Guide

INSTRUMENT PANEL TOP
COVER
REMOVAL
(1)Remove A-pillar trim. Using a trim stick (special
tool #C-4755) or equivalent, gently pry out and remove.
(2) Using a trim stick, disengage clips attaching
rear edge of top cover to instrument panel (Fig. 10).
NOTE: The Instrument Panel Top Cover may be hard
to unsnap from the instrument panel. Be sure not to
mar, scuff, or damage the instrument panel pad.
(3) Pull top cover rearward to disengage hooks
attaching front of top cover to instrument panel.
(4) Remove top cover from vehicle.
INSTALLATION
(1) Place instrument panel top cover in position on
vehicle (Fig. 10).
(2) Push top cover forward to engage hooks attach-
ing front of top cover to instrument panel.
(3) Engage clips attaching rear edge of top cover to
instrument panel.
(4) Pull top cover rearward.
(5) Install A-pillar trim.
LOWER CONSOLE
REMOVAL
(1) Remove screws attaching the lower console to
floor bracket and instrument panel (Fig. 11).
(2) Slide lower console rearward from around
instrument panel supports.(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2)
Install the lower console into the vehicle (Fig. 11).
(3) Slide console forward around instrument panel
supports.
(4) Install the screws attaching lower console to
floor bracket and instrument panel.
Fig. 9 INSTRUMENT PANEL END CAP
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL END CAP
Fig. 10 INSTRUMENT PANEL TOP COVER
1 - INSTRUMENT PANEL TOP COVER
2 - INSTRUMENT PANEL
Fig. 11 INSTRUMENT PANEL FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR CONSOLE
RSINSTRUMENT PANEL23-69
INSTRUMENT PANEL END CAP (Continued)
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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
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(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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(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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