Automatic HVAC Systems Chrysler Town & Country IV

MODEL IDENTIFICATION

MODEL IDENTIFICATION

SPECIFICATIONS

SPECIFICATIONS

BLEND DOOR ACTUATOR

The blend door actuators are reversible, 12-volt Direct Current (DC), servo motors. (Scheme 1) Models with the single zone HVAC system have a single blend air door which is controlled by a single blend door actuator. Models with the optional dual zone front HVAC system have dual blend air doors, which are controlled by 2 blend door actuators. The single zone blend door actuator is located on the driver side end of the HVAC housing unit, close to the dash panel. In the dual zone system, the same blend door actuator used for the single zone system becomes the passenger blend door actuator, and is mechanically connected to only the passenger side blend air door. In the dual zone system, a second separate blend door actuator is also located on the driver side end of the HVAC housing unit close to the instrument panel, and is mechanically connected to only the driver side blend air door. The blend door actuators are interchangeable with each other, as well as with the actuators for the mode door and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with 2 screws to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the proper blend air door. The blend door actuators do not require mechanical indexing to the blend door linkage, as they are electronically calibrated by the HVAC control module. The blend door actuators cannot be adjusted or repaired and, if damaged or faulty, they must be replaced.

Each blend door actuator is connected to the HVAC control module through the vehicle electrical system by a dedicated 2 wire take out and connector of the HVAC wire harness. The blend door actuator can move the blend air door in 2 directions. When the HVAC control module pulls the voltage on one side of the motor connection high and the other connection low, the blend air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the blend air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the blend air door stops and will not move. These same motor connections also provide a feed back signal to the HVAC control module. This feedback signal allows the module to monitor the operation and relative positions of the blend door actuator and the blend air door. The HVAC control module learns the blend air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuator can be diagnosed using a DRBIII® scan tool. See SELF-DIAGNOSTIC SYSTEM .

Scheme 1

BLOWER MOTOR (FRONT)

The blower motor is a 12-volt, Direct Current (DC) motor with a squirrel cage type blower wheel that is secured to the blower motor shaft. (Scheme 2) The blower motor and wheel are located near the passenger side end of the HVAC unit within the 2 halves of the intake air housing in the passenger compartment below the instrument panel. The blower motor and blower motor wheel are a factory balanced unit and cannot be adjusted or repaired. If faulty or damaged, the blower motor and blower wheel must be replaced as a unit.

The blower motor will operate whenever the ignition switch is in the On position and the HVAC control power is turned on. The blower motor can only be turned off by turning off the power at the HVAC control. The blower motor receives battery current whenever the front blower motor relay is energized. The front blower motor relay output circuit is protected by a fuse in the Intelligent Power Module (IPM) located in the engine compartment near the battery. In the Manual system the blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the blower motor speed is controlled by an electronic blower power module, which uses a pulse width modulated input from the ATC module and feedback from the blower motor to regulate the blower motor ground path it provides. The blower motor and wheel are used to control the velocity of air moving through the HVAC housing. The blower motor controls the velocity of the air flowing through the HVAC housing by spinning the blower wheel within the housing at the selected speed or in the ATC system at the selected or programmed speed.

Scheme 2

BLOWER MOTOR (REAR)

The blower motor is a 12-volt, Direct Current (DC) motor with a squirrel cage type blower wheel that is secured to the blower motor shaft. (Scheme 3) The blower motor and wheel are located in a housing near the top of the rear HVAC unit in the passenger compartment behind the right rear wheel house. The rear HVAC housing must be removed from the vehicle to access the blower motor and blower wheel for service. The blower motor and blower motor wheel are a factory balanced unit and cannot be adjusted or repaired. If faulty or damaged, the blower motor and blower wheel must be replaced as a unit.

The rear blower motor will operate whenever the ignition switch is in the On position, the HVAC control power is turned on and the rear HVAC system control switch on the front HVAC control is not in the Off position. The blower motor can only be turned off by turning off the rear system at the front HVAC control. The blower motor receives battery current whenever the rear blower motor relay is energized. The rear blower motor relay out put circuit is protected by a fuse in the Intelligent Power Module (IPM) located in the engine compartment near the battery. In the MTC system, the blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the blower motor speed is controlled by an electronic blower power module, which uses a pulse width modulated input from the ATC module and feedback from the blower motor to regulate the blower motor ground path it provides. The blower motor and wheel are used to control the velocity of it moving through the rear HVAC housing. The blower motor controls the velocity of the air flowing through the rear HVAC housing by spinning the blower wheel within the housing at the selected speed or in the ATC system at the selected or programmed speed.

Scheme 3

BLOWER MOTOR RELAY

Note. Relay terminal numbers are different than wiring harness connector terminal numbers. For blower motor relay terminal circuit reference (Scheme 4)and WIRING DIAGRAMS.

The blower motor relay is a International Standards Organization (ISO) mini-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns and terminal functions. The ISO mini-relay terminal functions are the same as a conventional ISO relay. However, the ISO mini-relay terminal pattern (or footprint) is different, the current capacity is lower and the physical dimensions are smaller than those of the conventional ISO relay. The blower motor relay is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for blower motor relay identification and location. The black, molded plastic case is the most visible component of the blower motor relay. Five male spade type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system, and the ISO designation for each terminal is molded into the base adjacent to each terminal.

The blower motor relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control the high current output to the blower motor resistor (manual HVAC control) or blower power module (ATC control). The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the IPM. The inputs and outputs of the blower motor relay include

1. The common feed relay terminal No. 30, receives a battery current input from the battery through a B(+) circuit at all times.
2. The coil ground, relay terminal No. 85, receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground.
3. The coil battery relay terminal No. 86, receives a battery current input from the battery through a B(+) circuit at all times.
4. The normally open relay terminal No. 87, provides a battery current output to the blower motor resistor (manual HVAC control) or blower power module (automatic HVAC control) through a fuse in the IPM on the fused front blower motor relay output circuit only when the blower motor relay coil is energized.
5. The normally closed relay terminal No. 87A, is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized.

See WIRING DIAGRAMS . The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices, and grounds.

Scheme 4

COMPRESSOR

The compressor used on this vehicle can be one of 2 models, depending upon the air conditioning system in the vehicle. All vehicles use the Nippondenso 10S20 compressor. This compressor uses an aluminum wash plate, teflon coated pistons and aluminum sleeveless cylinder walls. This compressor includes an integral high pressure relief valve. The compressor is secured low in the right front corner of the engine compartment to a mounting bracket on the cylinder block (2.4L engine), or directly to the cylinder block (3.3L and 3.8L engines) is integral to the compressor. This compressor cannot be repaired. If faulty or damaged, the entire compressor must be replaced. The compressor clutch, pulley, and clutch coil are available for service replacement.

The compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. The compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant. The compressor draws in low pressure refrigerant vapor from the evaporator through its suction port. It then compresses the refrigerant into a high pressure, high-temperature refrigerant vapor. The compressor pumps high pressure refrigerant vapor to the condenser through the compressor discharge port. The mechanical high pressure relief valve is designed to vent refrigerant from the system to protect against damage to the compressor or other system components, caused by condenser air flow restrictions or an overcharge of refrigerant. The valve only vents enough refrigerant to reduce the system pressure, then re-seats itself. The valve opens at a discharge pressure of 500-600 psi (3445-4135 kPa) or above, and closes when a minimum discharge pressure of 400 psi (2756 kPa) is reached.

COMPRESSOR CLUTCH

The compressor clutch assembly consists of a stationary electromagnetic coil with a zener diode, a hub bearing and pulley assembly, and a clutch plate. (Scheme 5) The electromagnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings. The clutch plate is keyed or splined to the compressor shaft, and secured with a bolt. The compressor clutch plate and pulley unit, or the clutch coil are available for separate service replacement. The clutch coil zener diode is integral to the clutch coil pigtail wire and connector and, if faulty or damaged, the clutch electromagnetic coil unit must be replaced.

The compressor clutch components provide the means to engage and disengage the compressor from the engine serpentine accessory drive belt. When the clutch coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. A zener diode is connected in parallel with the clutch electromagnetic coil. This diode controls the dissipation of voltage induced into the coil windings by the collapsing of the electromagnetic fields that occurs when the compressor clutch is disengaged. The zener diode dissipates this induced voltage by regulating a current path to ground. This arrangement serves to protect other circuits and components from potentially damaging voltage spikes in the vehicle electrical system that might occur if the voltage induced in the clutch coil windings could not be dissipated. The compressor clutch engagement is controlled by several components: the HVAC controls in the passenger compartment, the A/C pressure transducer on the liquid line, the evaporator temperature sensor on the expansion valve, the Powertrain Control Module (PCM) in the engine compartment, and the compressor clutch relay in the Intelligent Power Module (IPM). The PCM may delay compressor clutch engagement for up to 30 seconds.

Scheme 5

COMPRESSOR CLUTCH RELAY

Note. Relay terminal numbers are different than wiring harness connector terminal numbers. For blower motor relay terminal circuit reference (Scheme 4)and WIRING DIAGRAMS.

The compressor clutch relay (Scheme 4), is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns and terminal functions. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower and the physical dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. The black, molded plastic case is the most visible component of the compressor clutch relay. Five male spade-type terminals extend from the bottom of the base to connect the relay to the vehicle electrical system and the ISO designation for each terminal is molded into the base adjacent to each terminal.

The compressor clutch relay is an electromechanical switch that uses a low current input from the Powertrain Control Module (PCM) to control the high current output to the compressor clutch electromagnetic coil. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The compressor clutch relay terminals are connected to the vehicle electrical system through a receptacle in the Intelligent Power Module (IPM). The inputs and outputs of the compressor clutch relay include.

1. The common feed relay terminal No. 30, receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times.
2. The coil ground relay terminal No. 85, receives a ground input from the PCM through the compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground.
3. The coil battery relay terminal No. 86, receives a battery current input from the PCM through a fused ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions.
4. The normally open relay terminal No. 87, provides a battery current output to the compressor clutch coil through the compressor clutch relay output circuit only when the compressor clutch relay coil is energized.
5. The normally closed relay terminal No. 87A, is not connected to any circuit in this application, but provides a battery current output only when the compressor clutch relay coil is de-energized.

See WIRING DIAGRAMS . The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds

CONDENSER

The condenser is integral to a cooling module which includes the radiator, the electric cooling fan, the fan shroud, air seals and an automatic transmission oil cooler. The cooling module is located in the air flow in the front of the engine compartment behind the radiator grille. The condenser cannot be repaired or adjusted and if faulty or damaged it must be replaced. The condenser may be removed from the cooling module for service without removing the cooling module from the vehicle.

The condenser is a heat exchanger that allows the high pressure refrigerant gas being discharged by the compressor to give up its heat to the air passing over the condenser fins. When the refrigerant gas gives up its heat it condenses. When the refrigerant leaves the condenser, it has become a high pressure liquid refrigerant. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the air conditioning system. Therefore, it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct air flow. Also, any factory installed air seals or shrouds must be properly reinstalled following radiator or condenser service.

EVAPORATOR (FRONT)

The evaporator is located in the HVAC housing, behind the instrument panel. The evaporator is positioned in the HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator tubes. The HVAC housing must be removed from the vehicle to access the evaporator for service. The evaporator cannot be adjusted or repaired and if faulty or damaged it must be replaced.

Refrigerant enters the evaporator from the expansion as a low-temperature, low-pressure liquid/vapor mixture. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the evaporator.

EVAPORATOR (REAR)

The rear evaporator is located in the rear HVAC housing, behind the right rear wheel house. The evaporator is positioned in the rear HVAC housing so that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the compressor is engaged and circulating refrigerant through the evaporator tubes. The rear HVAC housing must be removed from the vehicle to access the evaporator for service. The evaporator cannot be adjusted or repaired and if faulty or damaged, it must be replaced.

Refrigerant enters the rear evaporator from the rear expansion valve as a low-temperature, low-pressure liquid. As air flows over the fins of the evaporator, the humidity in the air condenses on the fins and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the evaporator.

EVAPORATOR TEMPERATURE SENSOR

The evaporator temperature sensor is a switch that is installed on the top of the expansion valve in the right rear corner of the engine compartment. (Scheme 6) The sensor has a small probe that is inserted in a small well in the body of the expansion valve that is filled with a special silicone based thermal grease. A small molded plastic push-in retainer secures the sensor to a threaded hole in the top surface of the expansion valve. Two terminals within a molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.

The evaporator temperature sensor monitors the temperature of the evaporator through its connection to the top of the expansion valve. The sensor will change its internal resistance in response to the temperatures it monitors. The HVAC control module is connected to the sensor through a sensor ground circuit and a sensor signal circuit. As the evaporator temperature increases, the resistance of the sensor decreases and the voltage monitored by the module decreases. The module uses this monitored voltage reading to an indication of the evaporator temperature. The HVAC control module is programmed to respond to this input by sending electronic messages to the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus, and the PCM then cycles the air conditioning compressor clutch as necessary to optimize air conditioning system performance and to protect the system from evaporator freezing. The external location of the sensor and the use of a screw allows the sensor to be removed or installed from the expansion valve without disturbing the refrigerant in the system. The evaporator temperature sensor is diagnosed using a DRBIII® scan tool. See SELF-DIAGNOSTIC SYSTEM .

Scheme 6

EXPANSION VALVE (FRONT)

The front "H" valve-type Thermal Expansion Valve (TXV), is located at the dash panel between the liquid and suction lines, and the evaporator coil. The assembly consists of an H-valve body and a thermal sensor. High-pressure, low temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged the expansion valve must be replaced.

A mechanical sensor in the expansion valve control head monitors the temperature and pressure of the refrigerant leaving the evaporator coil through the suction line and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state which could damage the compressor. The thermo sensor measures refrigerant suction gas temperature which is monitored by the A/C control assembly.

EXPANSION VALVE (REAR)

The rear "H" valve-type Thermal Expansion Valve (TXV) is located at the rear of the rear HVAC housing between the evaporator line extension and the evaporator coil. High-pressure, low temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low-pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The expansion valve is a factory calibrated unit and cannot be adjusted or repaired. If faulty or damaged, the expansion valve must be replaced.

A mechanical sensor in the expansion valve control head monitors the temperature and pressure of the refrigerant leaving the coil through the suction line and adjusts the orifice size at the liquid line to let the proper amount of refrigerant into the evaporator coil to meet the vehicle cooling requirements. Controlling the refrigerant flow through the evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the compressor.

