Chrysler Town, Dodge Caravan. Manual - part 525

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) Carefully slide the heater core into the rear

heater-A/C unit housing.

(2) Using hand pressure, press firmly and evenly

on the heater core end plate until the four latch tabs
that secure the heater core in the rear heater-A/C
unit housing are fully engaged (Fig. 5).

(3) Remove the plugs or tape from the heater core

fittings and both heater hoses.

(4) Reconnect the heater hoses to the rear heater

core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).

(5) 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.).

(6) 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.).

(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).

(8) 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 - INSTALLATION).

(9) Drain the engine cooling system. (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

HEATER HOSE

REMOVAL

REFER TO THE APPLICABLE WARNINGS AND

CAUTIONS FOR THIS SYSTEM BEFORE PER-
FORMING THE FOLLOWING OPERATION. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING FRONT - WARNING - HEATER PLUMBING).

(1) Partially drain engine cooling system. Refer to

Group 7, Engine Cooling.

(2) Loosen clamp at the front end of the hose

located at the right, outboard side of the underbody,
rearward of the front crossmember. (Fig. 6)

(3) Carefully rotate hose back and forth while tug-

ging slightly away from connector nipple. If the hose
will not come off, slice the hose at the connector nip-
ple and peel off heater hose. This method will require
heater hose replacement.

CAUTION:
When removing hoses from outlet nipples, do not
use excessive force. Outlet nipples may become
damaged and leak engine coolant.

Fig. 5 Heater Core

1 - REAR HEATER-A/C HOUSING OUTLET
2 - REAR HEATER-A/C UNIT HOUSING
3 - LATCH (4)
4 - HEATER CORE
5 - RIGHT REAR WHEEL HOUSE
6 - HEATER HOSES

Fig. 6 Underbody Connections

1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES

24 - 100

PLUMBING - REAR

HEATER CORE (Continued)

(4) Compress insert in rear heater hose quick con-

nection and pull downward on hose.

(5) Remove (3) straps securing underbody lines.
(6) Separate and remove rear heater lines from

vehicle.

INSTALLATION

There are several heater core plumbing configura-

tions used on this model, depending upon the engine
size and other optional equipment. One plumbing
configuration is used for all 2.4L engines, while the
3.3L and 3.8L engines have unique heater return
plumbing on the engine for models with or without
an optional engine oil cooler. There are also unique
plumbing configurations at the heater core for mod-
els with or without the optional rear heater and air
conditioner. All models use a combination of formed
steel tubing and rubber hoses. In most cases, the
rubber hose is secured to the steel tubing with a
spring tension clamp.

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).

(1) Using spring tension clamp pliers, compress

and slide the clamps that secure each end of the
heater hose toward the center of the hose being
installed. Release the clamp when it is near the cen-
ter of the hose.

(2) Grasp one end of the heater hose being

installed firmly and carefully twist the hose back and
forth while pushing it over from the barbed end of
the nipple. Repeat this procedure at the opposite end
of the hose being installed.

(3) Using spring tension clamp pliers, compress

and slide the clamps that secure each end of the
heater hose over the tube or nipple. Release the
clamp when it is over the tube or nipple.

(4) Refill the engine cooling system. (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

SUCTION LINE

REMOVAL

The front air conditioner suction line includes the

low side service port on a section of tubing located
near the compressor. On models equipped with the
optional rear air conditioner, the front air conditioner
suction line also includes a suction line hose and
tube extension that connects the front suction line to
the suction line for the rear air conditioner.

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) Disconnect and isolate the battery negative

cable.

(3) Remove the air cleaner top cover and snorkel

from the air cleaner housing located on the right side
of the engine compartment.

(4) Disconnect the drain tube from the wiper mod-

ule drain on the right side of the engine compart-
ment.

(5) Remove the nut that secures the suction line

fitting to the top of the compressor.

(6) Disconnect the suction line fitting from the

compressor suction port.

(7) Remove the seal from the suction line fitting

and discard.

(8) Install plugs in, or tape over the opened suc-

tion line fitting and the compressor suction port.

(9) Disengage the retainer that secures the suction

line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment (Fig. 7).

(10) Remove the nut that secures the suction line

and liquid line fittings to the expansion valve.

(11) Disconnect the suction line and liquid line fit-

tings from the expansion valve.

(12) Remove the seals from the suction line and

liquid line fittings and discard.

(13) Install plugs in, or tape over the opened suc-

tion line and liquid line fittings and both expansion
valve ports.

(14) If the vehicle is equipped with the optional

rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.

