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Chrysler Town, Dodge Caravan. Manual - part 514

REMOVAL

The rear blower motor and blower wheel are ser-

viced only as a balanced unit. If either component is
faulty or damaged, the entire unit must be replaced.

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) Remove the rear heater-A/C unit housing from

the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).

(2) Disconnect the rear blower motor pigtail wire

connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.

(3) Remove the three screws that secure the

blower motor to the outboard side of the rear heater-
A/C unit housing (Fig. 5).

(4) Remove the blower motor and blower wheel

from the rear heater-A/C unit housing.

INSTALLATION

(1) Position the blower motor and blower wheel

onto the outboard side of the rear heater-A/C unit
housing.

(2) Install and tighten the three screws that secure

the blower motor to the rear heater-A/C unit housing.
Tighten the screws to 2 N·m (18 in. lbs.).

(3) Reconnect the rear blower motor pigtail wire

(4) 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).

REAR HEATER-A/C HOUSING

REMOVAL

WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING

THE

FOLLOWING

OPERATION.

(1) Recover the refrigerant from the refrigerant

system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD

PROCEDURE

REFRIGERANT

RECOVERY).

Fig. 5 Blower Motor

1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE

24 - 56

DISTRIBUTION - REAR

BLOWER MOTOR (Continued)

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).

(3) Disconnect and isolate the battery negative

cable.

(4) Raise and support the vehicle.
(5) Disconnect the underbody refrigerant line seal-

ing plate from the rear heater-A/C unit evaporator
extension line sealing plate that extends through the
rear floor panel behind the right rear wheel housing
(Fig. 6).

(6) Remove the seals from the liquid line and suc-

tion line fittings and discard.

(7) Install plugs in, or tape over the opened liquid

line and suction line fittings and both ports in the
evaporator extension line sealing plate.

(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.

Fig. 6 Refrigerant Lines

1 - UNDERBODY REFRIGERANT LINE SEALING PLATE

Fig. 7 Rear Heater-A/C Unit Mounting Studs

1 - REAR HEATER-A/C UNIT MOUNTING STUDS

DISTRIBUTION - REAR

24 - 57

REAR HEATER-A/C HOUSING (Continued)

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).

(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.

Fig. 8 Rear Heater-A/C Housing

1 - U-NUT (3)
2 - REAR HEATER-A/C HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE

5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)

24 - 58

DISTRIBUTION - REAR

REAR HEATER-A/C HOUSING (Continued)

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

COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).

(22) Evacuate the refrigerant system. (Refer to 24

- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM EVACUATE).

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

HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT

STANDARD

PROCE-

DURE - REFRIGERANT SYSTEM CHARGE).

(24) Run the HVAC Cooldown test to verify proper

operation(Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).

REAR HEATER DISTRIBUTION
DUCT

REMOVAL

(1) Remove the trim from the right quarter inner

panel.

(Refer

BODY/INTERIOR/RIGHT

QUARTER TRIM PANEL - REMOVAL).

(2) Remove the two screws that secure the rear

heater distribution duct to the right quarter inner
panel (Fig. 9).

(3) Slide the rear heater distribution duct forward

far enough to disengage it from the outlet on the
front of the rear heater-air conditioner unit housing.

(4) Remove the rear heater distribution duct from

the vehicle.

INSTALLATION

(1) Align the inlet end of rear heater distribution

duct with the outlet on the front of the rear heater-
air conditioner unit housing.

(2) Slide the rear heater distribution duct rear-

ward far enough to fully engage the inlet end of the
duct with the outlet on the front of the rear heater-
air conditioner unit housing.

(3) Install and tighten the two screws that secure

the rear heater distribution duct to the right quarter
inner panel. Tighten the screws to 1.6 N·m (14 in.
lbs.).

(4) Reinstall the trim onto the right quarter inner

panel.

(Refer

BODY/INTERIOR/RIGHT

QUARTER TRIM PANEL - INSTALLATION).

Fig. 9 Rear Heater Distribution Duct

1 - REAR HEATER DISTRIBUTION DUCT
2 - REAR HEATER-A/C UNIT OUTLET
3 - SCREW (2)

DISTRIBUTION - REAR

24 - 59

REAR HEATER-A/C HOUSING (Continued)

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