HEATER CORE (FRONT)

The heater core is located in the HVAC housing, under the instrument panel. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes integral heater core inlet and outlet ports. The removable heater hoses are held in place these ports by a sealing plate secured with a screw to the heater core tank. This removable heater core tube arrangement allows the heater core to be serviced without removing the HVAC housing from the vehicle. The heater core cannot be repaired and if faulty or damaged, it must replaced.

Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the air from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the HVAC housing is directed through the heater core.

HEATER CORE (REAR)

The rear Heater Core is located near the front of the rear HVAC housing, behind the right rear wheel house. It is a heat exchanger made of rows of tubes and fins. One end of the core is fitted with a molded plastic tank that includes integral heater core inlet and outlet nipples. The heater core can be serviced without removing the rear HVAC housing from the vehicle. The heater core cannot be repaired and if faulty or damaged, it must be replaced.

Engine coolant is circulated through heater hoses to the heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The blend air door allows control of the heater output air temperature by controlling how much of the air flowing through the rear HVAC housing is directed through the heater core.

HVAC SYSTEM (THREE ZONE AUTOMATIC) DESCRIPTION

The 3 Zone Automatic Temperature Control (ATC) allows occupants to select a comfort temperature, which is the perceived temperature level not the actual passenger compartment air temperature. The 3 Zone Automatic Temperature Control system includes a passenger compartment air filter. The filter element is the same size as the air conditioning evaporator to ensure ample capacity. A door at the base, of the HVAC housing below the glove box provides easy access to the filter element. The ATC computer utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs the internal circuitry and programming of the ATC computer allow it to control electronic functions and features of the ATC system. The inputs to the ATC computer are

1. Vehicle Speed/Engine RPM - The ATC computer monitors engine RPM, vehicle speed and Manifold Absolute Pressure information from the PCM.
2. Coolant Temperature - ATC computer monitors Coolant temperature received from the PCM and converts it to degrees Fahrenheit.
3. Ambient Temperature - ATC computer monitors Ambient temperature from the Compass Mini Trip Computer (CMTC) and converts it to degrees Fahrenheit.
4. Engine Miscellaneous Sensor Status - ATC computer monitors A/C disable information from the PCM.
5. Refrigerant Pressure - ATC computer monitors Barometric Pressure Intake Air Temperature, High Side Pressure and Methanol Content as broadcast by the PCM.
6. Door Ajar Status - The ATC computer monitors Driver Front Door, Passenger Front Door, Left Rear Door, Right Rear Door and Liftgate ajar information, as identified by the Body Control Module (BCM), to determine if all in-car temperatures should be maintained.
7. Dimming - The ATC computer monitors dimming status from the BCM to determine the required level of brightness and will dim accordingly.
8. Vehicle Odometer - The ATC computer monitors the vehicle odometer information from the BCM to prevent flashing the VF tube icons if the manual motor calibration or manual cool down tests have failed. Flashing of the display icons will cease when the vehicle odometer is greater than 3 miles.
9. English Metric - The ATC computer monitors the English/Metric information broadcast by the CMTC. The set temp displays for both the front and rear control heads will be set accordingly.
10. Vehicle Identification Number - The ATC computer monitors the last 8 characters of the VIN broadcast by the PCM and compares it to the information stored in EEPROM. If it is different, the new number will be stored over the old one and a motor calibration shall be initiated.
11. A/C System Information - The ATC computer will send a message for Evaporator Temperature too Low Fan Blower Relay status Evaporator Sensor Failure, Rear Window Defogger Relay and A/C Select.

Front Control Panel

The front control panel and integral computer is mounted in the instrument panel. The instrument panel mounted control and integral computer contains

1. A power button which allows the system to be completely turned off. The display is blank when the system is off.
2. Three rocker switches that select comfort temperatures from 59° to 85°F (15° to 30°C), which are shown in the vacuum fluorescent digital control display. If the set temp is 59°F (15°C) and the down button is pressed, the set temp value will become 59°F (15°C) but the display will show LO. If the set temp is 85°F (30°C) , and the up button is pressed, the set temp value will become 90°F (32°C) but the display will show HIGH. Temperatures can be displayed in either metric or Fahrenheit, which is controlled from the overhead console.
3. A rocker switch that selects a cool down rate. LO-AUTO or HI-AUTO are displayed when the system is in automatic operation.
4. A defroster button which turns on the defroster independently during full automatic control. A defroster symbol illuminates in the display when the button is pressed.
5. Air recirculation button. A Recirculation symbol appears in the display when the button is pressed or when the system exceeds 80 percent circulated air under automatic control due to high air conditioning demand.
6. Rear window defogger on/off switch. A graphic symbol shows when the defroster is on.
7. An air conditioning button that allows the compressor to be turned off. A Snowflake symbol is illuminated when air conditioning is on, whether under manual or automatic control.
8. Rotary knob for front fan speed selection can override the automatic controls LEDs surrounding the knob show the current setting.
9. Rotary knob for control of the Rear system.
10. A rotary knob for mode control can override the automatic controls LEDs surrounding the knob show the current setting.
11. Computer logic remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the system is off when the ignition is turned off it will be off when the engine is restarted, etc.
12. Computer logic provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally accompanied by increased fan noise, the proportion of recirculated to outside air gradually approaches full recirculation over a broad temperature range.
13. A graphic symbol of the windshield that illuminates when the windshield wiper deicer is active.

Rear Control Panel

A rear control panel centrally mounted on the headliner includes a vacuum-flourescent digital display a rocker control for temperature and rotary controls for adjustment of mode and fan speed control of the rear unit by intermediate seat passengers.

HVAC SYSTEM (THREE ZONE AUTOMATIC) OPERATION

Comfort temperature or perceived temperature is affected by air flow, sun impinging on exposed skin, etc. The air temperature may be higher or lower than the comfort temperature. Three infrared sensors, 2 in the instrument panel center stack, and one in the overhead-mounted rear control panel, independently measure the temperature of the driver, front passenger and rear compartment occupants to determine their comfort level relative to the selected comfort temperature. The HVAC computer in the control module adjusts the air flow rate and temperature to maintain the customer perceived comfort temperature. The air temperature in the passenger compartment at any time may be slightly higher or lower than the comfort temperature. For instance, on sunny summer days the air flow will probably be cooler than the comfort temperature on cold or cloudy days and at night it will probably be slightly warmer. Infrared Three Zone Temperature Control provides side-to-side and front-to-rear variation in comfort temperature settings. The Infrared Three Zone Automatic Temperature Control fan provides a continuously variable air flow rate to meet occupant comfort requirements.

1. AUTO HI/LO - This system features 2 sets of automatic control logic that allow either a rapid cool down rate or a somewhat slower cool down rate with less fan noise. HI-AUTO controls the system to reach its assigned temperature quickly with a higher fan speed. LO-AUTO controls the system to reach its assigned temperature somewhat slower with less fan noise. Both modes will automatically engage auto recirculation.
2. DEFROST - The front defrost function is active when the rear window defogger function is active or when the defog/defrost mode is selected.
3. RECIRC - The RECIRC button will close the air inlet door if the system is in auto recirc (indicator being displayed automatically), pressing the manual recirc button will disable the auto recirc function until one of the auto keys are pressed or the ignition is cycled. If Auto HI/LO is pressed while manual recirc is active, manual recirc will be deactivated.
4. REAR WINDOW DEFOGGER - Pushing the button sends a PCI bus message to the Intelligent Power Module which controls the Rear Window Defogger, and side view mirror (if equipped) circuitry. The defogger function will be active for 10 minutes and can be turned off by a switch press. The defogger will function while the control is in the OFF mode.
5. FAN/MODE - The Fan and Mode knobs have 17 manual selectable positions. Manually changing either of the rotary knobs for mode or fan speed settings makes control of that function alone manual for as long as the ignition is on. If only one is changed manually the other remains under automatic control. Pressing the HI-AUTO/LO-AUTO rocker switch restores full automatic control.
6. REAR CONTROL - When the Rear System control knob is moved to the OFF position, there will be a delay of approximately one second before the system actually turns off. This delay is to prevent an undesired blower dropout if the knob is moved through OFF to the other selections.
7. BLOWER DELAY TIMER - The word DELAY is displayed at start-up to signify that the system is waiting so that cold air will not be blowing. This tells the operator that it is unnecessary to turn the system off; raise the temperature setting or turn the fan speed setting down to prevent cold air from blowing. A countdown in minutes and seconds until the engine is warm enough to begin delivering heat to the passengers alternates with the DELAY message at 25 seconds countdown is based on actual measurement of the rate of engine coolant temperature change. During the delay time Defrost mode is selected and the fan operates at a low speed to keep the windshield fog free.

Primary control of the rear compartment unit is in the instrument panel center stack. The rear unit control knob there allows the driver to turn the rear unit off, allow control by the intermediate seat occupants, by switching to the REAR position, or provide fully automatic control based on the temperature setting shown on the, front control display.

1. REAR CONTROL - Selecting automatic control of the rear unit at the instrument panel, illuminates a Locked Padlock in the roar control panel display. Selecting REAR activates the rear control panel and the Padlock then appears unlocked.
2. FAN KNOB - The rear fan control has Off and AUTO positions and a range of manual speed settings that override the AUTO setting.
3. MODE KNOB - The mode control allows intermediate seat occupants to manually override the automatic mode and select any balance of air flow between overhead and floor outlets from full overhead to full floor.
4. SET TEMP - The rear set temp control will operate identical to the front controls. If the front control rear set temp button is pressed simultaneously with the rear control head, then the front control head press events shall have priority, i.e. if the front user presses Rear Set Temp down and the rear user presses Set Temp up, then the rear set temp will decrease.

INFRARED TEMPERATURE SENSOR (FRONT)

The infrared temperature sensor consists of 2 infrared transducers that are concealed behind a clear lens located near the bottom of the center panel outlet near the top of the instrument panel center bezel. (Scheme 7) These sensors are used only on models equipped with the optional Automatic Temperature Control (ATC) HVAC system. A molded plastic connector receptacle on the bottom of the panel outlet unit is concealed behind the center bezel. A short, dedicated jumper wire harness routed behind the center bezel connects the sensors directly to the ATC HVAC control module near the bottom of the center bezel. The infrared temperature sensor is integral to the center bezel panel outlet unit. The infrared sensors cannot be adjusted or repaired and, if faulty or damaged, the center bezel panel outlet unit must be replaced.

The dual infrared temperature sensors provide independent measurement inputs to the Automatic Temperature Control (ATC) HVAC control module that indicates the surface temperature of the driver seat and front seat passenger seat occupants. By using a surface temperature measurement, rather than an air temperature measurement, the ATC system is able to adjust itself to the comfort level as perceived by the occupant. This allows the system to detect and compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor inputs by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the individually selected comfort level temperatures of both the driver and passenger seat occupants. The ATC HVAC control module continually monitors the infrared sensor circuits, and will store a Diagnostic Trouble Code (DTC) for any problem it detects. This DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIII® scan tool.

Scheme 7

INFRARED TEMPERATURE SENSOR (REAR)

The rear infrared temperature sensor, consists of an infrared transducer that is concealed behind the lens of the rear HVAC control in the headliner. This sensor is used only on models equipped with the optional Automatic Temperature Control (ATC) HVAC system. The rear infrared temperature sensor is integral to the rear HVAC control. The infrared sensor cannot be adjusted or repaired and if faulty or damaged, the rear HVAC control unit, must be replaced.

The rear infrared temperature sensor provides an independent measurement input to the Automatic Temperature Control (ATC) HVAC control module that indicates the surface temperature of the rear seat occupants. By using a surface temperature measurement rather than an air temperature Measurement, the ATC system is able to adjust itself to the comfort level as perceived by the occupant. This allows the system to detect and compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor input by calculating and adjusting the air now temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperatures for the rear seat occupants. The ATC HVAC control module continually monitors the infrared sensor circuit, and will store a Diagnostic Trouble Code (DTC) for any problem it detects. Thin DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIII® scan tool.

MODE DOOR ACTUATOR

The mode door actuator is a reversible 12-volt Direct Current (DC), servo motor. (Scheme 8) The single mode door actuator is located on the driver side end of the HVAC housing unit. The mode door actuator is mechanically connected to the mode door. The mode door actuator is interchangeable with the actuators for the blend air door(s) and the recirculation air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. 2 integral mounting tabs allow the actuator to be secured with 2 screws to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the mode door. The mode door actuator does not require mechanical indexing to the mode door linkage, as it is electronically calibrated by the HVAC control module. The mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced.

The mode door actuator is connected to the HVAC control module through the vehicle electrical system by a dedicated 2-wire take out and connector of the HVAC wire harness. The mode door actuator can move the mode door in 2 directions. When the HVAC control module pulls the voltage on one side of the motor connection high and the other connection low, the mode door will move in one direction. When the module reverses the polarity of the voltage to the motor, the mode door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the HVAC control module. This feedback signal allows the module to monitor the operation and relative position of the mode door actuator and the mode door. The HVAC control module learns the mode door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator can be diagnosed using a DRBIII® scan tool. See SELF-DIAGNOSTIC SYSTEM .

Scheme 8

PASSENGER COMPARTMENT AIR FILTER

A passenger compartment air filter is standard equipment on models equipped with the dual zone or 3 zone temperature control systems. (Scheme 9) The filter element is the same size as the front air conditioner evaporator to ensure ample filtering capacity. A removable door on the bottom of the front HVAC housing below the glove box provides easy access to the filter element for replacement. Filter replacement is recommended at 15,000 mile (24,000 kilometer) intervals.

Scheme 9

POWER MODULE (FRONT)

A blower power module is used on this model when it is equipped with the optional Automatic Temperature Control (ATC). (Scheme 10) Models equipped with the standard manual HVAC control use a blower motor resistor instead of the blower power module. The blower power module is installed in a mounting hole in the evaporator housing, directly behind the glove box opening of the instrument panel. The module consists of a molded plastic mounting plate with 2 integral connector receptacles. Concealed behind the mounting plate within the evaporator housing is the power module electronic circuitry and a large finned, heat sink. The module mounting plate is secured with 2 screws to the evaporator housing and is accessed for service by rolling down the glove box from the instrument panel. The power module heat sink will get hot when in use, Do not touch the heat sink if the blower motor has been running. The blower power module cannot be adjusted or repaired and if faulty, or damaged, it must be replaced.

The blower power module is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A second connector receptacle receives the pigtail wire connector from the blower motor. The blower power module allows the microprocessor based Automatic Temperature Control (ATC) HVAC control module to calculate, and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the blower motor relay to change or maintain the desired blower speed. The blower power module is diagnosed using a DRBIII® scan tool.

