TownAndCountry 2008

HVAC Housing

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Removal & Installation



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


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


NOTE
The rear heater-A/C housing (HVAC) must be removed from the vehicle for service of the mode door actuator, blend door actuator, blower motor and blower motor resistor and, it must be disassembled for service of the A/C evaporator, heater core, mode-air door, and blend-air door.

  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. Raise and safely support the vehicle.
  10.  
  11. Remove the nut (2) that secures the underbody refrigerant extension lines (3) and the sealing plate (4) to the rear A/C expansion valve (1) which extends through the floor panel behind the right rear wheel housing.
  12.  
  13. Disconnect the underbody refrigerant extension lines from the rear A/C expansion valve and remove and discard the O-ring seals.
    NOTE
    Illustration shown with rear body cradle removed for clarity.



    Click image to see an enlarged view

    Fig. View of rear underbody refrigerant extension lines

  14.  
  15. Install plugs or tape to seal the opened underbody refrigerant line fittings and rear expansion valve ports.
    WARNING
    DO NOT apply excessive force on underbody heater lines or rear heater hose quick connect fittings when disconnecting the connections. Excessive force may damage or deform the fittings and or lines, causing an engine coolant leak.

  16.  
  17. Disconnect the underbody heater lines (4) from the rear heater core tubes (1) which extend through the rear floor panel in front of the right rear wheel housing by releasing the insert (2) in each rear quick connect fitting (3) and carefully pulling downward on the fittings while using a slight twisting motion.
  18.  
  19. Lower the underbody heater lines and drain any residual coolant from the lines into a suitable container.

    Click image to see an enlarged view

    Fig. View of rear underbody heater lines

  20.  
  21. Lower the vehicle.
  22.  
  23. Open the liftgate.
  24.  
  25. Using a trim stick remove the liftgate scuff plate.
  26.  
  27. Using a trim stick remove the upper D-pillar trim.
  28.  
  29. Using a trim stick remove the quarter trim bolster.
  30.  
  31. Remove the 3rd row lower seat belt webbing anchor (4).
  32.  
  33. Remove the 2nd row seat belt webbing anchor bolt.
  34.  
  35. Remove the 3rd row upper turning loop anchor bolt.
  36.  
  37. Remove the 6 quarter trim retaining screws.
  38.  
  39. Pull the trim from the inner quarter panel (1).
  40.  
  41. Remove the quarter trim panel (5).

    Click image to see an enlarged view

    Fig. Remove the rear quarter trim panel

  42.  
  43. Remove the metal support strap from the rear quarter panel and floor.
  44.  
  45. Disengage the rear floor distribution duct (1) from the 2 studs (2) located on the right inner quarter panel (3).
  46.  
  47. Slide the rear floor distribution duct forward and disengage it from the rear heater-A/C housing (4).
  48.  
  49. Remove the rear floor distribution duct from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the rear floor distribution duct from the vehicle

  50.  
  51. Remove the rear ceiling distribution ducts.
  52.  
  53. Disconnect the body wire harness from the rear heater-A/C wire harness connector (6).
  54.  
  55. Remove the 2 nuts (2) that secure the rear heater core tubes (8) to the floor panel (9).
  56.  
  57. Remove the bolt (7) that secures the rear heater core tubes to the right inner quarter panel (1).
  58.  
  59. Remove the 2 bolts (5) that secure the rear heater-A/C housing (4) to the 2 metal brackets (3) located on the rear inner quarter panel and remove the housing.
  60.  
  61. Remove the rear HVAC housing from the vehicle.

    Click image to see an enlarged view

    Fig. Rear HVAC components illustrated

  62.  

To install:

  1. Position the rear heater-A/C (HVAC) housing (4) into the vehicle.
  2.  
  3. Install the 2 bolts (5) that secure the rear HVAC housing to the 2 brackets (3) located on the rear inner quarter panel (1). Tighten the bolts to 27 inch lbs. (3 Nm).
  4.  
  5. Install the 2 nuts (2) that secure the rear heater core tubes (8) to the floor panel (9). Tighten the nuts to 27 inch lbs. (3 Nm).
  6.  
  7. Install the bolt (7) that secures the rear heater core tubes to the rear inner quarter panel. Tighten the bolt to 27 inch lbs. (3 Nm).
  8.  
  9. Connect the body wire harness to the rear HVAC wire harness connector (6).
  10.  
  11. Install the rear ceiling distribution duct.
  12.  
  13. Install the rear floor distribution duct.
  14.  
  15. Install the metal support strap to the rear quarter panel and floor. Tighten the fasteners securely.
  16.  
  17. Install the right rear quarter panel trim in reverse of the removal procedure.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the rear heater core tube fittings. Use only the specified O-rings as they are made of a special material designed for use with engine coolant. Use only engine coolant of the type recommended for the engine in the vehicle.
    WARNING
    DO NOT apply excessive force on underbody heater lines or rear heater hose quick connect fittings when connecting the connections. Excessive force may damage or deform the fittings and or lines, causing an engine coolant leak.

  22.  
  23. Connect the quick-connect fittings (3) for the underbody heater lines (4) to the rear heater core tubes (1) and engage the inserts (2). Make sure the inserts are fully engaged to the rear heater core tube fittings.
  24.  
  25. Remove the tape or plugs from the underbody refrigerant extension line fittings and rear expansion valve ports.
  26.  
  27. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear underbody refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  28.  
  29. Connect the underbody refrigerant extension lines (3) to the rear A/C expansion valve (1).
  30.  
  31. Install the nut (2) that secures the extension lines and sealing plate (4) to the to the rear A/C expansion valve. Tighten the nut to 17 ft. lbs. (23 Nm).
  32.  
  33. Lower the vehicle.
  34.  
  35. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  36.  
  37. If the heater core is being replaced, flush the cooling system.
  38.  
  39. Refill the engine cooling system with the proper type and amount of fluid.
  40.  
  41. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  42.  
  43. Charge the refrigerant system. Refer to Maintenance, Charging The System.
  44.  
  45. Calibrate the A/C-heater control. Refer to Reset Procedure.
  46.  

Reset Procedure



Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


NOTE
The A/C-heater control module must be recalibrated each time an actuator motor or the A/C-heater control is replaced. If the vehicle is so equipped, the calibration procedure also includes the rear HVAC positions for each actuator motor.

Calibrate the A/C-heater control with the following procedure:

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the ignition switch to the ON position.
  4.  
  5. If equipped with the Manual Temperature Control (MTC) system, press and hold the Rear Wipe/Wash and Recirculation buttons for at least 5 seconds.
  6.  
  7. If equipped with the Automatic Temperature Control (ATC) system, simultaneously press and hold the Power and Recirculation buttons on the A/C-heater control for at least 5 seconds.
  8.  
  9. The MTC A/C-heater control Rear Wipe/Wash button Light Emitting Diode (LED) and Recirculation button LED, or the ATC A/C-heater control Delay and Recirculation graphics, will begin to flash when the calibration procedure has begun.
  10.  
  11. The calibration procedure should take less than 2 minutes to complete for the MTC A/C-heater control, and less than 20 seconds for the ATC A/C-heater control. When the LED-s or graphics stop flashing, the calibration procedure is complete.
  12.  
  13. If the LED-s or graphics continue to flash beyond the 2 minute (manual) or 20 second (ATC) calibration time, this indicates that the A/C-heater control has detected a failure and a Diagnostic Trouble Code (DTC) has been set.
    NOTE
    The LED-s or graphics will continue to flash even after the ignition switch is cycled OFF and ON, until a successful calibration is completed or until the vehicle has been driven about 8 miles (13 km).

  14.  

 
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