(15) Raise and support the vehicle.
(16) Cut the tie strap located just forward of the

connections between the underbody plumbing and
the engine compartment plumbing for the rear
heater and air conditioner (Fig. 8).

(17) Disconnect the suction line extension fitting

from the underbody suction line fitting for the rear
air conditioner.

(18) Remove the seal from the underbody suction

line fitting and discard.

PLUMBING - REAR

24 - 101

HEATER HOSE (Continued)

(19) Install plugs in, or tape over the opened suc-

tion line fittings.

(20) Lower the vehicle.
(21) Remove the suction line from the engine com-

partment.

INSTALLATION

The front air conditioner suction line includes the

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) Position the suction line into the engine com-

partment.

(2) Remove the tape or plugs from the suction line

and liquid line fittings and both expansion valve
ports.

(3) Lubricate new rubber O-ring seals with clean

refrigerant oil and install them on the suction line
and liquid line fittings.

(4) Reconnect the liquid line and suction line fit-

tings to the expansion valve.

(5) Install and tighten the nut that secures the

suction line and liquid line fittings to the expansion
valve. Tighten the nut to 23 N·m (17 ft. lbs.).

(6) Engage the retainer that secures the suction

line routing clip to the filter-drier mounting bracket
on the side of the right front strut tower in the
engine compartment.

(7) Remove the tape or plugs from the compressor

suction port and the suction line fitting.

(8) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the suction line fit-
ting.

(9) Reconnect the suction line fitting to the com-

pressor suction port.

(10) Install and tighten the nut that secures the

suction line fitting to the compressor. Tighten the nut
to 23 N·m (17 ft. lbs.).

(11) Reconnect the drain tube to the wiper module

drain on the right side of the engine compartment.

(12) Reinstall the air cleaner top cover and snorkel

onto the air cleaner housing located on the right side
of the engine compartment.

(13) Reconnect the battery negative cable.
(14) If the vehicle is equipped with the optional

rear air conditioner, go to Step 15. If the vehicle does
not have the optional rear air conditioner, go to Step
21.

(15) Raise and support the vehicle.

Fig. 7 Suction Line

1 - EXPANSION VALVE
2 - SUCTION LINE EXTENSION (REAR A/C ONLY)
3 - NUT
4 - ROUTING CLIP (If Equipped)
5 - SUCTION LINE

Fig. 8 Underbody Connections

1 - SUCTION LINE EXTENSION
2 - LIQUID LINE EXTENSION
3 - TIE STRAP
4- HEATER LINE EXTENSIONS
5 - UNDERBODY LINES

24 - 102

PLUMBING - REAR

SUCTION LINE (Continued)

(16) Remove the tape or plugs from the suction

line extension fitting and the underbody suction line
fitting (Fig. 35).

(17) Lubricate a new rubber O-ring seal with clean

refrigerant oil and install it on the underbody suction
line fitting.

(18) Reconnect the suction line extension fitting to

the underbody suction line fitting. Tighten the fit-
tings to 23 N·m (17 ft. lbs.).

(19) Install a new tie strap just forward of the con-

nections between the underbody plumbing and the
engine compartment plumbing for the rear heater
and air conditioner.

(20) Lower the vehicle.
(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).

UNDERBODY LINES

DESCRIPTION

The rear heater-A/C unit plumbing is used only on

models with the optional rear heater-A/C unit. The
formed metal rear heater-A/C unit suction line, liquid
line, and heater lines are available for separate ser-
vice replacement. The molded and straight heater
hoses used on the rear heater-A/C unit can be ser-
viced in the vehicle. Refer to Group 7 - Cooling Sys-
tem for the heater hose service procedures.

OPERATION

The rear heater and A/C lines are all serviced as

individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any
contaminations that can get in to the system (Fig. 9),
(Fig. 10), (Fig. 12), (Fig. 11) and (Fig. 13).

Any kinks or sharp bends in the rear heater-A/C

unit plumbing will reduce the capacity of the entire
heating and air conditioning system. Kinks and
sharp bends reduce the system flow. High pressures
are produced in the refrigerant system when the air
conditioning compressor is operating. High tempera-
ture coolant is present in the heater plumbing when
the engine is operating. Extreme care must be exer-
cised to make sure that each of the plumbing connec-
tions is pressure-tight and leak free.

Fig. 9 Rear Heater and A/C Lines

1 - HEATER CONNECTION
2 - REAR A/C LINE BLOCK CONNECTION

PLUMBING - REAR

24 - 103

SUCTION LINE (Continued)

Content .. 523 524 525 526 ..