Scheme 10

POWER MODULE (REAR)

A blower power module is used on this model when it is equipped with the optional Automatic Temperature Control (ATC). (Scheme 11) Models equipped with the standard manual HVAC control use a blower motor resistor, instead of the blower power module. The blower power module is installed in a mounting hole in the back of the rear HVAC unit housing, directly above the expansion valve. The module consists of a molded plastic mounting plate with 2 integral connector receptacles. Concealed behind the mounting plate within the evaporator, housing is the power module electronic circuitry and a large finned, heat sink. The module mounting plate is secured with 2 screws to, the rear HVAC unit housing and is accessed for service by removing the right quarter and D-pillar trim panels. The power module heat sink will get hot when in use. Do not touch the heat sink if the blower motor has been running. The blower power module cannot be adjusted or repaired and if faulty or damaged, it must be replaced.

The blower power module is connected to the vehicle electrical system through a dedicated take out and connector of the rear HVAC wire harness. A second connector receptacle receives the pigtail wire connector from the blower motor. The blower power module allows the microprocessor based Automatic Temperature Control (ATC) HVAC control module to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the blower motor relay to change or maintain the desired blower speed. The blower power module is diagnosed using a DRBIII® scan tool.

Scheme 11

PRESSURE TRANSDUCER

The A/C pressure transducer (Scheme 12), is a switch that is installed on a fitting located on the refrigerant liquid line between the filter drier and the expansion valve in the right rear corner of the engine compartment. An internally threaded hex fitting on the transducer connects it to the externally threaded Schrader type fitting on the liquid line. A rubber O-ring seals the connection between the transducer and the liquid line fitting. Three terminals within a molded plastic connector receptacle on the top of the transducer connect it to the vehicle electrical system through a take out and connector of the headlamp and dash wire harness. The A/C pressure transducer cannot be adjusted or repaired and if faulty or damaged, it must be replaced.

The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the liquid line. The transducer will change its internal resistance in response to the pressures it monitors. The Powertrain Control Module (PCM) provides a 5 volt reference signal and a sensor ground to the transducer then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM is programmed to respond to this and other sensor inputs by controlling the operation of the air conditioning compressor clutch and the radiator cooling fan to help optimize air conditioning system performance and to protect the system components from damage. The A/C pressure transducer input to the PCM will also prevent the air conditioning compressor clutch from engaging when ambient temperatures are below about 50°F (10°C) due to the pressure/temperature relationship of the refrigerant. The Schrader type valve in the liquid line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the system. The A/C pressure transducer is diagnosed using a DRBIII® scan tool. See SELF-DIAGNOSTIC SYSTEM .

Scheme 12

RECEIVER-DRIER

The filter-drier is mounted in a bracket secured to the right front strut tower in the engine compartment. The filter-drier is connected between the front and rear sections of the liquid line between the condenser outlet and the evaporator inlet. The filter-drier cannot be repaired. If the filter-drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period, it must be replaced.

The filter-drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve. A desiccant bag is mounted inside the filter-drier canister to absorb any moisture which may have entered and become trapped within the refrigerant system. In addition during periods of high demand air conditioner operation, the filter-drier acts as a reservoir to store surplus refrigerant. Refrigerant enters the filter-drier as a high-pressure, low temperature liquid.

RECIRCULATION DOOR ACTUATOR

The recirculation door actuator is a reversible 12-volt Direct Current (DC), servo motor. (Scheme 13) The single recirculation door actuator is located on the passenger side end of the HVAC housing unit, on the bottom of the lower intake air housing. The recirculation door actuator is mechanically connected to the recirculation air door. The recirculation door actuator is interchangeable with the actuators for the blend air door(s) and the mode door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Two integral mounting tabs allow the actuator to be secured with 2 screws to the lower intake air housing. Each actuator also has an identical output shaft with splines that connects it to the linkage that drives the recirculation air door. The recirculation door actuator does not require mechanical indexing to the recirculation air door, as it is electronically calibrated by the HVAC control module. The recirculation door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced.

The recirculation door actuator is connected to the HVAC control module through the vehicle electrical system by a dedicated 2 wire take out and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation door in 2 directions. When the HVAC control module pulls the voltage on one side of the motor connection high and the other connection low, the recirculation air door will move in one direction. When the module reverses the polarity of the voltage to the motor, the recirculation air door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. These same motor connections also provide a feedback signal to the HVAC control module. This feedback signal allows the module to monitor the operation and relative position of the recirculation door actuator and the recirculation air door. The HVAC control module learns the recirculation air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator can be diagnosed using a DRBIII® scan tool. See SELF-DIAGNOSTIC SYSTEM .

Scheme 13

UNDERBODY LINES

The rear HVAC unit plumbing is used only on models with the optional rear HVAC Unit. The formed metal rear HVAC unit suction line, liquid line, and heater lines are available for separate service replacement. The molded and straight heater hoses used on the rear HVAC unit can be serviced in the vehicle.

The rear HVAC lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contamination that can get in to the system. (Scheme 14)- (Scheme 18).

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

COMPONENT LOCATION

COMPONENT LOCATION

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

HVAC CONTROL CALIBRATION

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

1. Turn the ignition switch to the On position.
2. Simultaneously depress and hold the Power and Recirculation buttons on the HVAC control for at least 5 seconds. The manual HVAC control power Light Emitting Diode (LED) and Recirculation LED, or the Automatic Temperature Control (ATC) HVAC control Delay and Recirculation graphics will begin to flash when the calibration procedure has begun.
3. The calibration procedure should take less than 2 minutes to complete for the manual HVAC control and less than 20 seconds for the ATC HVAC control. When the LEDs or graphics stop flashing, the calibration procedure is complete.
4. If the LEDs or graphics continue to flash beyond the normal 3 minute (manual) or 20 second (ATC) calibration time, it indicates that the HVAC control has detected a failure and a Diagnostic Trouble Code (DTC) has been set. Use a DRBIII® scan tool to perform further diagnosis. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . The LEDs 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 kilometers).

PRELIMINARY INSPECTION

Verify customers complaint. Before performing any testing, perform a visual inspection. Check system fuses. Check connectors for loose, damaged or corroded terminals. Check for damaged wiring harness. Check for damaged or binding actuator cable. If area of fault cannot be located or repaired during preliminary inspection, check self-diagnostic system. See SELF-DIAGNOSTIC SYSTEM . Repair as necessary.

If no problem is found, attempt diagnosis by symptom. See SYMPTOM TESTS .

A/C PERFORMANCE

Note. When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection.

An air conditioning performance test is the best way to determine whether the system is performing up to standard. This test also provides valuable clues as to the possible cause of trouble with the air conditioning system. The ambient air temperature in the location where the vehicle will be tested must be a minimum of 70°F (21°C) for this test.

1. Connect a tachometer to monitor the engine speed.
2. Remove the caps from the refrigerant system service ports and attach a manifold gauge set to monitor the refrigerant system pressures.
3. Set the HVAC controls so that the compressor is engaged, the air within the vehicle is being recirculated, the output air is directed through the panel outlets, the temperature control is in the full cool position and the blower motor is operating at its highest speed.
4. Start the engine and allow the engine to operate for about 5 minutes or until it reaches normal operating temperature. Then hold the engine speed at 1000 RPM with the compressor clutch engaged. If the compressor clutch does not engage, proceed with diagnosis of the compressor clutch coil. See «COMPONENT TESTS»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
5. Close all the vehicle windows and doors.
6. Insert a thermometer in the left center panel outlet and operate the engine for 5 minutes.
7. With the compressor clutch engaged, record the left center panel outlet discharge air temperature, the discharge pressure (high side service port), and the suction pressure (low side service port). The compressor clutch may cycle, depending upon the ambient temperature and humidity. If the clutch cycles, use the readings obtained before the clutch disengaged.
8. Compare the discharge air temperature reading to the performance temperature and pressure chart. (Scheme 29) If the temperature reading is high, check the refrigerant system for leaks and proper refrigerant charge level. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Scheme 29

HEATER PERFORMANCE (FRONT)

Check the coolant level, drive belt tension, radiator air flow, and cooling fan operation. Start the engine and allow it to warm up to normal temperature.

Maximum Heater Output

Engine coolant is provided to the heater system by two 5/8 inch (16 mm) inside diameter heater hoses. With the engine idling at normal running temperature, set the HVAC controls as follows. Temperature control to full Heat, Mode control to Floor, Blower control to the highest speed setting. Using a test thermometer, check the air temperature coming from the center floor outlets and compare this reading to the Temperature Reference table. See PERFORMANCE TEMPERATURE & PRESSURE .

If the floor outlet air temperature is insufficient, check that the cooling system is operating to specifications. Both heater hoses should be HOT to the touch (the coolant return hose should be slightly cooler than the supply hose). If the coolant return hose is much cooler than the supply hose, locate and repair the engine coolant flow obstruction in heater system.

PERFORMANCE TEMPERATURE & PRESSURE

Possible Location Or Cause Of Obstructed Coolant Flow

1. Pinched or kinked heater hoses.
2. Improper heater hose routing.
3. Plugged heater hoses or supply and return ports at cooling system connections.
4. Plugged heater core.
5. Air locked heater core.
6. Restrictor in backwards.

If coolant flow is verified and the heater floor outlet temperature is insufficient, a mechanical problem may exist.

Possible Location Or Cause Of Insufficient Heat

1. Obstructed cowl air intake.
2. Obstructed heater system outlets.
3. Blend air door not functioning properly.

Temperature Control

If heater floor outlet temperature cannot be adjusted with the HVAC control temperature control lever, one of the following could require service

1. Blend air door binding.
2. Faulty blend air door motor.
3. Improper engine coolant temperature.
4. Faulty HVAC control.

HEATER PERFORMANCE (REAR)

Successful completion of the rear heater performance check will confirm that the rear heater core is properly filled with engine coolant. If the check is not successful, either there is still air trapped in the rear heater core or the rear heater plumbing is restricted. This check should be performed with the vehicle in a shop where the ambient temperature is about 70°F (21°C).

1. Start the engine and allow it to idle until it warms up to normal operating temperature.
2. Adjust the HVAC controls so that the front heater is turned Off, the rear heater is set for full Heat, and the rear blower motor is at its highest speed setting.
3. Use an accurate test thermometer to measure the temperature of the air being discharged from the rear heater outlet located at the base of the right C-pillar.
4. Proper discharge air temperature readings should be from 135° to 145°F (57° to 63°C).

RETRIEVING DIAGNOSTIC TROUBLE CODES

Using scan tool, retrieve DTCs. If DTCs are present, see DIAGNOSTIC TESTS . Diagnose and repair as necessary. After repairs, clear DTCs. If no DTCs are present, attempt diagnosis by symptom. See SYMPTOM TESTS .

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS

CLEARING DIAGNOSTIC TROUBLE CODES

To clear DTCs, follow scan tool manufacturers instructions.

SUMMARY

If no hard DTCs are present, and driveability symptoms or intermittent DTCs exist, attempt diagnosis by symptom, or by testing individual components related to system fault. See TROUBLE SHOOTING and/or COMPONENT TESTS . If no problem is found, verify proper system operation. See PERFORMANCE TESTS .

Note. Always clear DTCs once repairs are complete. See CLEARING DIAGNOSTIC TROUBLE CODES . Road test vehicle and retrieve DTCs to determine if complaint or DTC is repaired.

DIAGNOSTIC TESTS

Note. For diagnostic tests, see appropriate SELF DIAGNOSIS article in ENGINE PERFORMANCE or appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

Note. For circuit reference, see WIRING DIAGRAMS .

A/C COOL DOWN TEST

The HVAC control module can perform an A/C cool down test, which is a test performed daring the manufacturing process to confirm that the air conditioning system is performing satisfactorily. This test can also provide a quick confirmation of air conditioning system performance to the service technician. If the test is completed satisfactorily, no further service is required. If the test is failed, see PERFORMANCE TESTS , to confirm the A/C system is operating properly, or use a DRBIII® scan tool to diagnose the A/C system control and distribution systems. See SELF-DIAGNOSTIC SYSTEM .

Manual Temperature Control

The front blower speed and rear blower speed (if equipped with rear HVAC) must be set to High and the evaporator temperature sensor, must be greater than 55°F (12.7°C) or the test will fail immediately. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than 5 seconds. The PWR and A/C LEDs will blink on and off until the test is complete. If the LEDs stop blinking before 2 minutes, then the cool down test has been completed successfully. If the 2 minutes expire without the expansion valve temperature reaching 20°F (-6.6°C) less than the outside air temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the LEDs will continue to blink until the vehicle has been driven for greater than 8 miles.

Automatic Temperature Control

The ambient air temperature in the room where the vehicle will be tested must be a minimum of 70°F (21°C) for this test. The test is activated by depressing the A/C and PWR buttons simultaneously and holding them depressed for no less than 4 seconds. The snowflake icon and the DELAY text in the ATC display will blink on and off alternately until the test is complete, If the snowflake icon and the DELAY text stop blinking before 2 minutes, then the cool down test has been completed successfully. If the 2 minutes expire without the evaporator temperature reaching 20°F (-6.6°C) less than the evaporator initial temperature, then the cool down test has been failed and further A/C system diagnosis is required. If the test is failed, the snowflake icon and the DELAY text will continue to blink across ignition cycles until the vehicle has been driven for greater than 8 miles.

