Chrysler Town, Dodge Caravan. Manual - part 510

INSTALLATION

(1) Note the “Airflow” 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 “Airflow” arrow properly ori-

ented, carefully slide the filter fully upward into the
evaporator housing through the air filter opening.

(3) With the latch still positioned against its

opened stop, reinstall the air filter door onto the
lower evaporator 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 heater-A/C unit housing
through one or a combination of the four main hous-
ing outlets: defrost, demist, panel, or floor. Once the
conditioned air exits the unit housing, it is directed
through molded plastic ducts to the various outlets in
the vehicle interior. These outlets and their locations
are as follows:

• Defroster 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.

• Demister 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.

• Instrument 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), 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.

• Front 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.

• Front 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 heater-A/C unit distri-
bution housing.

• Rear 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 heater-A/C unit distribution
housing.

REMOVAL

REMOVAL - 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

Fig. 2 Air Filter Door

1 - AIR FILTER DOOR
2 - LATCH
3 - CLOSED STOP
4 - LOWER EVAPORATOR HOUSING
5 - OPENED STOP

24 - 40

DISTRIBUTION - FRONT

AIR FILTER (Continued)

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 battery negative

cable.

(2) Remove the center bezel from the instrument

panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).

(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.

REMOVAL - DEMISTER OUTLET

(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.

REMOVAL - FRONT DOOR REAR OUTLET

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the trim panel from the front door

inner panel. (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - REMOVAL).

(3) Using a trim stick or another suitable wide

flat-bladed tool, depress the four latch features (two
top and two bottom) that secure the outlet to the
inside of the trim panel rear outlet opening and push
the outlet unit out through the opening (Fig. 5).

(4) Remove the front door rear outlet through the

outside of the front door trim panel outlet opening.

Fig. 3 Center Bezel 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

DISTRIBUTION - FRONT

24 - 41

AIR OUTLETS (Continued)

REMOVAL - INSTRUMENT PANEL OUTLET

(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. 6).

(2) Remove the instrument panel outlet from the

panel duct opening in the instrument panel top pad.

INSTALLATION

INSTALLATION - 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 and tighten 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.

INSTALLATION - DEMISTER OUTLET

(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.

INSTALLATION - FRONT DOOR REAR OUTLET

(1) Position the front door rear outlet through the

outside of the front door trim panel outlet opening.

(2) While keeping the outlet aligned with the door

duct opening behind the trim panel, use hand pres-
sure to press the outlet firmly and evenly through
the outside of the front door trim panel outlet open-
ing until the four latch features (two top and two bot-
tom) that secure the outlet to the inside of the
opening are fully engaged.

(3) Reinstall the trim panel onto the front door

inner panel. (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - INSTALLATION).

(4) Reconnect the battery negative cable.

INSTALLATION - INSTRUMENT PANEL OUTLET

(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.

Fig. 5 Front Door Rear Outlet

1 - FRONT DOOR REAR OUTLET
2 - FRONT DOOR TRIM PANEL

Fig. 6 Instrument Panel Outlet

1 - INSTRUMENT PANEL TOP PAD
2 - INSTRUMENT PANEL OUTLET
3 - TRIM STICK

24 - 42

DISTRIBUTION - FRONT

AIR OUTLETS (Continued)

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. 7). The
blower motor and wheel are located near the passen-
ger side end of the heater-A/C unit within the two
halves of the intake air housing in the passenger
compartment

below

the

instrument

panel.

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 blower motor will operate whenever the igni-

tion switch is in the On position and the heater-A/C
control power is turned on. The blower motor can
only be turned off by turning off the power at the
heater-A/C control. The blower motor receives battery
current whenever the front blower motor relay is
energized. The front blower motor relay output cir-
cuit is protected by a fuse in the Intelligent Power
Module (IPM) located in the engine compartment
near the battery. In the Manual system, the blower
motor speed is controlled by regulating the path to
ground through the blower control switch and the
blower motor resistor. In the ATC system, the blower
motor speed is controlled by an electronic blower
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
blower motor to regulate the blower motor ground
path it provides. The blower motor and wheel are

used to control the velocity of air moving through the
heater-A/C unit housing. The blower motor controls
the velocity of the air flowing through the heater-A/C
housing by spinning the blower wheel within the
housing at the selected speed or, in the ATC system,
at the selected or programmed speed.

DIAGNOSIS AND TESTING - BLOWER MOTOR

BLOWER MOTOR INOPERATIVE

(1) Check the fuse (Fuse 10 - 40 ampere) in the

Intelligent Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.

(2) Turn the ignition switch to the On position. Be

certain that the heater-A/C control power is turned
on. Check for battery voltage at the fuse (Fuse 10 -
40 ampere) in the IPM. If OK, go to Step 3. If not
OK, proceed to diagnosis of the front blower motor
relay. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS

FRONT/BLOWER

MOTOR

RELAY - DIAGNOSIS AND TESTING).

(3) Turn the ignition switch to the Off position.

Disconnect and isolate the battery negative cable.
Disconnect the front HVAC wire harness connector
for the front blower motor resistor (Manual Temper-
ature Control) or the front blower power module
(Automatic Temperature Control) from the resistor or
module connector receptacle. Reconnect the battery
negative cable. Turn the ignition switch to the On
position. Be certain that the heater-A/C control
power is turned on. Check for battery voltage at the
fused front blower motor relay output circuit cavity
of the front HVAC wire harness connector for the
front blower motor resistor (MTC) or the front blower
power module (ATC). If OK, go to Step 4. If not OK,
repair the open fused front blower motor relay output
circuit to the IPM as required.

Fig. 7 Blower Motor

1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS

DISTRIBUTION - FRONT

24 - 43

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