Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 138
To install, reverse the preceding operation.
BLOWER MOTOR WHEEL
REMOVAL AND INSTALLATION
Blower motor must be removed from vehicle before
performing this operation.
(1) Remove the spring type retaining ring from the
center of the blower wheel (Fig. 18). Note the location
of the blower wheel on the blower motor shaft.
(2) Remove blower wheel from blower motor shaft.
To install, reverse the preceding operation. To pre-
vent noise or vibration, rotate the blower wheel by
hand to check for rubbing.
HEATER CORE
REMOVAL AND INSTALLATION
Refer to Heater A/C Unit Recondition in this Group.
EVAPORATOR COIL
REMOVAL AND INSTALLATION
Refer to Heater A/C Unit Recondition in this Group.
HEATER-A/C UNIT HOUSING
REMOVAL AND INSTALLATION
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY
DISCHARGED
BEFORE
PROCEEDING
WITH THIS OPERATION.
(1) Set parking brake.
(2) Disconnect negative battery cable.
(3) Discharge refrigerant system.
(4) Disconnect all engine compartment lines and
vacuum hoses.
(5) Drain engine coolant. Plug coolant lines.
(6) Remove the steering column cover.
(7) Remove the left under panel silencer.
(8) Remove the right under panel silencer.
(9) Remove the center bezel (clips to instrument
panel).
(10) Remove the accessory switch carrier.
(11) Remove Heat-A/C controls.
(12) Remove standard storage module.
(13) Remove the right lower instrument panel.
(14) Remove the right 40-way wiring bracket.
(15) Remove the lower right reinforcement, body
computer bracket, and mid-to-lower reinforcement as
one assembly.
(16) Disconnect all necessary instrument panel wir-
ing and temporarily route wiring out of the way.
(17) Disconnect the A/C unit hanger strap from the
unit and temporarily re-position.
(18) Remove the rubber condensate drain tube (in
engine compartment).
(19) Remove the four nuts (in the engine compart-
ment) securing the unit to the dash panel.
(20) Pull the entire unit rearward until the studs on
the unit clear the dash panel. Drop the unit down and
pull it rearward to remove it from vehicle.
To install the assembly, reverse the preceding opera-
tion.
HEATER A/C UNIT RECONDITION
Heater-A/C Housing must be removed from vehicle
before performing this operation. Refer to Heater-A/C
Unit Housing—Removal and Installation.
DISASSEMBLY
(1) Place heater/A/C unit assembly (Fig. 19) on
workbench.
(2) Remove one screw retaining the vacuum har-
ness. Feed harness through hole in cover.
(3) Remove thirteen screws from top cover and re-
move cover. Temperature control door will come out
with the cover. Remove the nut and lever from the door
shaft to remove the temperature door from the cover.
(4) Remove screw from heater core tube retaining
bracket and lift heater core out of unit (Fig. 20).
(5) Remove A/C evaporator coil out of unit (Fig. 21).
Fig. 18 Blower Wheel Retaining Ring Removal and
Installation
Fig. 19 Heater/A/C Assembly
.
HEATING AND AIR CONDITIONING
24 - 47
(6) Disconnect
actuator
linkage
from
fresh/recirculation door and vacuum lines from actua-
tor. Loosen two nuts attaching actuator to housing and
remove actuator (Fig. 22).
(7) Remove four screws attaching fresh/recirculation
cover to unit and lift off cover (Fig. 23).
(8) Fresh/recirculating door may now be removed
from its housing.
(9) To remove heat defrost door, remove retaining
clip from shaft inside the housing. Pull shaft from
housing and remove door.
(10) To remove mode door, remove retaining clip
from shaft inside the housing. Pull the shaft from the
housing and remove door.
ASSEMBLY
(1) Place evaporator coil into unit.
(2) Place heater core into unit and fasten with
screws.
(3) Reinstall blower wheel onto blower motor shaft
and secure with retaining clamp.
(4) Feed blower motor wires through hole in hous-
ing. Lower blower assembly (rubber seal in place) into
housing. Pull wiring grommet into place and install
three mounting screws.
(5) Install blower motor assembly (five screws) to
housing.
(6) Install fresh/recirculating door into housing. In-
stall fresh/recirculating cover (four screws). Rotate
actuator shaft into door and slide actuator into bracket
and tighten two nuts.
Fig. 20 Removing or Installing Heater Core Assem-
bly
Fig. 21 Removing or Installing A/C Evaporator Coil
Fig. 22 Removing or Installing Fresh/Recirc Vacuum
Actuator and Linkage
Fig. 23 Evaporator Heater Assembly
24 - 48
HEATING AND AIR CONDITIONING
.
(7) To install mode door to housing, insert door shaft
through housing and door pivot. Push on shaft retainer
(Fig. 24).
(8) To install demister door, connect wire rod to mode
door. Insert pivot end of door into hole in housing.
Position opposite into slot.