BODY VERIFICATION TEST-VER. 1

1. Disconnect all jumper wires and reconnect all previously disconnected components and connectors.
2. With the DRBIII®, record and erase all DTCs from ALL modules. Cycle the ignition on then off.
3. If the Sentry Key Immobilizer Module (SKIM), the Powertrain Control Module (PCM), or the Engine Control Module (ECM) was replaced, proceed to Step 12 . If the SKIM, PCM, or ECM was not replaced, continue to the next step.
4. If the Body Control Module (ECM) was replaced, turn the ignition on for 15 seconds (to allow the new BCM to learn VIN) or engine may not start (if VTSS equipped). If the vehicle is equipped with VTSS, use the DRBIII® and enable VTSS.
5. Program all other options as needed.
6. If any actuators were replaced in the HVAC System with the DRBIII® in HVAC, select System bests then select HVAC Door Recuperation (manual temperature system only).
7. If any actuators were replaced in the ATC System, with the DRBIII® in Automatic Temp Control, select Miscellaneous then select Reset ATC Head.
8. For 3 Zone HVAC Systems, if HVAC Control/Rear Blower Rear Control was replaced/Rear Blend Pot Circuit Open/Short DTC was set/any rear blend pot circuit was repaired, proceed to step 9 & 10 . Otherwise, proceed to step 11 .
9. With DRBIII® in HVAC, select System Tests then select HVAC Door Recuperation. Door Recuperation must pass before proceeding to next step.
10. With DRBIII® in HVAC, select System Tests then select Reset Rear Blend Switch Span. Rotate Rear Blend/Mode control on Rear Blower Rear Control to full cold. Wait 5 seconds, then rotate control to full hot.
11. If any repairs were made to the power sliding door or power liftgate, use the DRBIII® and perform the open and close system tests. Observe the instructions on the DRBIII® screen. Proceed to step 16 .
12. Obtain the vehicles unique PIN assigned to its original SKIM from either the vehicles invoice or from Chryslers Customer Assistance Center (1-800-992-1997).
13. Once Secured Access Mode is active, the SKIM will remain in that mode for 60 seconds.
14. With the DRBIII®, select THEFT ALARM, SKIM, MISCELLANEOUS and select SKIM REPLACED. Enter the 4 digit PIN to put the SKIM in Secured Access Mode.
15. The DRBIIII® will prompt for the following steps. Program the country code into the SKIMS memory. Program the vehicles VIN into the SKIM memory. Transfer the vehicles Secret Key data from the PCM.
16. Using the DRBIII®, program all customer keys into the SKIM memory. This requires that the SKIM be in Secured Access Mode, using the 4 digit PIN.
17. Note: If the PCM or ECM is replaced, the VIN and the unique Secret Key data must be transferred from the SKIM to the PCM or ECM. This procedure requires the SKIM to be placed in Secured Access Mode using the 4-digit PIN.
18. Note: If 3 attempts are made to enter Secured Access Mode using an incorrect PIN, Secured Access Mode will be locked out for one hour which causes the DRBIII® to display "No Deep from SKIM". To exit this mode, turn ignition to Run for one hour.
19. Ensure that all accessories are turned off and the battery is fully charged.
20. Start and run the engine for 2 minutes. Operate all functions of the system that caused the original concern.
21. Turn the ignition off and wait 5 seconds. Turn the ignition on and using the DRBIII®, read DTCs from ALL modules. Are any DTCS present or is the original condition still present? If Yes, repair is not complete, refer to the appropriate symptom. See «SYMPTOM TESTS»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__symptom-tests) . If No, repair is complete.

SYMPTOM TESTS

Note. For circuit reference, see WIRING DIAGRAMS .

SYMPTOM TEST DIRECTORY

BLOWER MOTOR NOISE/VIBRATION DIAGNOSIS

Note. For circuit reference, see WIRING DIAGRAMS .

Scheme 30

Note. For circuit reference, see WIRING DIAGRAMS .

Blower Motor Inoperative

1. Check the fuse (Fuse 10-40 ampere), in the Intelligent Power Module (IPM). If okay, go to step 2 . If not okay, repair the shorted circuit or component as required and replace the faulty fuse.
2. Turn the ignition switch to the On position. Be certain that the HVAC control power is turned on. Check for battery voltage at the fuse (Fuse 10-40 ampere) in the IPM. If okay, go to step 3 . If not okay, proceed to diagnosis of the front blower motor relay. See «BLOWER MOTOR RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
3. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Disconnect the front HVAC wire harness connector for the front blower motor resistor (Manual Temperature Control) or the front blower power module (Automatic Temperature Control) from the resistor or module connector receptacle. Reconnect the negative battery cable. Turn the ignition switch to the On position. Be certain that the HVAC control power is turned on. Check for battery voltage at the fused front blower motor relay output circuit cavity of the front HVAC wire harness connector for the front blower motor resistor (MTC) or the front blower power module (ATC). If okay go to step 4 . If not okay, repair the open fused front blower motor relay output circuit to the IPM as required.
4. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Disconnect the front blower motor pigtail wire connector from the connector receptacle of the front blower motor resistor (MTC) or the front blower power module (ATC). Use jumper wires to connect a battery and ground feeds to the blower motor pigtail wire connector. The blower motor should operate. If okay with ATC, use a DRBIII® scan tool to diagnose the front blower power module. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . If okay, replace the faulty front blower motor.

Note. For circuit reference, see WIRING DIAGRAMS .

1. Check Fuse No. 12 (25 ampere) in the Intelligent Power Module (IPM). If okay, go to step 2 . If not okay, repair the shorted circuit or component as required and replace the faulty fuse.
2. Turn the ignition switch to the On position. Be certain that rear HVAC control power is turned on. Check for battery voltage at Fuse No. 12 (25 ampere) in the IPM. If okay, go to step 3 . If not okay, proceed to diagnosis of the rear blower motor relay. See «BLOWER MOTOR RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
3. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Disconnect the rear HVAC wire harness connector for the rear blower motor resistor (Manual Temperature Control) or the rear blower power module (Automatic Temperature Control) from the resistor or module connector receptacle. Reconnect the negative battery cable. Turn the ignition switch to the On position. Be certain that the rear HVAC control power is turned on. Check for battery voltage at the fused rear blower motor relay output circuit cavity of the rear HVAC wire harness connector for the rear blower motor resistor (MTC) or the rear blower power module (ATC). If okay, go to step 4 . If not okay, repair the open fused front blower motor relay output circuit to the IPM as required.
4. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Disconnect the rear blower motor pigtail wire connector from the take out and connector of the rear HVAC wire harness (MTC) or the connector receptacle of the rear blower power module (ATC). Use jumper wires to connect a battery and ground feeds to the blower motor pigtail wire connector. The blower motor should operate. If okay with ATC, use a DRBIII® scan tool to diagnose the rear blower power module. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . If not okay, replace the faulty rear blower motor. See «BLOWER MOTOR (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.

Note. For circuit reference, see WIRING DIAGRAMS .

The blower motor relay (Scheme 31), is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for front blower motor relay identification and location. Remove the relay from the IPM to perform the following tests

1. A relay in the de-energized position should have continuity between relay terminals No. 87A and 30, and no continuity between relay terminals No. 87 and 30. If okay, go to step 2 . If not okay, replace the faulty relay. See «BLOWER MOTOR RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
2. Resistance between relay terminals No. 85 and 86 (electromagnet) should be 70-80 ohms. If okay, go to step 3 . If not okay, replace the faulty relay. See «BLOWER MOTOR RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
3. Connect a battery to relay terminals No. 85 and 86. There should now be continuity between relay terminals 30 and 87, and no continuity between relay terminals No. 87A and 30. If okay, use a DRBIII® scan tool to perform further diagnosis of the relay circuits. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . If not okay, replace the faulty relay. See «BLOWER MOTOR RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.

Scheme 31

Note. For circuit reference, see WIRING DIAGRAMS .

Note. Prior to a vehicle being removed from service or stored for more than 2 weeks, the compressor should be operated to ensure adequate refrigerant oil distribution throughout the system components. Turn on the air conditioner for a minimum of 5 minutes with outside air and the highest blower speed selected.

Noise Diagnosis

Excessive noise while the air conditioning compressor is operating can be caused by loose compressor mounts, a loose compressor clutch, or high operating pressures in the refrigerant system. Verify compressor drive belt condition, proper compressor mounting, correct refrigerant charge level, and compressor head pressure before compressor repair is performed. With the close tolerances within the compressor, it is possible to experience a temporary lockup. The longer the compressor is inactive, the more likely the condition is to occur. This condition is the result of normal refrigerant migration within the refrigerant system caused by ambient temperature changes. The refrigerant migration may wash the refrigerant oil out of the compressor.

Belt Noise

If the compressor drive belt slips at initial start-up, it does not necessarily mean the compressor has failed. The following procedure can be used to identify a compressor drive belt noise problem.

1. Start the vehicle and run at idle.
2. Turn the air conditioner On and listen for belt squeal.
3. If belt squeal is heard, turn the air conditioner Off immediately. If the belt squeal stops when the air conditioner is turned Off, perform the following repair procedures.

1. Using an appropriate sized oil filter wrench or a strap wrench, grasp the outer diameter of the compressor clutch hub. While facing the compressor, rotate the hub clockwise, then counterclockwise. If the hub rotates proceed to the next step. If the hub will not rotate, the compressor is internally damaged and must be replaced.
2. Turn the hub clockwise 5 complete revolutions and remove the tool.
3. Start the vehicle and run at idle.
4. Turn the air conditioning On. Observe the compressor and the system for normal operation, noting cooling performance and noise levels. Operate for 5 minutes before turning the air conditioning Off. If acceptable cooling performance is observed during compressor operation, the compressor does not need to be replaced.
5. Inspect the drive belt for wear, damage, and proper tension.

COMPRESSOR CLUTCH COIL

Note. For circuit reference, see WIRING DIAGRAMS .

The air conditioning compressor clutch coil electrical circuit is controlled by the Powertrain Control Module (PCM) through the compressor clutch relay, which is located in the Intelligent Power Module (IPM) in the engine compartment near the battery. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks.

Preliminary Checks

1. If the compressor clutch will not engage, verify the refrigerant charge level. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. If the refrigerant charge level is okay, go to step 2 . If the refrigerant charge level is not okay, adjust the refrigerant charge as required.
2. If the A/C compressor clutch still will not engage, disconnect the headlamp and dash wire harness connector for the A/C pressure transducer and check for battery current at the connector with the engine running and the HVAC control set to the A/C mode. If okay, go to «Tests»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__diagnostic-procedure) . If not okay, use a DRBIII® scan tool to perform further diagnosis. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .

Diagnostic Procedure

1. Ensure that battery is fully charged.
2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil.
3. With the HVAC control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed.
4. The compressor clutch should engage immediately, and the clutch coil voltage should be within 2 volts of the battery voltage. If the coil voltage is not within 2 volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop. If the compressor clutch does not engage, use a DRBIII® scan tool to perform further diagnosis. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
5. With the ambient temperature at 70°F (21°C), the compressor clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5 to 12.5 volts at the clutch coil. If the voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until the voltage reads below 12.5 volts. If the compressor clutch coil current reading is zero, the coil is open and must be replaced. If the compressor clutch coil current reading is 4 amperes or more, the coil is shorted and must be replaced.

Note. For circuit reference, see WIRING DIAGRAMS and (Scheme 4).

The compressor clutch relay (Scheme 4), is located in the Intelligent Power Module (IPM), which is in the engine compartment near the battery. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. Remove the relay from the IPM to perform the following tests

1. A relay in the de-energized position should have continuity between terminals No. 87A and 30, and no continuity between terminals No. 87 and 30. If okay go to step 2 . If not okay, replace the faulty relay. See «COMPRESSOR CLUTCH RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
2. Resistance between terminals No. 85 and 86 (electromagnet) should be 70-80 ohms. If okay, go to step 3 . If not okay, replace the faulty relay. See «COMPRESSOR CLUTCH RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
3. Connect a battery to terminals No. 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals No. 87A and 30. If okay, use a DRBIII® scan tool to perform further diagnosis of the relay circuits. See «SELF-DIAGNOSTIC SYSTEM»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . If not okay, replace the faulty relay. See «COMPRESSOR CLUTCH RELAY»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.

EXPANSION VALVE

Note. The expansion valve should only be tested following testing of the compressor.

Note. Liquid CO is required to test the expansion valve. This material is available from most welding supply facilities. Liquid CO is also available from companies which service and sell fire extinguishers.

When testing the expansion valve, the work area and the vehicle temperature must be 70° to 85°F (21° to 27°C). To test the expansion valve

1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level.
2. Close all doors, windows and vents to the passenger compartment.
3. Set the HVAC conditioner controls so that the compressor is operating the temperature control is in the highest temperature position the mode door is directing the output to the floor outlets and the blower is operating at the highest speed setting.
4. Start the engine and allow it to idle at 1000 RPM. After the engine has reached normal operating temperature allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator.
5. If the refrigerant charge is sufficient the discharge (high pressure) gauge should read 140 to 240 psi (965 to 1655 kPa). The suction (low pressure) gauge should read 20 to 30 psi (140 kPa to 207 kPa). If okay, go to step 6 . If not okay, replace the faulty expansion valve. See «EXPANSION VALVE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) or «EXPANSION VALVE (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
6. If the suction (low pressure) gauge reads within the specified ranges freeze the expansion valve control head for 30 seconds using liquid CO or another suitable super cold material. Do not spray R-134a or R-12 refrigerant on the expansion valve control head for this test. The suction (low pressure) gauge reading should drop by 10 psi. If okay, go to step 7 . If not okay, replace the faulty expansion valve. See «EXPANSION VALVE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) or «EXPANSION VALVE (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
7. Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 20 to 30 psi (140 kPa to 240 kPa). If not okay, replace the faulty expansion valve. See «EXPANSION VALVE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) or «EXPANSION VALVE (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) under REMOVAL & INSTALLATION.
8. When expansion valve testing is complete, test the overall air conditioner performance. See «A/C PERFORMANCE»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__ac-performance) under PERFORMANCE TESTS.

Note. For circuit reference, see WIRING DIAGRAMS .

The A/C pressure transducer is tested using a DRBIII® scan-tool. See SELF-DIAGNOSTIC SYSTEM . Before testing the A/C pressure transducer, be certain that the transducer wire harness connection is clean of corrosion and properly connected. For the air conditioning system to operate, an A/C pressure transducer voltage reading between 0.451 and 4.519 volts is required. Voltages outside this range indicates a low or high refrigerant system pressure condition to the Powertrain Control Module (PCM). The PCM is programmed to respond to a low or high refrigerant system pressure by suppressing operation of the compressor. See for the possible condition indicated by the transducer voltage.

A/C PRESSURE TRANSDUCER VOLTAGE

REMOVAL & INSTALLATION

Note. For removal and installation procedures not covered in this article, see COMPRESSOR SERVICING article in GENERAL SERVICING.

Removal

The single zone HVAC system is equipped with a single blend door actuator. The dual zone system has 2 blend door actuators, one for the driver side blend air door and one for the passenger side blend air door. The same service procedures can be used for each of these actuators.

1. Disconnect and isolate the negative battery cable. Remove the silencer from beneath the driver side end of the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
2. Remove the 3 screws that secure the heater core shield to the left end of the HVAC housing. (Scheme 32) Pull the heater core shield rearward far enough to disengage the 2 location tabs that position the front of the shield to the receptacles in the 2 lower finger formations of the HVAC housing near the dash panel.
3. Remove the heater core shield from the HVAC housing. Disconnect the HVAC wire harness connector for the blend door actuator from the actuator connector receptacle. (Scheme 8)
4. Remove the 2 screws that secure the blend door actuator to the HVAC housing. Remove the blend door actuator from the HVAC housing.

