TownAndCountry 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.


WARNING
The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened, or removed from the heater core. Failure to follow this warning may result in a coolant leak.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Recover the refrigerant from the refrigerant system. Refer to Maintenance, Discharging The System.
  8.  
  9. Remove the nut (3) that secures the A/C suction line (1) and the A/C liquid line (4) 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 washer seals.

    Click image to see an enlarged view

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

  12.  
  13. Remove the 2 bolts (1) that secure the A/C expansion valve (2) to the A/C evaporator.
  14.  
  15. Remove the A/C expansion valve from the A/C evaporator and remove and discard the O-ring seals.
  16.  
  17. Install plugs or tape to seal the opened refrigerant line fittings and the evaporator and expansion valve ports.
  18.  
  19. Loosen the clamps and disconnect the heater hoses (4) from the heater core. Plug the heater core ports.
    NOTE
    Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure.



    Click image to see an enlarged view

    Fig. Remove the bolts (1) that secure the A/C expansion valve (2) to the A/C evaporator

  20.  
  21. Remove the bolt that secures the HVAC housing to the engine compartment side of the dash panel.
  22.  
  23. Remove the defroster grille from the top of the instrument panel.
  24.  
  25. Remove the bolt (1) that secures the HVAC air inlet housing (3) to the passenger side of the dash panel (2).
    NOTE
    Illustration shown with instrument panel removed for clarity.



    Click image to see an enlarged view

    Fig. Remove the bolts (1) that secure the A/C expansion valve (2) to the A/C evaporator

  26.  
  27. Remove the instrument panel and HVAC housing as an assembly and place them on a workbench. Refer to Instrument Panel, removal & installation.
  28.  
  29. Remove the 2 screws that secure the defroster duct to the top of the instrument panel cover.
  30.  
  31. Remove the bolt that secures the HVAC housing to the front of the instrument panel support, near the lower center of the instrument panel.
  32.  
  33. 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)

  34.  
  35. Remove the bolt that secures the passenger side of the HVAC air distribution housing to the underside of the instrument panel support.
  36.  
  37. Disconnect the instrument panel wire harness from the HVAC wire harness connector.
  38.  
  39. Remove the bolt that secures the passenger side end of the HVAC housing to the underside of the instrument panel support.
  40.  
  41. Carefully remove the HVAC housing from the instrument panel.
  42.  
  43. Remove the defroster duct from the top of the HVAC air distribution housing.
    NOTE
    If the foam seal from the front of the HVAC housing is deformed or damaged, it must be replaced.

  44.  
  45. Remove the foam seal (1) from the front of the HVAC housing (2).
  46.  
  47. Remove the 2 screws (4) that secure the heater core cover (5) to the driver side of the air distribution housing (3).

    Click image to see an enlarged view

    Fig. Remove the foam seal from the HVAC housing

  48.  
  49. Rotate and tilt the heater core cover as necessary to disengage the retaining tab that secures the front of the cover to the HVAC housing and remove the cover.
  50.  
  51. Carefully pull the heater core (1) out of the driver side of the air distribution housing (2).

    Click image to see an enlarged view

    Fig. Carefully pull the heater core (1) out of the driver side of the air distribution housing (2)

  52.  

To install:


WARNING
The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened, or removed from the heater core. Failure to follow this warning may result in a coolant leak and possible serious injury.


NOTE
If the foam seal around the heater core is deformed or damaged, it must be replaced.

  1. Carefully install the heater core (1) into the driver side of the air distribution housing (2).
  2.  
  3. Position the front of the heater core cover (5) to the front of the HVAC housing (2) and engage the retaining tab that secures the cover to the housing.
  4.  
  5. Install the heater core cover to the driver side of the air distribution housing (3) and install the 2 screws (4). Tighten the screws to 10 inch lbs. (1 Nm).
  6.  
  7. Install the foam seal (1) onto the front of the HVAC housing.
  8.  
  9. Install the A/C expansion valve.
    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.

  10.  
  11. Install the defroster duct to the top of the HVAC air distribution housing.
  12.  
  13. Position the HVAC housing into the instrument panel support
  14.  
  15. Loosely install the bolt that secures the passenger side end of the HVAC housing to the underside of the instrument panel support.
  16.  
  17. Loosely install the bolt that secures the passenger side of the HVAC air distribution housing to the underside of the instrument panel support.
  18.  
  19. Connect the instrument panel wire harness to the HVAC wire harness connector.
  20.  
  21. Loosely install the bolt that secures the driver side of the HVAC air distribution housing to the underside of the instrument panel support.
  22.  
  23. Loosely install the bolt that secures the HVAC housing to the front of the instrument panel support.
  24.  
  25. Tighten all of the bolts that secure the HVAC housing to the instrument panel support to 27 inch lbs. (3 Nm).
  26.  
  27. 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).
  28.  
  29. 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.
  30.  
  31. Install the instrument panel. Refer to Instrument Panel, removal & installation.
  32.  
  33. 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).
  34.  
  35. Install the defroster grille onto the top of the instrument panel.
  36.  
  37. 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).
  38.  
  39. Remove the tape or plugs from the opened refrigerant line fittings and expansion valve and heater core ports.
  40.  
  41. 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.

  42.  
  43. Connect the A/C suction line (1) and the A/C liquid line (5) to the A/C expansion valve (2).
  44.  
  45. 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).
  46.  
  47. Connect the heater hoses (4) to the heater core. Tighten the clamps securely.
  48.  
  49. Reconnect the negative battery cable and tighten the nut to 45 inch lbs. (5 Nm).
  50.  
  51. If the heater core is being replaced, flush the cooling system.
  52.  
  53. Refill the engine cooling system with the proper type and amount of fluid.
  54.  
  55. Evacuate the refrigerant system. Refer to Maintenance, Evacuating The System.
  56.  
  57. Charge the refrigerant system. Refer to Maintenance, Charging The System.
  58.  
  59. Calibrate the A/C-heater control. Refer to Reset Procedure.
  60.  

 
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