(9) To install heat/defrost door, insert door shaft
through housing and door pivot. Push on shaft re-
tainer.
(10) Install heat distribution duct to bottom of hous-
ing with three screws.
(11) To install temperature control door, install door
shaft into lower pivot in the case housing. Place unit
cover over housing while feeding temperature door
shaft through cover. If the temperature control door is
attached to the cover, feed the door into the housing
with the cover. Direct the bottom pivot of the door with
your hand through the mode door opening.
(12) To install housing cover, line up cover to housing
using pilot pins, the temperature door, and screw holes
for alignment. Install thirteen screws.
(13) Route vacuum harness through holes in cover.
Install screw to retain vacuum harness. Make all
vacuum hose attachments to vacuum actuators.
CONDENSATE DRAIN TUBE
REMOVAL AND INSTALLATION
(1) Raise vehicle.
(2) Locate rubber Drain Tube on right side of dash
panel (Fig. 25).
(3) Squeeze clamp and remove drain tube.
To install, reverse the preceding operation. Check the
drain tube nipple on the heater-A/C housing for any
obstructions.
Fig. 24 Removing or Installing Mode Door Shaft
Fig. 25 Condensate Water Drain Tube—Typical
.
HEATING AND AIR CONDITIONING
24 - 49
AUXILIARY REAR HEATING OR HEATING-AIR/CONDITIONING
INDEX
page
page
Air Distribution Duct
. . . . . . . . . . . . . . . . . . . . . . . 51
Auxiliary Under Body Heater Plumbing
. . . . . . . . . 52
Auxiliary Under Body Refrigerant Plumbing
. . . . . . 52
Diagnostic Procedures
. . . . . . . . . . . . . . . . . . . . . 50
Evaporator and Expansion Valve
. . . . . . . . . . . . . 51
General Information
. . . . . . . . . . . . . . . . . . . . . . . 50
Heater Core
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Rear Blower Resistor Block
. . . . . . . . . . . . . . . . . 51
Rear Heater A/C Air Outlets
. . . . . . . . . . . . . . . . . 50
Rear Heater A/C Blower Motor
. . . . . . . . . . . . . . . 51
Rear Heater A/C Control
. . . . . . . . . . . . . . . . . . . 50
Rear Heater A/C Control Illumination Bulb
. . . . . . . 50
Rear Heater-A/C Unit
. . . . . . . . . . . . . . . . . . . . . . 51
GENERAL INFORMATION
For
proper
operation
of
the
rear
heating-
air/conditioning system, refer to the Owner’s Manual
supplied with the vehicle.
The auxiliary rear heater functions the same as the
heater-A/C system. The rear heater utilizes the same
components as the rear heater-A/C system. Only the
refrigerant components have been omitted.
The auxiliary rear heating-air/conditioning system is
located in the left rear quarter panel. It is a manually
operated device, controlled by the rear-seat occupant.
The rear heater A/C control operates in conjunction
with the front heater A/C control. A four position
blower (override) switch is located on the instrument
panel (Fig. 1). The vehicle operator can use the rear
heater-A/C blower instrument panel switch to operate
the blower at HI or LO speed, regardless of the setting
of the rear control. In the OFF position, the rear control
will not function. In the ON position, the rear control
will function normally.
Air from inside the vehicle is drawn into the air
intake grille in the left rear quarter trim panel. The air
enters the blower and is pushed through the heater
core and A/C evaporator coil (if equipped). When the
HEAT mode is selected, the airflow is directed from the
heat outlets at the floor. When the FAN or A/C mode is
selected, the airflow is directed from the upper air
outlets.
DIAGNOSTIC PROCEDURES
When diagnosing electrical problems in the auxiliary
rear heater or rear A/C system, refer to Group 8W,
Wiring Diagrams.
When diagnosing mechanical problems in the auxil-
iary rear heater or rear A/C systems, refer to the
Diagnostic and Test procedures sections for (front)
heater-A/C.
REAR HEATER A/C CONTROL
REMOVE AND INSTALL
(1) Pry outward on the outside upper and lower
corners of the control.
(2) Separate the control from the trim panel and
disconnect the wire connectors.
To install, push the control into the opening until it
locks into place.
REAR HEATER A/C CONTROL ILLUMINATION BULB
REMOVE AND INSTALL
(1) Remove rear heater A/C control from trim panel.
(2) On the back of control opposite from the wire
connectors, locate the bulb socket lug.
(3) Rotate the socket counterclockwise and pull the
socket from the control.
To install, reverse the preceding operation. Refer to
the back of Group 8L, Lamps, for bulb usage.
REAR HEATER A/C AIR OUTLETS
REMOVAL AND INSTALL
(1) Pry outward on the outside upper and lower
corners of the outlets.
(2) Separate the air outlet from the trim panel.
To install, push the outlet firmly into the opening
until it locks into place.
Fig. 1 Rear Heater, Rear Heater-A/C Controls
24 - 50
HEATING AND AIR CONDITIONING
.
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