Scheme 32

Installation

1. Position the blend door actuator onto the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. Install and tighten the 2 screws that secure the blend door actuator to the HVAC housing.
2. Reconnect the HVAC housing wire harness connector for the blend door actuator to the actuator connector receptacle. Position the heater core shield onto the HVAC housing. Be certain that the 2 location tabs on the front of the shield are engaged in the receptacles in the 2 lower finger formations of the evaporator housing near the dash panel.
3. Install and tighten the 3 screws that secure the heater core shield to the left end of the HVAC housing. Reinstall the silencer under the driver side end of the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
4. Reconnect the negative battery cable. Perform the HVAC control calibration procedure.

1. Disconnect and isolate the negative battery cable. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
2. Remove the 2 screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
3. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the blend door actuator. (Scheme 1)
4. Remove the 2 screws that secure the blend door actuator to the rear HVAC housing. Pull the blend door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the blend air door pivot.
5. Raise the blend door actuator far enough to access and disconnect the rear HVAC wire harness connector for the actuator from the actuator connector receptacle. Remove the blend door actuator from between the rear HVAC housing and the quarter inner panel.

1. Position the blend door actuator between the rear HVAC housing and the quarter inner panel.
2. Reconnect the rear HVAC housing wire harness connector for the blend door actuator to the actuator connector receptacle.
3. Position the blend door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door pivot.
4. Install and tighten the 2 screws that secure the blend door actuator to the rear HVAC housing.
5. Push the top of the rear HVAC housing back into position against the right quarter inner panel.
6. Install and tighten the screw that secures the front of the rear HVAC housing to the right quarter inner panel.
7. Install and tighten the 2 screws that secure the back of the rear HVAC housing unit housing to the right D-pillar.
8. Install and tighten the 2 screws the secure the top of the quarter trim panel attaching the bracket to the quarter inner panel.
9. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel.
10. Reconnect the negative battery cable.
11. Preform the HVAC control calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.

1. Disconnect the blower motor pigtail harness connector from the connector receptacle of either the blower motor resistor or power module, depending how vehicle is equipped. (Scheme 23) Remove the lower right trim panel and roll back the carpet.
2. Remove front HVAC Housing from the vehicle. See «HVAC HOUSING (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
3. Remove the 2 screws that secure the recirculation door actuator and disengage the wire harness from the routing clips molded into the bottom of the lower air intake housing. Remove the one screw (from the top) that secures the lower air intake housing to the upper air intake housing.
4. Remove the 4 screws (from the bottom) that secures the lower air intake housing to the lower half of the evaporator housing and the upper air intake housing. Push the rubber grommet on the blower motor pigtail wires through the hole to the lower intake air housing. (Scheme 33)
5. Feed the blower motor pigtail wires and electrical connector through the grommet hole in the lower intake air housing. Relocate the recirculation air door as necessary to access and remove the 3 screws that secure the blower motor to the blower housing in the lower half of the evaporator housing. (Scheme 2)
6. Gently flex the recirculation air door far enough to remove the blower motor and blower wheel from the blower housing in the lower half of the evaporator housing.

Scheme 33

The blower motor and blower wheel are serviced only as a balanced unit. If either component is faulty or damaged the entire unit must be replaced.

1. Gently flex the recirculation air door far enough to position the blower motor and blower wheel into the blower housing in the lower half of the evaporator housing.
2. Install and tighten the 4 screws that secure the blower motor to the blower housing in the lower half of the evaporator housing. Feed the blower motor pigtail wires and electrical connector through the grommet hole in the lower intake air housing and seat the rubber grommet.
3. Position the upper pivot of the recirculation door into the opening at the top of the air inlet housing and hold in place while the lower air inlet housing is placed in position.
4. Install and tighten the 3 screws (from the bottom) that secure the lower air intake housing to the lower half of the evaporator housing. Install and tighten the one screw that secures the upper intake air housing to the lower intake air housing.
5. Install the recirculation actuator making certain that the splines are aligned and secure the actuator with 2 screws and tighten. Route the wiring into the molded in routing clips.
6. Position the carpet into location and install the lower right trim panel. Connect the blower motor pigtail wire harness electrical connector back into either the power module or resistor receptacle.
7. Perform the HVAC Calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.
8. Perform the HVAC Control Cool Down Test. See «A/C COOL DOWN TEST»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__ac-cool-down-test) under PERFORMANCE TESTS.
9. Install the HVAC housing. See «HVAC HOUSING (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .

BLOWER MOTOR (FRONT) - LATE PRODUCTION WITHOUT HVAC HOUSING REMOVAL

Note. The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing.

Scheme 34

Scheme 35

1. Disconnect and isolate the battery negative cable.
2. Remove the passenger side door sill plate and cowl panel.
3. Pull back the carpet to access the front upper screw that secures air inlet housing.
4. Remove the recirculation door actuator (Refer to «RECIRCULATION DOOR ACTUATOR»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) ).
5. Disconnect the blower motor pigtail harness connector from the blower motor resistor block or power module, depending how vehicle is equipped.
6. Remove the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing (Scheme 34)
7. Remove the four screws (from the bottom) that secure the lower air inlet housing to the lower HVAC housing and upper air inlet housing.
8. Push the rubber grommet on the blower motor pigtail through the hole in the lower air inlet housing (Scheme 35)
9. Feed the blower motor pigtail and electrical connector through the opening in the lower air inlet housing and remove lower air inlet housing from vehicle.
10. Relocate the recirculation air door as necessary to access and remove the three screws that secure the blower motor to the lower half of the HVAC housing.
11. Gently flex the recirculation air door far enough to remove the blower motor and blower wheel from the housing.
12. Remove the blower motor from the housing by rotating and tilting blower motor as necessary. Note the position of the blower motor mounting tabs (Scheme 36)

1. Position the blower motor to the HVAC housing. Align the blower motor mounting tabs to the proper tabs on the housing.
2. Gently flex the recirculation air door far enough to position the blower motor and wheel into the lower half of the HVAC housing.
3. Install the three screws that secure the blower motor to the lower half of the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
4. Feed the blower motor pigtail and electrical connector through the grommet hole in the lower air inlet housing and seat the rubber grommet.
5. Position the recirculation door into the lower air inlet housing.
6. Install the four screws (from the bottom) that secure the lower air inlet housing to the lower HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
7. Install the one screw (from the top) that secures the lower air inlet housing to the upper air intake housing. Tighten the screws to 2 N.m (17 in. lbs.).
8. Connect the blower motor pigtail harness connector to the blower motor resistor block or power module, depending how vehicle is equipped.
9. Install the recirculation door actuator (Refer to «RECIRCULATION DOOR ACTUATOR»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) ).
10. Install the recirculation door actuator wire harness lead into the routing clip on the lower air inlet housing.
11. Reinstall the carpet.
12. Install the passenger side door sill plate and cowl panel.
13. Reconnect the battery negative cable.
14. Perform the heater-A/C control calibration procedure (Refer to «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) ).

The rear blower motor and blower wheel are serviced only as a balanced unit. If either component is faulty or damaged, the entire unit must be replaced.

1. Remove the rear HVAC housing from the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
2. Disconnect the rear blower motor pigtail wire connector. With manual temperature control the blower pigtail wire is connected to a take out and connector of the rear HVAC housing wire harness. With automatic temperature control the blower pigtail wire is connected to a receptacle on the blower power module.
3. Remove the 3 screws that secure the blower motor to the outboard side of the rear HVAC housing. (Scheme 3) Remove the blower motor and blower wheel from the rear HVAC housing.

1. Position the blower motor and blower wheel onto the outboard side of the rear HVAC housing.
2. Install and tighten the 3 screws that secure the blower motor to the rear HVAC housing.
3. Reconnect the rear blower motor pigtail wire connector. With manual temperature control the blower pigtail wire is connected to a take out and connector of the rear HVAC housing wire harness. With automatic temperature control the blower pigtail wire is connected to a receptacle on the blower power module.
4. Reinstall the rear HVAC housing into the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .

1. Disconnect and isolate the negative battery cable. Unlatch and remove the cover from the Intelligent Power Module (IPM). (Scheme 37)
2. See the fuse and relay layout map molded into the inner surface of the IPM cover for front blower motor relay identification and location. Remove the front blower motor relay from the IPM by pulling the relay straight up.

Scheme 36

1. See the fuse and relay layout map molded into the inner surface of the Intelligent Power Module (IPM) cover for front blower motor relay identification and location. Position the front blower motor relay to the proper receptacle in the IPM.
2. Align the front blower motor relay terminals with the terminal cavities in the IPM relay receptacle. Push down firmly on the front blower motor relay until the terminals are fully seated in the terminal cavities in the IPM receptacle.
3. Install and latch the cover onto the IPM. Reconnect the negative battery cable.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Disconnect and isolate the negative battery cable. Remove the nut that secures the suction line fitting to the top of the compressor.
3. Disconnect the suction line fitting from the compressor suction port. Remove the seal from the suction line fitting and discard.
4. Install plugs in, or tape over the opened suction line fitting and the compressor suction port. Remove the nut that secures the discharge line fitting to the top of the compressor.
5. Disconnect the discharge line fitting from the compressor discharge port. Remove the seal from the discharge line fitting and discard.
6. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. Raise and support the vehicle.
7. Remove the serpentine accessory drive belt from the front of the engine. Disconnect the engine wire harness connector for the compressor clutch coil from the coil pigtail wire connector on the top of the compressor. (Scheme 38)and (Scheme 39).
8. On models with the 3.3L and 3.8L engines, disengage the retainer on the engine wire harness compressor clutch coil take out from the bracket on the top of the compressor. On models with the 2.4L engine, remove the 4 screws that secure the compressor to the mounting bracket on the engine.
9. On models with the 3.3L and 3.8L engines, remove the 3 screws and one nut that secure the compressor to the engine. Remove the compressor from the engine compartment.

Scheme 37

Scheme 38

Removal (Compressor Mounting Bracket 2.4L)

1. Remove the compressor from the mounting bracket.
2. Remove the 4 screws that secure the compressor mounting bracket to the engine. (Scheme 40)
3. Remove the compressor mounting bracket from the engine.

Scheme 39

Note. If a replacement compressor is being installed, be certain to check the refrigerant oil level. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

1. Position the compressor into the engine compartment. On models with the 2.4L engine, loosely install the 4 screws that secure the compressor to the mounting bracket on the engine.
2. On models with the 3.3L and 3.8L engines, loosely install the 3 screws and one nut that secure the compressor to the engine. Tighten each of the fasteners using the following sequence: The upper screw at the rear of the compressor. The lower screw at the rear of the compressor. The lower screw at the front of the compressor. The upper nut at the front of the compressor.
3. On models with the 3.3L and 3.8L engines only, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the compressor.
4. Reconnect the engine wire harness connector for the compressor clutch coil to the coil pigtail wire connector on the top of the compressor. Reinstall the serpentine accessory drive belt onto the front of the engine.
5. Lower the vehicle. Remove the tape or plugs from the compressor discharge port and the discharge line fitting.
6. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Reconnect the discharge line fitting to the compressor discharge port.
7. Install and tighten the nut that secures the discharge line fitting to the compressor. Remove the tape or plugs from the compressor suction port and the suction line fitting.
8. Lubricate a NEW rubber O-ring seal with clean refrigerator oil and install it on the suction line fitting. Reconnect the suction line fitting to the compressor suction port.
9. Install and tighten the nut that secures the suction line fitting to the compressor. Reconnect the negative battery cable.
10. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Installation (Compressor Mounting Bracket 2.4L)

1. Position the compressor mounting bracket onto the engine.
2. Install and tighten the 4 screws that secure the compressor mounting bracket to the engine.
3. Reinstall the compressor onto the mounting bracket.

1. Disconnect and isolate negative battery cable. Unlatch and remove the cover from the Intelligent Power Module (IPM).
2. See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location. Remove the compressor clutch relay from the IPM by pulling it straight up.

1. See the fuse and relay layout map molded into the inner surface of the Intelligent Power Module (IPM) cover for compressor clutch relay identification and location. Position the compressor clutch relay into the proper receptacle in the IPM. Align the compressor clutch relay terminals with the terminal cavities in the IPM relay receptacle.
2. Push down firmly on the compressor clutch relay until the terminals are fully seated in the terminal cavities in the IPM receptacles. Install and latch the cover onto the IPM. Reconnect the battery negative cable.

Note. Before removing the condenser, note the location of each of the radiator and condenser air seals. These air seals are used to direct air through the condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air conditioning and engine cooling system to preform as designed.

Note. If the condenser is being replaced, add one fluid ounce (30 milliliters) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compress in the vehicle.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Remove the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. (Scheme 41)
3. Remove the 5 small screws that secure the front fascia grille inserts to the radiator sight shield. Remove the radiator sight shield from the radiator closure panel crossmember.
4. Remove the 2 screws that secure the hood latch unit to the front of the radiator closure panel crossmember and move the latch out of the way over the top of the crossmember. Mark the location of latch for reinstallation. Disconnect the hoses from the transmission oil cooler fittings on the left side of the cooling module.
5. Remove the nut that secures the discharge line fitting to the condenser on the right side of the cooling module. Disconnect the discharge line fitting from the condenser inlet port. Remove the seal from the discharge line fitting and discard.
6. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. Remove the nut that secures the liquid line fitting to the condenser on the right side of the cooling module. Disconnect the liquid line fitting from the condenser outlet port. Remove the seal from the liquid line fitting and discard.
7. Install plugs, or tape over the opened liquid line fitting and the condenser outlet port. Remove the screw that secures the top of the mounting bracket on each side of the condenser to the cooling module. (Scheme 42)
8. Lift the condenser transmission oil cooler and mounting brackets as a unit far enough to disengage the locating pin that secures the mounting brackets in the lower mount rubber isolators on each side of the cooling module. Remove the condenser, transmission oil cooler, and mounting brackets from the vehicle as a unit.
9. Remove the 2 screws that secure each mounting bracket to the sides of the condenser. Remove the screw that secures the left mounting bracket to the side of the transmission oil cooler.
10. Remove the left mounting bracket from the side of the condenser and transmission oil cooler. Remove the condenser from the right mounting, bracket and transmission oil cooler unit.

