GrandCaravan 2008

Removal & Installation

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Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


CAUTION
Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait 2 minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury.


CAUTION
Refer to the applicable warnings and cautions for the A/C system before performing the following operation. Failure to follow the warnings and cautions may result in serious or fatal injury.


NOTE
The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator and the recirculation and air distribution housings.


NOTE
Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Recover the refrigerant from the refrigerant system. Refer to Maintenance, Discharging The System.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove the nut (3) that secures the A/C suction line (1) and the A/C liquid line (5) to the A/C expansion valve (2).
  10.  
  11. Disconnect the A/C suction and liquid lines from the A/C expansion valve and remove and discard the dual-plane seals.
  12.  
  13. Loosen the clamps and disconnect the heater hoses (4) from the heater core.
  14.  
  15. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve and heater core ports.

    Click image to see an enlarged view

    Fig. Disconnect the A/C suction and liquid lines from the A/C expansion valve

  16.  
  17. Remove the bolt that secures the HVAC housing to the engine compartment side of the dash panel (2).
  18.  
  19. Remove the defroster grille from the top of the instrument panel.
  20.  
  21. Remove the bolt (1) that secures the HVAC air inlet housing (3) to the passenger side of the dash panel (2).
  22.  
  23. Remove the instrument panel and HVAC housing as an assembly and place them on a workbench. Refer to Instrument Panel, removal & installation.
  24.  
  25. Remove the 2 screws (1) that secure the defroster duct (2) to the top of the instrument panel cover (3).
  26.  
  27. Remove the bolt that secures the HVAC housing to the front of the instrument panel support, near the lower center of the instrument panel.
  28.  
  29. Remove the bolt (1) that secures the driver side of the HVAC air distribution housing (2) to the underside of the instrument panel support (3).

    Click image to see an enlarged view

    Fig. Remove the bolt (1) that secures the driver side of the HVAC air distribution housing (2) to the underside of the instrument panel support (3)

  30.  
  31. Remove the bolt (1) that secures the passenger side of the HVAC air distribution housing (4) to the underside of the instrument panel support (3).
  32.  
  33. Disconnect the instrument panel wire harness from the HVAC wire harness connector (2).

    Click image to see an enlarged view

    Fig. Remove the bolt that secures the passenger side of the HVAC air distribution housing to the underside of the instrument panel

  34.  
  35. Remove the bolt that secures the passenger side end of the HVAC housing to the underside of the instrument panel support.
  36.  
  37. Carefully remove the HVAC housing from the instrument panel.
  38.  
  39. Remove the defroster duct from the top of the HVAC air distribution housing.
  40.  

To install:


NOTE
Replacement of the refrigerant line seals is required anytime a refrigerant line or expansion valve is disconnected or removed. Failure to replace the rubber and metal dual-plane seals may result in a refrigerant system leak.

  1. Install the defroster duct to the top of the HVAC air distribution housing.
  2.  
  3. Position the HVAC housing into the instrument panel support
  4.  
  5. Loosely install the bolt that secures the passenger side end of the HVAC housing to the underside of the instrument panel support.
  6.  
  7. Loosely install the bolt that secures the passenger side of the HVAC air distribution housing to the underside of the instrument panel support.
  8.  
  9. Connect the instrument panel wire harness to the HVAC wire harness connector.
  10.  
  11. Loosely install the bolt that secures the driver side of the HVAC air distribution housing to the underside of the instrument panel support.
  12.  
  13. Loosely install the bolt that secures the HVAC housing to the front of the instrument panel support.
  14.  
  15. Tighten all of the bolts that secure the HVAC housing to the instrument panel support to 27 inch lbs. (3 Nm).
  16.  
  17. Install the 2 screws that secure the defroster duct to the top of the instrument panel cover. Tighten the screws to 17 inch lbs. (2 Nm).
  18.  
  19. Position the instrument panel and HVAC housing into the vehicle as an assembly. Make sure to align the condensate drain with the drain tube located in the center of the floor panel and to fully engage the floor distribution ducts to the outlets in the bottom of the HVAC housing.
  20.  
  21. Install the instrument panel. Refer to Instrument Panel, removal & installation.
  22.  
  23. Install the bolt that secures the HVAC air inlet housing to the passenger side of the dash panel. Tighten the bolt to 27 inch lbs. (3 Nm).
  24.  
  25. Install the defroster grille onto the top of the instrument panel.
  26.  
  27. Install the bolt that secures the HVAC housing to the engine compartment side of the dash panel. Tighten the bolt to 27 inch lbs. (3 Nm).
  28.  
  29. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve and heater core ports.
  30.  
  31. Lubricate new dual-plane seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
    WARNING
    Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur.

  32.  
  33. Connect the A/C suction line (1) and the A/C liquid line (5) to the A/C expansion valve (2).
  34.  
  35. Install the nut (3) that secures the A/C suction and liquid lines to the A/C expansion valve. Tighten the nut to 17 ft. lbs. (23 Nm).
  36.  
  37. Connect the heater hoses (4) to the heater core. Tighten the clamps securely.
  38.  
  39. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  40.  
  41. If the heater core is being replaced, flush the cooling system.
  42.  
  43. Refill the engine cooling system with the proper type and amount of fluid.
  44.  
  45. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  46.  
  47. Charge the refrigerant system. Refer to Maintenance, Charging The System.
  48.  
  49. Calibrate the A/C-heater control. Refer to Reset Procedure.
  50.  

 
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