overheating CHRYSLER CARAVAN 2003 User Guide

INSTALLATION
(1) Remove the tape or plugs from the evaporator
tube fittings and both expansion valve ports.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
tube fittings.
(3) Position the expansion valve onto the evapora-
tor tubes.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube sealing
plate. Tighten the screws to 11 N´m (97 in. lbs.).
(5) Reinstall the rear evaporator line extension
onto the expansion valve. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - REAR/EVAPO-
RATOR - INSTALLATION - EVAPORATOR LINE
EXTENSION).
(6) Install the foam insulator wrap over the rear
expansion valve.
(7) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
(8) Run the HVAC Cooldown Test to verify proper
operation.
HEATER CORE
DESCRIPTION
The rear heater core is located near the front of
the rear heater-A/C unit housing, behind the right
rear wheel house. It is a heat exchanger made of
rows of tubes and fins. One end of the core is fitted
with a molded plastic tank that includes integral
heater core inlet and outlet nipples. The heater core
can be serviced without removing the rear heater-A/C
unit housing from the vehicle. The heater core cannot
be repaired and, if faulty or damaged, it must be
replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
the rear heater-A/C unit housing is directed through
the heater core.
STANDARD PROCEDURE - HEATER CORE
FILLING
In its final installed position, the rear heater core
is positioned higher than the radiator fill cap. There-fore, when the cooling system is drained and refilled,
gravity will not refill the heater core with coolant to
the proper level. This may result in two problems:1.
Insufficient coolant level in the engine cooling sys-
tem, which may result in engine overheating.2.Air
entrapped within the rear heater core, which may
result in insufficient rear heater performance. There
are two methods that may be employed to prevent
these problems:1.Pre-filling of the rear heater core.
2.Thermal cycling of the engine cooling system. Fol-
lowing are descriptions of both prevention methods,
as well as a method to verify rear heater perfor-
mance.
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).
PRE-FILLING
If the rear heater core or the rear heater-A/C hous-
ing have been removed from the vehicle for service,
the rear heater core may be pre-filled with the proper
engine coolant mixture prior to reconnecting the
heater hoses to the heater core hose fittings.
(1) The heater core should be installed in the rear
heater-A/C unit housing, and the rear heater-A/C
unit housing should be installed in the vehicle.
(2) Take the proper precautions to protect the car-
peting below the rear heater core from spilled engine
coolant and have absorbent toweling readily avail-
able to mop up any spills.
(3) Insert the small end of an appropriate funnel
into the upper hose fitting of the heater core (Fig. 4).
Fig. 4 Pre-Filling Heater Core - Typical
1 - REAR HEATER CORE
24 - 98 PLUMBING - REARRS
EXPANSION VALVE (Continued)
ProCarManuals.com