Scheme 40

Scheme 41

1. Position the condenser to the right mounting bracket and transmission oil cooler unit. Position the left mounting bracket onto the side of the condenser and transmission oil cooler.
2. Install and tighten the screw that secures the left mounting bracket to the side of the transmission oil cooler. Install and tighten the 2 screws that secure each mounting bracket to the sides of the condenser.
3. Position the condenser, transmission oil cooler, and mounting brackets into the vehicle as a unit. Be certain that the locating pins that secure the mounting brackets are engaged in the lower mount rubber isolators on each side of the cooling module.
4. Install and tighten the 2 screws that secure the top of the mounting bracket on each side of the condenser to the cooling module. Remove the tape or plugs from the condenser outlet port and the liquid line fitting.
5. 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 condenser outlet port on the right side of the cooling module.
6. Install and tighten the nut that secures the liquid line fitting to the condenser. Remove the tape or plugs from the condenser inlet port and the discharge line fitting.
7. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Reconnect the discharge line fitting to the condenser inlet port on the right side of the cooling module.
8. Install and tighten the nut that secures the discharge line fitting to the condenser. Reconnect the hoses to the transmission oil cooler fittings on the left side of the cooling module.
9. Reposition the hood latch unit to the front of the radiator closure panel crossmember. Install and tighten the 2 screws that secure the hood latch unit to the front of the radiator closure panel crossmember. Check and adjust the hood latch as needed.
10. Position the radiator sight shield onto the radiator closure panel crossmember. Install and tighten the 5 small screws that secure the front fascia grille inserts to the radiator sight shield.
11. Install and tighten the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember.
12. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Remove the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. (Scheme 41) Remove the 5 small screws that secure the front fascia grille inserts to the radiator sight shield.
3. Remove the radiator sight shield from the radiator closure panel crossmember. Remove the nut that secures the discharge line fitting to the condenser on the right side of the cooling module. (Scheme 43)
4. Disconnect the discharge line fitting from the condenser inlet port. Remove the seal from the discharge line fitting and discard.
5. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. Remove the nut that secures the discharge line fitting to the top of the compressor. (Scheme 44)
6. Disconnect the discharge line fitting from the compressor discharge port. Remove the seal from the discharge line fitting and discard.
7. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. Remove the discharge line from the engine compartment.

Scheme 42

Scheme 43

1. Position the discharge line into the engine compartment. Remove the tape or plugs from the compressor discharge port and the discharge line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting.
2. Reconnect the discharge line fitting to the compressor discharge port on the top of the compressor. Install and tighten the nut that secures the discharge line fitting to the compressor.
3. Remove the tape or plugs from the condenser inlet port and the discharge line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting.
4. Reconnect the discharge line fitting to the condenser inlet port on the right side of the cooling module. Install and tighten the nut that secures the discharge line fitting to the condenser.
5. Position the radiator sight shield onto the radiator closure panel crossmember. Install and tighten the 5 small screws that secure the front fascia grille inserts to the radiator sight shield.
6. Install and tighten the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember.
7. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

1. Remove the HVAC housing from the vehicle. See «HVAC HOUSING (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems). 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 (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
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 HVAC housing to the inboard end of the evaporator housing. (Scheme 45)
5. Pull the top of the HVAC housing away from the evaporator housing far enough to disengage the 2 hook formations on the bottom of the HVAC housing from the 2 receptacles on the evaporator housing. (Scheme 46)
6. 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. (Scheme 47) 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. (Scheme 48) Remove the 12 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. (Scheme 49)
10. 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 the evaporator housing.

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

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.
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 HVAC housing in the 2 receptacles on the evaporator housing. Roll the top of the HVAC 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 HVAC 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)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
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)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
10. Reinstall the HVAC housing into the vehicle. See «HVAC HOUSING (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Run the HVAC Control Actuator Calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.

1. Remove the rear HVAC housing from the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems). Remove the rear evaporator line extension from the expansion valve.
2. Remove the rear expansion valve from the rear evaporator. Remove the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the expansion valve.
3. Remove the 3 screws that secure the upper half of the rear HVAC housing to the lower half. (Scheme 50) Remove the 3 small metal spring clips that secure the upper half of the rear HVAC housing to the lower half.
4. Carefully separate and remove the upper half of the rear HVAC housing from the lower half. Remove the evaporator from the lower half of the rear HVAC housing.

Scheme 49

Removal (Line Extension)

1. Remove the rear HVAC housing from the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems). Remove the screw that secures the plate that captures and seals the evaporator line extension within the base of the rear HVAC housing. (Scheme 51)
2. Remove the capture plate from the rear HVAC housing base. Carefully peel back the expansion valve foam insulator wrap far enough to access the evaporator line extension sealing plate on the bottom of the expansion valve. (Scheme 52)
3. Remove the 2 screws that secure the expansion valve bracket to the lower rear HVAC housing. Remove the nut that secures the expansion valve bracket to the expansion valve stud.
4. Remove the expansion valve bracket from the expansion valve stud. Remove the nut that secures the evaporator line extension seal plate to the expansion valve stud.
5. Remove the evaporator line extension seal plate from the expansion valve stud. Remove the evaporator line extension from the expansion valve and the rear HVAC housing base.
6. Remove the seals from the evaporator line extension fittings and discard. Install plugs in, or tape over the opened evaporator line extension fittings and both expansion valve ports.

Scheme 50

Scheme 51

1. Carefully lower the evaporator and its foam wrap into the lower half of the rear HVAC housing. Position the upper half of the rear HVAC housing onto the lower half.
2. Install the 3 small metal spring clips that secure the upper half of the rear HVAC housing to the lower half. Install and tighten the 3 screws that secure the upper half of the rear HVAC housing to the lower half.
3. Install the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the expansion valve. Reinstall the rear expansion valve onto the rear evaporator.
4. Reinstall the rear evaporator extension line onto the expansion valve. Reinstall the rear HVAC housing into the vehicle. See «HVAC HOUSING (REAR).»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems)

Installation (Line Extension)

1. Remove the tape or plugs from the evaporator line extension fittings and both expansion valve ports. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the evaporator line extension fittings.
2. Position the evaporator line extension to the expansion valve and the rear HVAC housing base. Position the evaporator line extension seal plate over the expansion valve stud.
3. Install and tighten the nut that secures the evaporator line extension seal plate to the expansion valve stud. Position the expansion valve bracket over the expansion valve stud.
4. Install and tighten the 2 screws that secure the expansion valve bracket to the lower rear HVAC housing. Install and tighten the nut that secures the expansion valve bracket to the expansion valve stud.
5. Carefully restore the expansion valve foam insulator wrap back around the expansion valve. Position the plate that captures and seals the evaporator line extension onto the rear HVAC housing base.
6. Install and tighten the screw that secures the capture plate to the base of the rear HVAC housing. Reinstall the rear HVAC housing into the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .

1. Disconnect and isolate the negative battery cable. Remove the air cleaner housing from the right side of the engine compartment.
2. Remove the windshield wiper assembly from the vehicle. See appropriate WIPER/WASHER article in ACCESSORIES & EQUIPMENT. Remove the temperature sensor attaching screw from the expansion valve.
3. Pull the evaporator temperature sensor away from the expansion valve far enough to access the Red release ring on the wiring connector. Push the Red ring toward the connector to release lock and remove the HVAC housing wire harness connector from the temperature sensor.
4. Remove the evaporator temperature sensor from the engine compartment.

Note. Any grease removed with the old temperature sensor must be replaced, failure to do so could result in poor A/C performance.

1. Position the evaporator temperature sensor into the right rear corner of the engine compartment.
2. Reconnect the HVAC wire harness connector for the evaporator temperature sensor to the sensor connector receptacle. Position the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve.
3. Install the temperature sensor retaining screw and tighten. Install the window wiper assembly to the vehicle. See appropriate WIPER/WASHER article in ACCESSORIES & EQUIPMENT.
4. Reinstall the air cleaner housing into the right side of the engine compartment. Reconnect the negative battery cable.
5. Run the HVAC Cool Down test to verify system is operating properly. See «A/C COOL DOWN TEST»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__ac-cool-down-test) under PERFORMANCE TESTS.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the negative battery 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. (Scheme 53) 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 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.

Scheme 52

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 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 negative battery cable. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

1. Remove the rear HVAC housing from the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Carefully remove the foam insulator wrap from the rear expansion valve.
2. Remove the rear evaporator line extension from the expansion valve. See «EVAPORATOR (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Remove the 2 screws that secure the expansion valve to the evaporator tube sealing plate.
3. Remove the expansion valve from the evaporator tubes. Remove the seals from the evaporator tube fittings and discard. Install plugs in, or tape over the opened evaporator tube fittings and both expansion valve ports.

1. Remove the tape or plugs from the evaporator tube fittings and both expansion valve ports. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings.
2. Position the expansion valve onto the evaporator tubes. Install and tighten the 2 screws that secure the expansion valve to the evaporator tube sealing plate.
3. Reinstall the rear evaporator line extension onto the expansion valve. See «EVAPORATOR (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Install the foam insulator wrap over the rear expansion valve.
4. Reinstall the rear HVAC housing into the vehicle. See «HVAC HOUSING (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Run the HVAC Cool down Test to verify proper operation. See «A/C COOL DOWN TEST»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__ac-cool-down-test) .

Removal (Extension Tubes)

1. Drain the engine cooling system. Disconnect and isolate the negative battery cable. Disconnect the heater hoses from the heater hose tubes. See «HEATER HOSES (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
2. Remove the silencer from beneath the driver side end of the instrument panel. Remove the 3 screws that secure the heater core shield to the left end of the HVAC housing. (Scheme 54)
3. Pull the heater core shield rearward far enough to disengage the 2 location tabs that position the front of the shield to the receptacles in the 2 lower finger formations of the evaporator housing near the dash panel. Remove the heater core shield from the HVAC housing.
4. Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. Remove the screw that secures the heater core tube sealing plate to the heater core supply and return ports. (Scheme 55)
5. Push both heater hoses simultaneously toward the dash panel far enough to disengage their fittings from the heater core supply and return ports. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports.
6. Use absorbent toweling to mop up any engine coolant spills from the preceding operation. Pull both heater hoses simultaneously slightly away from the HVAC housing and rearward far enough to disengage the engine compartment ends of the tubes from the dash panel seal.
7. Remove the heater hoses and sealing plate as a unit from beneath the instrument panel. Use absorbent toweling to clean up any engine coolant spills from the preceding operation.

Scheme 53

Scheme 54

Removal (Heater Core)

1. Drain the engine cooling system. Disconnect and isolate the negative battery cable.
2. Remove the silencer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside. Remove the brake light switch from its mounting bracket.
3. Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm. Remove the 3 screws that secure the heater core shield to the left end of the HVAC housing. (Scheme 54)
4. Pull the heater core shield rearward far enough to disengage the 2 location tabs that position the front of the shield to the receptacles in the 2 lower finger formations of the evaporator housing near the dash panel. Remove the heater core shield from the HVAC housing.
5. Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to mop up any spills. Remove the screw that secures the heater core tube sealing plate to the heater core supply and return ports. (Scheme 55)
6. Push both heater hoses simultaneously toward the dash panel far enough to disengage their fittings from the heater core supply and return ports. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports.
7. Use absorbent toweling to mop up any engine coolant spills from the preceding operation. Remove the 2 screws that secure the heater core mounting plate to the HVAC housing
8. While pulling the accelerator pedal upward and pushing the brake pedal downward enough for clearance, pull the heater core out of the HVAC housing. (Scheme 56)and (Scheme 57).
9. Use absorbent toweling to mop up any engine coolant spills from the preceding operation. Also, if the heater core was leaking use absorbent toweling and reach into the heater core opening to mop up any residual engine coolant within the HVAC housing.

Scheme 55

Scheme 56

Installation (Extension Tubes)

1. Remove the plugs or tape from both heater core tube fittings and both heater core ports. Position the heater hoses and sealing plate as a unit beneath the instrument panel.
2. Align the engine compartment ends of both heater hoses with the openings in the dash panel seal and push them simultaneously forward through the seal far enough to engage the heater core ends of the tubes with the heater core supply and return ports. Position both heater hoses and the sealing plate simultaneously to the heater core supply and return ports.
3. The heater hoses each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports which indicates that the tubes are properly indexed. Install and tighten the screw that secures the heater core tube sealing plate to the heater core supply and return ports.
4. Position the heater core shield onto the HVAC housing. Be certain that the 2 location tabs on the front of the shield are engaged in the receptacles in the 2 lower finger formations of the evaporator housing near the dash panel. Install and tighten the 3 screws that secure the heater core shield to the left end of the HVAC housing.
5. Reinstall the silencer under the driver side end of the instrument panel. Reconnect the heater hoses to the heater hose tubes. See «HEATER HOSES (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
6. Reconnect the negative battery cable. Refill the engine cooling system.

Installation (Heater Core)

1. While pushing the brake pedal downward and pulling the accelerator pedal upward far enough for clearance, slide the heater core into the HVAC housing. Install and tighten the 2 screws that secure the heater core mounting plate to the HVAC housing.
2. Remove the plugs or tape from the heater core tube fittings and both heater core ports. Position both heater hoses and the sealing plate simultaneously to the heater core supply and return ports.
3. The heater hoses each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. Install and tighten the screw that secures the heater core tube sealing plate to the heater core supply and return ports.
4. Position the heater core shield onto the HVAC housing. Be certain that the 2 location tabs on the front of the shield are engaged in the receptacles in the 2 lower finger formations of the evaporator housing near the dash panel. Install and tighten the 3 screws that secure the heater core shield to the left end of the HVAC housing.
5. Reconnect the power brake booster input rod (push rod) to the pin on the brake pedal arm. Reinstall the brake light switch into its mounting bracket.
6. Reinstall the silencer boot around the base of the lower steering shaft on the dash panel. Reconnect the negative battery cable. Refill the engine cooling system. Operate system for 2 thermostat cycles to assure elimination of air in the system.

1. Drain the engine cooling system. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel.
2. Remove the rear heater distribution duct from the right quarter inner panel. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
3. Remove the screw that secures, the front of the rear HVAC housing to the right quarter inner panel. Take the proper precautions to protect the carpeting below the rear heater core from spilled engine coolant and have absorbent toweling readily available to mop up any spills.
4. Disconnect the heater hoses at the rear heater core. See «HEATER HOSES (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__heater-hoses-rear). Install plugs in, or tape over the opened heater core fittings and both heater hoses. (Scheme 58)
5. Use absorbent toweling to clean up any engine coolant spills from the preceding operation. Release the 4 latch tabs that secure the heater core in the rear HVAC housing. Carefully pull the heater core straight out of the rear HVAC housing.

