Chrysler Town, Dodge Caravan. Manual - part 512

INSTALLATION

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) Position the defroster duct to the instrument

panel.

(2) Install the fasteners that secure the defroster

duct to the instrument panel armature.

(3) Reinstall the instrument panel in the vehicle.

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT

PANEL

ASSEMBLY

INSTALLA-

TION).

(4) Reconnect the battery negative cable.

DEMISTER DUCTS

REMOVAL

(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 demister

ducts to the instrument panel armature.

(5) Disengage the demister ducts from the demis-

ter outlets.

(6) Remove the demister ducts from the instru-

ment panel.

INSTALLATION

(1) Position the demister ducts to the instrument

panel.

(2) Engage the demister ducts to the demister out-

lets.

(3) Install the fasteners that secure the demister

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.

FLOOR DISTRIBUTION DUCTS

REMOVAL

(1) Roll back the carpet on the front floor from

under the instrument panel toward the rear of the
vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).

(2) Lift the center floor distribution duct upward

far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 12).

(3) Pull the floor distribution duct assembly rear-

ward far enough to disengage the center floor distri-
bution duct from the outlet on the bottom of the
heater-A/C housing unit.

(4) Disassemble the right and/or left floor distribu-

tion ducts from the center floor distribution duct as
required.

24 - 48

DISTRIBUTION - FRONT

DEFROSTER DUCT (Continued)

INSTALLATION

(1) Assemble the right and/or left floor distribution

ducts onto the center floor distribution duct as
required.

(2) Slide

the

floor

distribution

duct

assembly

under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.

(3) Align the locator hole on the center floor distri-

bution duct with the weld stud on the front floor
panel.

(4) Using hand pressure, push the locator hole of

the center floor distribution duct down over the weld
stud on the front floor panel.

(5) Reinstall the carpet onto the front floor panel

and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).

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).

(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) Remove the windshield wiper module from the

vehicle(Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).

Fig. 12 Floor Distribution Ducts

1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD

DISTRIBUTION - FRONT

24 - 49

FLOOR DISTRIBUTION DUCTS (Continued)

(5) 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).

(6) Disconnect the heater hoses from the heater

core tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).

(7) Remove the four nuts that secure the heater-

A/C unit housing studs to the engine compartment
side of the dash panel (Fig. 13).

(8) Remove the instrument panel from the passen-

ger compartment. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).

(9) Remove the floor distribution duct from the

heater-A/C unit housing. (Refer to 24 - HEATING &
AIR

CONDITIONING/DISTRIBUTION

FRONT/

FLOOR DISTRIBUTION DUCTS - REMOVAL).

(10) Remove the one screw that secures the heat-

er-A/C unit housing bracket to the passenger com-
partment side of the dash panel (Fig. 14).

(11) 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).

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

24 - 50

DISTRIBUTION - FRONT

HVAC HOUSING (Continued)

(8) Install the windshield wiper module(Refer to 8

- ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).

(9) Reconnect the battery negative cable.
(10) Refill the engine cooling system. (Refer to 7 -

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

(11) Evacuate the refrigerant system. (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM EVACUATE).

(12) Charge the refrigerant system. (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM CHARGE).

PANEL DUCTS

REMOVAL

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.

DISTRIBUTION - FRONT

24 - 51

HVAC HOUSING (Continued)

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