Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 139
REAR BLOWER RESISTOR BLOCK
REMOVE AND INSTALL
(1) Remove the left lower quarter trim panel. Refer
to Group 23, Body.
(2) Disconnect wire connectors from resistor block.
(3) Remove two attaching screws from resistor block
and separate from the heater-A/C unit.
To install, reverse the preceding operation.
REAR HEATER A/C BLOWER MOTOR
REMOVE AND INSTALL
(1) Remove the left lower quarter trim panel. Refer
to Group 23, Body.
(2) Remove one blower cover to floor attaching screw
and seven blower cover to unit attaching screws.
(3) Rotate blower cover from under heater-A/C unit
cover.
(4) Compress the clamp at the center of the blower
wheel and pull the wheel from the blower shaft.
(5) Remove three blower motor attaching screws.
(6) Separate the blower motor from the housing unit.
To install, reverse the preceding operation.
REAR HEATER-A/C UNIT
REMOVE AND INSTALL
WARNING: ON VEHICLES EQUIPPED WITH REAR
A/C, THE REFRIGERANT SYSTEM MUST BE DIS-
CHARGED BEFORE PERFORMING THE FOLLOWING
OPERATION. THE ENGINE COOLING SYSTEM MUST
ALSO BE RELIEVED OF ALL PRESSURE.
(1) Drain engine cooling system. Refer to Group 7,
Cooling System. Disconnect heater hoses at rear
heater-A/C unit.
(2) Discharge refrigerant system. Disconnect A/C
plumbing from rear heater-A/C unit.
(3) Remove left lower quarter trim panel. Refer to
Group 23, Body.
(4) Remove the attaching screws securing the air
distribution duct to the rear wheel housing.
(5) Remove the attaching screws securing the heater
unit to the floor pan.
(6) Remove attaching screw securing the unit to the
quarter panel support.
(7) Lift the unit enough to clear the floor pan and
remove the unit from the vehicle.
To Install, Reverse the preceding operation. Install
new gaskets at refrigerant lines and expansion valve.
Evacuate and charge the refrigerant system. Refill the
cooling system. Test for leaks and overall performance.
AIR DISTRIBUTION DUCT
REMOVE AND INSTALL
(1) Remove left quarter trim panel. Refer to Group
23, Body.
(2) Remove the screws securing the A/C duct to the
heater-A/C unit and the body.
(3) Pull the distribution duct straight up to remove.
To Install, Reverse the preceding operation.
HEATER CORE
REMOVE AND INSTALL
(1) Drain the engine coolant system.
(2) Disconnect heater tubing from the under body
heater lines to the rear unit.
(3) Remove the lower left quarter trim panel. Refer
to Group 23, BODY.
(4) Remove FAN-A/C distribution duct.
(5) Remove heater-unit cover.
(6) Carefully pull the heater core and heater tubes
straight out of the unit.
(7) Raise the heater core to drain residual coolant
from the core.
(8) Disconnect two heater hose clamps that attach
plumbing to the heater core tube.
(9) To install, reverse the preceding operation.
EVAPORATOR AND EXPANSION VALVE
REMOVE
WARNING: THE REFRIGERANT SYSTEM MUST BE
DISCHARGED BEFORE PERFORMING THE FOLLOW-
ING OPERATION. THE ENGINE COOLING SYSTEM
MUST ALSO BE RELIEVED OF ALL PRESSURE.
(1) Remove left quarter trim panel. Refer to Group
23, Body.
(2) Remove FAN-A/C distribution duct.
(3) Remove rear A/C unit.
(4) Remove unit cover.
(5) Remove the bolt that mounts the unified refrig-
erant plumbing block to the expansion valve.
(6) Carefully pull the evaporator and expansion
valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots.
(7) Remove and discard the aluminum gasket be-
tween the plumbing extension and the expansion
valve.
(8) Cover the plumbing extension sealing surface to
prevent contamination.
(9) Bring evaporator and expansion valve to a clean
work space.
(10) Remove two 1/4-20 Torx Head screws.
(11) Remove expansion valve.
.