Scheme 57

1. Carefully slide the heater core into the rear HVAC housing. Using hand pressure press firmly and evenly on the heater core end plate until the 4 latch tabs that secure the heater core in the rear HVAC housing are fully engaged. (Scheme 58)
2. Remove the plugs or tape from the heater core fittings and both heater hoses. Reconnect the heater hoses to the rear heater core. See «HEATER HOSES (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__heater-hoses-rear).
3. Install and tighten the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Install and tighten the screw than secures the back of the rear HVAC housing to the right D-pillar.
4. Reinstall the rear heater distribution duct onto the right quarter inner panel. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Refill the engine cooling system.

There are several heater core plumbing configurations used on this model, depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines. (Scheme 59) While the 3.3L and 3.8L engines have unique heater return plumbing on the engine, for models with or without an optional engine oil cooler. (Scheme 62)and (Scheme 63). There are also unique plumbing configurations at the heater core for models with or without the optional rear HVAC. (Scheme 60)and (Scheme 61). All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp.

1. Drain the engine cooling system.
2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose to the tube or nipple toward the center of the hose to be removed. Release the clamp when it is off of the tube or nipple.
3. After the clamp has been moved, grasp the end of the hose firmly and carefully twist the hose back and forth while pulling it away from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being removed. If this procedure is not successful in removing the hose from the nipple, carefully make parallel cut through the hose where it is engaged on the nipple and peel the hose off of the nipple. This method of removal will require heater hose replacement.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

There are several heater, core plumbing configurations used on this model, depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines, while the 3.3L and 3.8L engines have unique heater return plumbing on the engine for models with or without an optional engine oil cooler. There are also unique plumbing configurations at the heater core for models with or without the optional rear heater and air conditioner. All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp.

1. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose toward the center of the hose being installed. Release the clamp when it is near the center of the hose. Grasp one end of the heater hose being installed firmly and carefully twist the hose back and forth while pushing it over from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being installed.
2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tube or nipple. Release the clamp when it is over the tube or nipple. Refill the engine cooling system.

HEATER HOSES (REAR)

1. Partially drain engine cooling system. Loosen clamp at the front end of the hose located at the right outboard side of the underbody rearward of the front crossmember. (Scheme 15)
2. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. Compress insert in rear heater hose quick connection and pull downward on hose. (Scheme 17)
3. Remove 3 straps securing underbody lines. (Scheme 14) Separate and remove rear heater lines from vehicle.

There are several heater core plumbing configurations used on this model depending upon the engine size and other optional equipment. One plumbing configuration is used for all 2.4L engines, while the 3.3L and 3.8L engines have unique heater return plumbing on the engine for models with or without an optional engine oil cooler. There are also unique plumbing configurations at the heater core for models with or without the optional rear HVAC. All models use a combination of formed steel tubing and rubber hoses. In most cases, the rubber hose is secured to the steel tubing with a spring tension clamp.

1. Using spring tension clamp pliers compress and slide the clamps that secure each end of the heater hose toward the center of the hose being installed. Release the clamp when it is near the center of the hose. Grasp one end of the heater hose being installed firmly and carefully twist the hose back and forth while pushing it over from the barbed end of the nipple. Repeat this procedure at the opposite end of the hose being installed.
2. Using spring tension clamp pliers compress and slide the clamps that secure each end of the heater hose over the tube or nipple. Release the clamp when it is over the tube or nipple. Refill the engine cooling system.

1. Disconnect and isolate the negative battery cable. Remove the center bezel from the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
2. Place the instrument panel center bezel unit face down on a suitable work surface. Take the proper precautions to protect the center bezel from cosmetic damage. If the vehicle is equipped with the optional Automatic Temperature Control (ATC) system, disconnect the infrared sensor jumper harness connector from the receptacle on the back of the HVAC control. (Scheme 64)
3. Remove the 6 screws that secure the HVAC control to the back of the instrument panel center bezel. Remove the HVAC control from the instrument panel center bezel.

Scheme 63

1. Position the HVAC control onto the back of instrument panel center bezel. Install and tighten the 6 screws that secure the HVAC control to the back of the instrument panel center bezel.
2. If the vehicle is equipped with the optional ATC system, reconnect the infrared sensor jumper harness connector to the receptacle on the back of the HVAC control.
3. Reinstall the center bezel onto the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable. Using a trim stick or another suitable wide flat bladed tool, gently pry the top edge of the rear HVAC control bezel away from the headliner far enough to release the 2 snap clip retainers. (Scheme 65)
2. Pull the rear HVAC control and bezel unit rearward far enough to access the headliner wire harness connector on the back of the controls. Disconnect the headliner wire harness connector for the rear HVAC control from the control connector receptacle.
3. Remove the rear HVAC control from the headliner. Remove the 3 screws that secure the rear HVAC control to the bezel. (Scheme 66) Remove the rear HVAC control from the bezel.

Scheme 64

Scheme 65

1. Position the rear HVAC control onto the bezel. Install and tighten the 3 screws that secure the rear HVAC control to the bezel.
2. Position the rear HVAC control and bezel unit to the headliner. Reconnect the headliner wire harness connector for the rear HVAC control to the control connector receptacle.
3. Insert the locator tabs on the back of the rear HVAC control and bezel unit over the forward edge of the headliner opening for the control. Slide the rear HVAC control and bezel unit forward far enough to align the snap clips on the bezel with the snap clip receptacles on the retainer above the headliner.
4. Using hand pressure, press the top edge of the rear HVAC control bezel upward until the 2 snap clips are fully seated in their receptacles. Reconnect the negative battery cable. Using the DRB-III® reset the Rear Temperature Selector calibration values.
5. Verify that the Actuator Calibration Test of the Front Control has passed. If an Actuator Calibration Test has not passed correct any errors before proceeding further. Rotate the Rear Temperature Selector counter clockwise to the Cold Position, allow the selector to remain in the Cold Position for 5 seconds.
6. Rotate the Rear Temperature Selector clockwise to the Hot Position, allow the Selector to remain in the Hot Position for 5 seconds. Calibration is now complete.

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 negative battery cable. Disconnect the liquid line and suction line from the expansion valve. See «SUCTION LINE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) and «LIQUID LINE»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems).
3. Disconnect the heater hoses from the heater core. See «HEATER HOSES (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems). Remove the 4 nuts that secure the HVAC housing studs to the engine compartment side of the dash panel. (Scheme 67)
4. 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. (Scheme 68) Pull the HVAC housing rearward far enough for the mounting studs to clear the dash panel and remove the unit from the passenger compartment.

Scheme 66

Scheme 67

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)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
4. Reconnect the suction line and liquid line to the expansion valve. See «SUCTION LINE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) and «LIQUID LINE»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) . Reconnect the negative battery 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.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Drain the engine cooling system. Disconnect and isolate the negative battery cable. Raise and support the vehicle.
3. Disconnect the underbody refrigerant line sealing plate from the rear HVAC unit evaporator extension line sealing plate that extends through the rear floor panel behind the right rear wheel housing. (Scheme 69)
4. Remove the seals from the liquid line and suction line fittings and discard. Install plugs in, or tape over the opened liquid line and suction line fittings and both ports in the evaporator extension line sealing plate. Remove the 3 nuts that secure the rear HVAC unit mounting studs to the rear floor panel behind the right rear wheel housing. (Scheme 70) Lower the vehicle.
5. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Remove the HVAC distribution duct from the rear HVAC unit and the rear roof duct.
6. Disconnect the body wire harness connector for the rear HVAC housing from the rear HVAC wire harness connector located near the expansion valve at the back of the unit. Remove the 2 screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel.
7. Remove the 2 screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing. Remove the rear heater distribution duct from the right quarter inner panel.
8. Take the proper precautions to protect the carpeting below the rear heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. Disconnect the heater hoses at the rear heater core. See «HEATER HOSES (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__heater-hoses-rear). Install plugs in, or tape over the opened heater core fittings and both heater hoses.
9. Use absorbent toweling to mop up any engine coolant spills from the preceding operation. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. (Scheme 28)
10. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Lift the rear HVAC housing up far enough for the lower mounting studs and the evaporator extension lines to clear the mounting holes in the rear floor panel.
11. Remove the rear HVAC housing from the vehicle. Use absorbent toweling to mop up any engine coolant spills from the preceding operation.

Scheme 68

Scheme 69

Note. If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings.

1. Position the rear HVAC housing into the vehicle with the evaporator extension line sealing plate inserted into the rectangular hole in the rear floor panel behind the right rear wheel house. Align the rear HVAC housing lower mounting studs with the mounting holes in the rear floor panel and lower the unit to the floor.
2. Install and tighten the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Install and tighten the screw that secures the back of the rear HVAC housing to the right D-pillar.
3. Remove the plugs, or tape from both heater core fittings and both heater hoses. Reconnect the heater hoses to the rear heater core. See «HEATER HOSES (REAR)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__heater-hoses-rear) .
4. Reinstall the rear heater distribution duct onto the right quarter inner panel. Install and tighten the 2 screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing.
5. Install and tighten the 2 screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Reconnect the body wire harness connector for the rear HVAC housing to the rear HVAC wire harness connector located near the expansion valve at the back of the unit.
6. Reinstall the auxiliary A/C distribution duct onto the rear HVAC unit and the rear roof duct. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel.
7. Raise and support the vehicle. Install and tighten the 3 nuts that secure the rear HVAC unit mounting studs to the rear floor panel behind the right rear wheel housing.
8. Remove the tape or plugs from the underbody liquid line and suction line fittings and both ports in the rear HVAC unit evaporator extension line sealing plate that extends through the rear floor panel behind the right rear wheel housing. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the liquid line and suction line fittings. See «SUCTION LINE (FRONT)»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) and «LIQUID LINE»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
9. Reconnect the underbody refrigerant line sealing plate to the evaporator extension line sealing plate. Install and tighten the screw that secures the underbody refrigerant line sealing plate to the evaporator extension line sealing plate.
10. Lower the vehicle. Reconnect the negative battery cable. Refill the engine cooling system.
11. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Run the HVAC cool down test to verify proper operation. See «A/C COOL DOWN TEST»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__ac-cool-down-test) .

Removal (Front Section)

Note. The front air conditioner liquid line is serviced in 2 sections. The front section connects between the condenser and the filter/drier and includes the high side service port on the fitting for the filter/drier. The rear section connects between the filter/drier and the expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the optional rear air conditioner, the rear section of the front air conditioner liquid line also includes a liquid line hose and tube extension that connects the front liquid line to the liquid line for the rear air conditioner.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner housing from the right side of the engine compartment. Remove the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. (Scheme 41)
3. Remove the 5 small screws that secure the front fascia grille inserts to the radiator sight shield. Remove the radiator sight shield from the radiator closure panel crossmember.
4. Remove the nut that secures the liquid line fitting to the condenser on the right side of the cooling module. (Scheme 43) Disconnect the liquid line fitting from the condenser outlet port.
5. Remove the seal from the liquid line fitting and discard. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.
6. Disengage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. (Scheme 71) Remove the screw that secures the liquid line front section fitting to the top of the filter-drier.
7. Disconnect the liquid line fitting from the filter-drier inlet port. Remove the seal from the liquid line fitting and discard. Install plugs in, or tape over the opened liquid line fitting and the filter-drier inlet port. Remove the front section of the front liquid line from the engine compartment.

Scheme 70

Removal (Rear Section)

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the negative battery 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. Remove the A/C pressure transducer from the fitting on the front liquid line rear section. See «PRESSURE TRANSDUCER»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems). Remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. (Scheme 71)
4. Remove the A/C ground strap eyelet terminal connector from the weld stud. Remove the screw that secures the liquid line rear section fitting to the top of the filter-drier.
5. Disconnect the liquid line fitting from the filter-drier outlet port. Remove the seal from the liquid line fitting and discard. 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 expansion valve.
6. Disconnect the suction line and liquid line fittings from the expansion valve. 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. If the vehicle is equipped with the optional rear air conditioner, go to step 8. If the vehicle does not have the optional rear air conditioner, remove the front liquid line rear section from the engine compartment.
8. Raise and support the vehicle. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC. (Scheme 72)
9. Disconnect the front liquid line extension fitting from the underbody liquid line fitting for the rear air conditioner. Remove the seal from the underbody liquid line fitting and discard.
10. Install plugs in, or tape over the opened liquid line fittings. Lower the vehicle. Remove the front liquid line rear section from the engine compartment.

Scheme 71

Installation (Front Section)

1. Position the front section of the front liquid line into the engine compartment. Remove the tape or plugs from the liquid line front section fitting for the filter-drier and the filter-drier inlet port.
2. 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 inlet port on the top of the filter-drier.
3. Install and tighten the screw that secures the liquid line fitting to the filter-drier. Engage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment.
4. Remove the tape or plugs from the condenser outlet port and the liquid line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
5. Reconnect the liquid line fitting to the condenser outlet port on the right side of the cooling module. Install and tighten the nut that secures the liquid line fitting to the condenser.
6. Position the radiator sight shield onto the radiator closure panel crossmember. Install and tighten the 5 small screws that secure the front fascia grille inserts to the radiator sight shield.
7. Install and tighten the 2 large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. Reinstall the air cleaner housing into the right side of the engine compartment.
8. Reconnect the negative battery cable. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Installation (Rear Section)

1. Position the rear section of the front liquid line into the engine compartment. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports.
2. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. Reconnect the liquid line and suction line fittings to the expansion valve.
3. Install and tighten the nut that secures the suction line and liquid line fittings to 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.
4. 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.
5. Install and tighten the screw that secures the liquid line fitting to the filter-drier. Reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower.
6. Install and tighten the nut that secures the A/C ground strap to the weld stud. Reinstall the A/C pressure transducer onto the fitting on the front liquid line rear section. See «PRESSURE TRANSDUCER»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems) .
7. 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. Reconnect the negative battery cable.
8. If the vehicle is equipped with the optional rear air conditioner, go to step 9 . If the vehicle does not have the optional rear air conditioner, remove the front liquid line rear section from the engine compartment.
9. Raise and support the vehicle. Remove the tape or plugs from the liquid line rear section extension fitting and the underbody liquid line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line fitting. Reconnect the liquid line rear section extension fitting to the underbody liquid line fitting.
10. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC module. Lower the vehicle. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

1. Disconnect and isolate the negative battery cable. Remove the silencer from under the drivers side end of the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
2. Disconnect the HVAC wire harness connector for the mode door actuator from the actuator connector receptacle. (Scheme 8) Remove the 2 screws that secure the mode door actuator to the HVAC housing. Remove the mode door actuator from the HVAC housing.

