2002 Dodge Caravan SE

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Isaac Henderson
5 years ago
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1 EVAPORATOR (FRONT) Removal 1. Remove the HVAC housing from the vehicle. See HVAC HOUSING (FRONT). Remove the heater hoses from the heater core. 2. Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. Remove the expansion valve from the evaporator inlet and outlet tube fittings. See EXPANSION VALVE. 3. Disconnect the HVAC wire harness connector for the blower motor from the motor connector receptacle on the bottom of the outboard end of the evaporator housing. Disengage the HVAC wire harness from the routing clips molded into the outside of the HVAC housing components. 4. Remove the 3 screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. See Fig Pull the top of the distribution housing away from the evaporator housing far enough to disengage the 2 hook formations on the bottom of the distribution housing from the 2 receptacles on the evaporator housing. See Fig Remove the 2 screws that secure the upper intake air housing to the lower intake air housing. Remove the 3 screws that secure the upper intake air housing to the top of the outboard end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening. 7. Remove the upper intake air housing from the top of the evaporator housing to expose the recirculation air door and the blower wheel housing. See Fig. 43. Remove the 2 screws that secure the upper half of the recirculation air door to the lower half of the door. 8. Remove the upper half of the recirculation air door from the lower half of the door. See Fig. 44. Remove the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half. 9. Carefully separate and remove the upper half of the evaporator housing from the lower half. Be certain not to lose the rubber grommet for the HVAC wire harness evaporator temperature sensor take out. This grommet is located on the inboard side of the flange around the expansion valve/evaporator tube opening on the dash panel side of the unit where it is captured in notched area between the upper and lower housing halves. See Fig Carefully lift the evaporator and its foam wrap out of the lower half of the evaporator housing as a unit. Be certain not to lose the clam shell type rubber seal that is fitted to the evaporator inlet and outlet tubes where they exit he evaporator housing.

2 Fig. 41: Removing & Installing Distribution Housing From Evaporator

3 Fig. 42: Disengaging Distribution Housing Hooks

4 Fig. 43: Removing & Installing Upper Intake Air Housing

5 Fig. 44: Removing & Installing Upper Recirculation Air Door

6 Fig. 45: Removing & Installing Upper Evaporator Housing From Lower Installation 1. Carefully lower the evaporator and its foam wrap into the lower half of the evaporator housing as a unit. Be certain that the clam shell type rubber seal is fitted to the evaporator inlet and outlet tubes where they exit the evaporator housing. 2. Position the upper half of the evaporator housing onto the lower half. Be certain that the rubber grommet and the HVAC wire harness take out for the evaporator temperature sensor are captured in the notched area between the upper and lower housing halves. Install and tighten the 12 screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half. 3. Position the upper half of the recirculation air door onto the lower half of the door. Install and tighten the 2 screws that secure the upper half of the recirculation air door to the lower half of the door.

7 4. Position the upper intake air housing onto the top of the evaporator housing over the recirculation air door and the blower wheel housing. Be certain that the upper pivot of the recirculation air door is captured in the pivot receptacle of the upper intake air housing. 5. Install and tighten the 3 screws that secure the upper intake air housing to the top of the out board end of the evaporator housing. Be certain not to miss the screw located just inside the inboard side of the fresh air intake opening. Install and tighten the 2 screws that secure the upper intake air housing to the lower intake air housing. 6. Engage the 2 hook formations on the bottom of the distribution housing in the 2 receptacles on the evaporator housing. Roll the top of the distribution housing up into position against the evaporator housing. 7. Install and tighten the 3 screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing. Engage the HVAC wire harness in the routing clips molded into the outside of the HVAC housing components. 8. Reconnect the HVAC wire harness connector for the blower motor with the motor connector receptacle on the bottom of the outboard end of the evaporator housing. Reinstall the expansion valve onto the evaporator inlet and outlet tube fittings. See EXPANSION VALVE (FRONT). 9. Install a NEW foam seal onto the HVAC housing seal flange around the fresh air inlet opening and the expansion valve/evaporator tube opening on the dash panel side of the unit. Reinstall the heater hoses into the heater core. See HEATER CORE (FRONT). 10. Reinstall the HVAC housing into the vehicle. See HVAC HOUSING (FRONT). Run the HVAC Control Actuator Calibration procedure. See HVAC CONTROL CALIBRATION. EXPANSION VALVE (FRONT) Removal 1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the battery negative cable. 2. Remove the air cleaner housing from the right side of the engine compartment. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 3. Disconnect the headlamp and dash wire harness connector for the A/C pressure transducer from the transducer on the front liquid line rear section. See Fig. 49. Remove the screw that secures the front liquid line rear section fitting to the top of the filter drier. 4. Disconnect the liquid line fitting from the filter drier outlet port. Remove the seal from the liquid line fitting and discard. 5. Install plugs in, or tape over the opened liquid line fitting and the filter drier outlet port. Remove the nut that secures the suction line and liquid line fittings to the stud on the expansion valve. 6. Disconnect the suction line and liquid line fittings from the expansion valve and move the lines out of the way. Remove the seals from the suction line and liquid line fittings and discard. 7. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. Remove the 2 screws that secure the expansion valve to the evaporator tube tapping plate. 8. Disconnect the HVAC wire harness connector for the evaporator temperature sensor from the sensor on the top of the expansion valve. Remove the expansion valve from the evaporator inlet and outlet tube