HEATING AND AIR CONDITIONING
24 - 51
(12) Measure and record the amount of residual oil
from the removed evaporator.
INSTALL
(1) Replace the aluminum gaskets (one on evapora-
tor plate and one on plumbing plate).
(2) Hold expansion valve against evaporator sealing
plate (do not scratch the sealing surface). Install two
screws and tighten to 100
6 30 inch pounds (11 6 3
N
Im).
(3) Carefully install the evaporator and expansion
valve straight into the unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots.
(4) Determine the amount of old refrigerant oil
drained from the evaporator. Add this amount (of clean
refrigerant oil) back into the system.
(5) Carefully align the expansion valve onto the pilot
tube of the plumbing sealing plate (do not scratch the
sealing surface). Install the bolt through the plumbing
plate into the unit sealing plate and tighten to 200
6
30 inch pounds (23
6 3 NIm).
(6) Install unit cover and air distribution duct.
(7) Install quarter trim panel, evacuate/charge sys-
tem, and test performance.
AUXILIARY UNDER BODY HEATER PLUMBING
REMOVAL AND INSTALLATION
WARNING: THE ENGINE COOLING SYSTEM MUST
BE RELIEVED OF ALL PRESSURE.
(1) Drain the engine cooling system. Refer to Group
7, Cooling System.
(2) In the engine compartment, and disconnect two
auxiliary rear heater hoses from the (front) heater hose
tee fittings.
(3) Hoist the vehicle. Disconnect two push-together
couplings from the auxiliary rear heater core tubes
protruding through the floor pan.
(4) Remove four bolts and one pal nut holding the
plumbing to the floor pan and lower the plumbing from
the vehicle (Fig. 2).
To Install, Reverse the preceding operation.
AUXILIARY UNDER BODY REFRIGERANT PLUMB-
ING
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE
DISCHARGED BEFORE PERFORMING THE FOLLOW-
ING OPERATION.
(1) Hoist the vehicle. Disconnect two tube-fittings
from the engine compartment plumbing.
(2) Remove the bolt from the unified plumbing block
(left side of car, outboard of rail, forward of fuel tank).
(3) Carefully pull refrigerant line assembly down
(take care NOT to scratch the sealing surface with the
tube pilots). Remove and discard the aluminum gasket
and cover unit sealing surface to prevent contamina-
tion.
(4) Remove two screws holding plumbing to the fuel
tank support and left-side support rail (near muffler
support bracket).
(5) Remove two screws holding the plumbing to the
floor pan.
(6) Disconnect the parking brake system at hook
above muffler and the cable connection near the sup-
port rails.
(7) Fish the nylon tubing and unified plumbing block
above the muffler support member.
(8) Lower the plumbing from the vehicle.
(9) Measure the residual oil in the under body
plumbing out of each end of the plumbing. The low-side
(larger diameter line) has a check valve that can
restrict oil flow from the tube-fitting to the unified
plumbing end of the hose. Measure clean 500 SUS
viscosity wax-free refrigerant oil to be returned to the
refrigerant system.
INSTALL
(1) Protect the plumbing ends from scratches. If
plumbing is new, do not remove the shipping caps until
joining together.
(2) Reverse the preceding steps from the REMOVAL
procedure.
(3) New gaskets and O-rings are required for instal-
lation. The O-rings must be covered with clean refrig-
erant oil prior to installation.
(4) Connect the tube-fittings to the engine compart-
ment under body plumbing. Avoid misalignment of the
threads (cross threading) and tighten to 200 in-lbs.
(5) Remove the shipping cap from the plumbing side
sealing surface and verify that the aluminum gasket is
present.
Fig. 2 Rear Heater Under body Plumbing
24 - 52
HEATING AND AIR CONDITIONING
.
(6) Carefully align the pilot tubes of the plumbing
line block into the unit (take care not to scratch the
sealing surface).
(7) Install the bolt through the plumbing plate into
the unit sealing plate and tighten to 200
6 30 inch
pounds (23
6 3 NIm) (Fig. 3).
Fig. 3 Rear A/C Under body Plumbing
.
HEATING AND AIR CONDITIONING
24 - 53
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