1. Position the mode door actuator onto the HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
2. Install and tighten the 2 screws that secure the mode door actuator to the HVAC housing. Reconnect the HVAC wire harness connector for the mode door actuator to the actuator connector receptacle.
3. Reinstall the silencer under the driver side end of the instrument panel. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Reconnect the negative battery cable.
4. Perform the HVAC control calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.

1. Disconnect and isolate the negative battery cable. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel.
2. Remove the 2 screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar.
3. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the mode door actuator. (Scheme 1)
4. Remove the 2 screws that secure the mode door actuator to the rear HVAC housing. Pull the mode door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the mode door linkage.
5. Raise the mode door actuator far enough to access and disconnect the rear HVAC wire harness connector for the actuator from the actuator connector receptacle. Remove the mode door actuator from between the rear HVAC housing and the quarter inner panel.

1. Position the mode door actuator between the rear HVAC housing and the quarter inner panel. Reconnect the rear HVAC wire harness connector for the mode door actuator to the actuator connector receptacle.
2. Position the mode door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage.
3. Install and tighten the 2 screws that secure the mode door actuator to the rear HVAC housing. Push the top of the rear HVAC housing back into position against the right quarter inner panel.
4. Install and tighten the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Install and tighten the screw that secures the back of the rear HVAC housing to the right D-pillar.
5. Install and tighten the 2 screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel.
6. Reconnect the negative battery cable. Perform the HVAC control calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.

1. Locate the air filter door on the bottom of the lower evaporator housing just outboard of the passenger side of the instrument panel center stack. (Scheme 73)
2. Slide the air filter door latch toward the rear of the vehicle until it engages the opened stop on the door. Pull the air filter door straight downward to disengage it from the air filter opening of the lower evaporator housing.
3. Use your fingers to reach through the air filter opening of the lower evaporator housing far enough to grasp the air filter. Pull the air filter straight down and out of the evaporator housing. (Scheme 73)

Scheme 72

1. Note the "airflow" directional arrow imprinted on the foam seal around the frame of the air filter. This arrow should always be oriented towards the center of the vehicle. With the air filter "airflow" arrow properly oriented, carefully slide the filter fully upward into the evaporator housing through the air filter opening.
2. With the latch still positioned against its opened stop, reinstall the air filter door onto the lower evaporator housing air filter opening. Slide the air filter door latch toward the front of the vehicle until it hits the closed stop on the door.

1. Disconnect and isolate the negative battery cable. Open the glove box.
2. Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box downward. Reach through the glove box opening to access and disconnect the instrument panel wire harness connector for the power module from the module connector receptacle.
3. Reach through the glove box opening to access and disconnect the blower motor pigtail wire connector from the power module connector receptacle. Remove the 2 screws that secure the power module to the evaporator housing. Remove the power module from the evaporator housing.

1. Position the power module into the evaporator housing. Install and tighten the 2 screws that secure the power module to the evaporator housing. Tighten the screws.
2. Reconnect the blower motor pigtail wire connector to the power module connector receptacle. Reconnect the instrument panel wire harness connector for the power module to the module connector receptacle.
3. Flex both sides of the glove box bin inward near the top far enough for the rubber glove box stop bumpers to clear the sides of the glove box opening, then roll the glove box upward. Close and latch the glove box. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel.
2. Disconnect the rear HVAC wire harness connector for the blower power module from the resistor connector receptacle. (Scheme 11) Disconnect the blower motor pigtail wire connector from the blower power module connector receptacle.
3. Remove the 2 screws that secure the blower power module to the rear HVAC unit housing. Remove the blower power module from the rear HVAC unit housing.

1. Position the blower power module into the rear HVAC unit housing. Install and tighten the 2 screws that secure the blower power module to the rear HVAC unit housing. See «TORQUE SPECIFICATIONS»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__torque-specifications) .
2. Reconnect the blower motor pigtail wire to the blower power module connector receptacle. Reconnect the rear HVAC wire harness connector for the blower power module to the module connector receptacle.
3. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. Reconnect the negative battery cable.

1. Disconnect and isolate the negative battery cable. Disconnect the headlamp and dash wire harness connector for the A/C pressure transducer from the transducer connector receptacle. (Scheme 12)
2. Using an open end wrench, unscrew the A/C pressure transducer from the fitting on the liquid line between the filter drier and the expansion valve. Remove the seal from the A/C pressure transducer fitting and discard.

1. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the A/C pressure transducer fitting. Using an open end wrench, install and tighten the A/C pressure transducer onto the fitting on the liquid line between the filter drier and the expansion valve.
2. Reconnect the headlamp and dash wire harness connector for the A/C pressure transducer to the transducer connector receptacle. Reconnect the negative battery cable.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Remove the air cleaner housing from the right side of the engine compartment.
2. Remove the screw that secures the liquid line front section fitting to the top of the filter-drier. (Scheme 13) Disconnect the liquid line fitting from the filter-drier inlet port.
3. Remove the seal from the liquid line fitting and discard. Install plugs in, or tape over the opened liquid line fitting and the filter-drier inlet port. Remove the screw that secures the liquid line rear section fitting to the top of the filter-drier.
4. Disconnect the liquid line fitting from the fliter-drier outlet port. Remove the seal from the liquid line fitting and discard. Install plugs in, or tape over the opened liquid line fitting and the filter-drier outlet port.
5. Remove the 2 nuts that secure the filter-drier mounting bracket to the weld studs on the side of the right front strut tower. Remove the filter-drier and mounting bracket unit from the studs.

1. Position the filter-drier and mounting bracket unit onto the weld studs on the side of the right front strut tower. Install and tighten the 2 nuts that secure the filter-drier mounting bracket to the studs.
2. Remove the tape or plugs from the liquid line rear section fitting for the filter-drier and the filter-drier outlet port. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
3. Reconnect the liquid line fitting to the filter-drier outlet port on the top of the filter-drier. Install and tighten the screw that secures the liquid line fitting to the filter-drier.
4. Remove the tape or plugs from the liquid line front section fitting for the filter-drier and the filter-drier inlet port. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
5. Reconnect the liquid line fitting to the filter-drier inlet port on the top of the filter-drier. Install and tighten the screw that secures the liquid line fitting to the filter-drier. Reinstall the air cleaner housing into the right side of the engine compartment.
6. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

1. Disconnect and isolate the negative battery cable. Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator. Disconnect the HVAC housing wire harness connector for the recirculation door actuator from the actuator connector receptacle. (Scheme 13)
2. Remove the 2 screws that secure the recirculation door actuator to the lower intake air housing. Remove the recirculation door actuator from the lower intake air housing.

1. Position the recirculation door actuator onto the lower intake air housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation air door.
2. Install and tighten the 2 screws that secure the recirculation door actuator to the lower intake air housing. Reconnect the HVAC wire harness connector for the recirculation door actuator to the actuator connector receptacle.
3. Reposition the carpet on the passenger side front floor back up to the dash panel. Reconnect the negative battery cable.
4. Perform the HVAC control calibration procedure. See «HVAC CONTROL CALIBRATION»(/chrysler/town-country/iv-2000-2005/remont/automatic-hvac-system/#automatic-hvac-systems__hvac-control-calibration) under ADJUSTMENTS.

1. Remove the protective cap from the A/C service port. (Scheme 12) Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
2. Using a standard Schrader-type valve core tool, remove the valve core from the A/C service port. Install a plug in or tape over the opened A/C service port.

1. Lubricate the A/C service port valve core with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the compressor in the vehicle. Remove the tape or plug from the A/C service port.
2. Using a Schrader-type valve core tool, install and tighten the replacement valve core into the A/C service port.
3. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Reinstall the protective cap onto the A/C service port.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner top cover and snorkel from the air cleaner housing located on 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. Remove the nut that secures the suction line fitting to the top of the compressor. Disconnect the suction line fitting from the compressor suction port.
4. Remove the seal from the suction line fitting and discard. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
5. Disengage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment. (Scheme 74) Remove the nut that secures the suction line and liquid line fittings to the expansion valve.
6. Disconnect the suction line and liquid line fittings from the expansion valve. 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. If the vehicle is equipped with the optional rear air conditioner, go to step 8. If the vehicle does not have the optional rear air conditioner, remove the suction line from the engine compartment.
8. Raise and support the vehicle. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC housing. (Scheme 72)
9. Disconnect the suction line extension fitting from the underbody suction line fitting for the rear air conditioners. Remove the seal from the underbody suction line fitting and discard. Install plugs in, or tape over the opened suction line fittings. Lower the vehicle. Remove the suction line from the engine compartment.

Scheme 73

1. Position the suction line into the engine compartment. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports.
2. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. Reconnect the liquid line and suction line fittings to the expansion valve.
3. Install and tighten the nut that secures the suction line and liquid line fittings to the expansion valve. Engage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment.
4. Remove the tape or plugs from the compressor suction port and the suction line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
5. Reconnect the suction line fitting to the compressor suction port. Install and tighten the nut that secures the suction line fitting to the compressor.
6. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. Reinstall the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment.
7. Reconnect the negative battery cable. If the vehicle is equipped with the optional rear air conditioner, go to step 8 . If the vehicle does not have the optional rear air conditioner, evacuate and charge system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
8. Raise and support the vehicle. Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting.
9. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the under body suction line fitting. Reconnect the suction line extension fitting to the underbody suction line fitting.
10. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC housing. Lower the vehicle.
11. Evacuate and recharge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

The front air conditioner suction line includes the low side service port on a section of tubing located near the compressor. On models equipped with the optional rear air conditioner the front air conditioner suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear air conditioner.

1. Recover the refrigerant from the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Disconnect and isolate the negative battery cable.
2. Remove the air cleaner top cover and snorkel from the air cleaner housing located on 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. Remove the nut that secures the suction line fitting to the top of the compressor. Disconnect the suction line fitting from the compressor suction port.
4. Remove the seal from the suction line fitting and discard. Install plugs in, or tape over the opened suction line fitting and the compressor suction port.
5. Disengage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment. (Scheme 74) Remove the nut that secures the suction line and liquid line fittings to the expansion valve.
6. Disconnect the suction line and liquid line fittings from the expansion valve. 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. If the vehicle is equipped with the optional rear air conditioner, go to step 8. If the vehicle does not have the optional rear air conditioner; remove the suction line from the engine compartment.
8. Raise and support the vehicle. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC. (Scheme 72)
9. Disconnect the suction line extension fitting from the underbody suction line fitting for the rear air conditioner.
10. Remove the seal from the underbody suction line fitting and discard. Install plugs in, or tape over the opened suction line fittings.
11. Lower the vehicle. Remove the suction line from the engine compartment.

1. Position the suction line into the engine compartment. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports.
2. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. Reconnect the liquid line and suction line fittings to the expansion valve.
3. Install and tighten the nut that secures the suction line and liquid line fittings to the expansion valve. Engage the retainer that secures the suction line routing clip to the filter-drier mounting bracket on the side of the right front strut tower in the engine compartment.
4. Remove the tape or plugs from the compressor suction port and the suction line fitting. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting.
5. Reconnect the suction line fitting to the compressor suction port. Install and tighten the nut that secures the suction line fitting to the compressor.
6. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. Reinstall the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment.
7. Reconnect the negative battery cable. If the vehicle is equipped with the optional rear air conditioner, go to step 8 . If the vehicle does not have the optional rear air conditioner, evacuate and charge the system.
8. Raise and support the vehicle. Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting.
9. Lubricate a NEW rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting. Reconnect the suction line extension fitting to the underbody suction line fitting.
10. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear HVAC. Lower the vehicle.
11. Evacuate and charge the refrigerant system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Removal (A/C Lines)

1. Recover A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING. Hoist and support vehicle.
2. Loosen screw and remove the other screw at each of the 3 brackets holding the A/C lines to the underbody. (Scheme 14) Remove both A/C lines from the 2 rear retaining clamps behind rear wheel.
3. Remove both compression fittings at front of A/C lines. (Scheme 15) Remove bolt securing A/C lines to block located at A/C housing, behind rear wheel and separate block. (Scheme 18)
4. Remove rear wheel. Separate ABS harness from flex hose clamps. Remove heater lines from underbody brackets.
5. Pinch off rubber heater line hoses at front of vehicle. Loosen hose clamps at front of heater lines and allow them to hang from vehicle.
6. Remove rear A/C lines from vehicle. Remove nylon wedge holding lines into rear block. see scheme 75

Scheme 74

Removal (Heater Lines)

1. Raise and support vehicle. Pinch off rubber heater line hose.
2. Disconnect quick connect fitting at C-pillar. Loosen screw and remove the other screw at each of the 3 brackets holding the front of the line to the underbody.
3. Lower rear of line and drain coolant into a suitable container. Loosen hose clamps at front of line and remove line from vehicle.

Installation (A/C Lines)

1. Before installing, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax free refrigerant oil. Install A/C line into rear block with nylon wedge.
2. Install A/C lines into 5 underbody brackets. Connect forward compression fittings. Install bolt at sealing block to rear A/C housing.
3. Install ABS harness into clips. Install heater hoses into underbody brackets. Install lines into front hoses and install hose clamps.
4. Lower vehicle. Evacuate and recharge the system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.

Installation (Heater Lines)

1. Install line into underbody straps. Install line into front hose and install hose clamp. Connect quick fitting at rear of line.
2. Lower vehicle. Fill cooling system. Inspect for leaks.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

For HVAC wiring diagrams see appropriate diagram.

1. «AIR CONDITIONING»(ref-141291-S04930469652002061800000) in SYSTEM WIRING DIAGRAMS article in WIRING DIAGRAMS.
2. «AIR CONDITIONING»(ref-141292-S38287071792002061800000) in SYSTEM WIRING DIAGRAMS article in WIRING DIAGRAMS.
3. «AIR CONDITIONING»(ref-141293-S38126132692002061800000) in SYSTEM WIRING DIAGRAMS article in WIRING DIAGRAMS.

See also:
• SELF-DIAGNOSTIC SYSTEM
• WIRING DIAGRAMS
• SYMPTOM TESTS
• DIAGNOSTIC TESTS
• CLEARING DIAGNOSTIC TROUBLE CODES
• Tests
• A/C PERFORMANCE
• HVAC CONTROL CALIBRATION
• A/C COOL DOWN TEST
• HEATER HOSES (REAR)
• TORQUE SPECIFICATIONS