8 fittings. 9. Remove the seals from the evaporator inlet and outlet tube fittings and discard. Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports. Fig. 49: Removing & Installing Expansion Valve Installation 1. Remove the tape or plugs from the evaporator inlet and outlet tube fittings and both ports on the back of the expansion valve. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the

9 evaporator inlet and outlet tube fittings. 2. Position the expansion valve onto the evaporator inlet and outlet tube fittings. Install and tighten the 2 screws that secure the expansion valve to the evaporator tube tapping plate plate. 3. Reconnect the HVAC housing wire harness connector for the evaporator temperature sensor to the sensor connector receptacle on the top of the expansion valve. Remove the tape or plugs from the front liquid line rear section and suction line fittings for the expansion valve and both ports on the front of the expansion valve. 4. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the front liquid line rear section and suction line fittings for the expansion valve. Reconnect the liquid line and suction line fittings to the expansion valve. 5. Install and tighten the nut that secures the suction line and liquid line fittings to the stud on the expansion valve. Remove the tape or plugs from the liquid line rear section fitting for the filter drier and the filter drier outlet port. 6. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. Reconnect the liquid line fitting to the filter drier outlet port on the top of the filter drier. 7. Install and tighten the screw that secures the liquid line fitting to the filter drier. Tighten the screw. Reconnect the headlamp and dash wire harness connector for the A/C pressure transducer to the transducer on the front liquid line rear section. 8. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. Reinstall the air cleaner housing into the right side of the engine compartment. 9. Reconnect the battery negative cable. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. HVAC HOUSING (FRONT) Removal 1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Drain the engine cooling system. 2. Disconnect and isolate the battery negative cable. Disconnect the liquid line and suction line from the expansion valve. See SUCTION LINE (FRONT) and LIQUID LINE (FRONT). 3. Disconnect the heater hoses from the heater hoses. See HEATER HOSE (FRONT). Remove the 4 nuts that secure the HVAC housing studs to the engine compartment side of the dash panel. See Fig Remove the instrument panel from the passenger compartment. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Remove the floor distribution duct from the HVAC housing. 5. Remove the screw that secures the HVAC housing bracket to the passenger compartment side of the dash panel. See Fig. 64. Pull the HVAC housing rearward far enough for the mounting studs to clear the dash panel and remove the unit from the passenger compartment.

10 Fig. 63: Removing & Installing HVAC housing Studs

11 Fig. 64: Removing & Installing HVAC Housing Installation 1. Position the HVAC housing against the dash panel in the passenger compartment with the 4 mounting studs located in their proper mounting holes in the dash panel. Install and tighten the screw that secures the HVAC housing bracket to the passenger compartment side of the dash panel. 2. Install and tighten the 4 nuts that secure the HVAC housing studs to the engine compartment side of the dash panel. Reinstall the floor distribution duct onto the HVAC housing. 3. Reinstall the instrument panel into the passenger compartment. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Reconnect the heater hoses to the heater hoses. See HEATER HOSE (FRONT). 4. Reconnect the suction line and liquid line to the expansion valve. See SUCTION LINE (FRONT) and LIQUID LINE (FRONT). Reconnect the battery negative cable. 5. Refill the engine cooling system. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

DISTRIBUTION > HOUSING, HVAC > INSTALLATION > AIR INLET HOUSING

Page 1 of 6 Service Manual: HEATING & AIR CONDITIONING - Print Date: SERVICE INFORMATION - 2500 HD & 3500 HD DISTRIBUTION > HOUSING, HVAC > INSTALLATION > AIR INLET HOUSING Fig 1: Front Of Air Inlet Housing