2001 Dodge Caravan Sport MANUAL A/C-HEATER SYSTEMS Caravan, Town & Country, & Voyager

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Myron Mitchell
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1 SPECIFICATIONS NOTE: Information for Caravan includes the Grand Caravan. SPECIFICATIONS Application Specification Compressor Type Nippondenso 10S20H Compressor Belt Tension (1) System Oil Capacity (2) Front A/C 9.0 ozs. Front & Rear A/C 13.4 ozs. Refrigerant (R-134a) Capacity Front A/C 34.0 ozs. Front & Rear A/C 46.0 ozs. System Operating Pressures (3) High Side psi ( kg/cm 2 ) Low Side psi ( kg/cm 2 ) (1) Belt tension is automatically adjusted by dynamic tensioner. (2) Use ND-8 PAG refrigerant oil. (3) Operating pressure with ambient temperature of 70 F (21 C). DESCRIPTION WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Vehicle may be equipped with either single zone, dual zone or 3 zone manual Heater, Ventilation & Air Conditioning (HVAC) systems. Single zone HVAC system (base model) allows one temperature setting for entire vehicle. Dual zone HVAC system allows for independent side-to-side temperature zone control of discharge air for driver and passenger sides of vehicle. This is accomplished by separate temperature control levers for driver and front passenger zones. Three zone HVAC system consists of a front dual zone HVAC system with a rear HVAC unit (if equipped). Rear zone control panel is located in headliner, near center of vehicle. Primary control of rear zone is maintained by HVAC control module and rear control/blower switch located on front A/C-heater control panel. Rear zone climate will follows driver climate settings, except when rear control/blower switch is in REAR position. When rear control/blower switch is in REAR position, rear occupants can control climate settings from rear zone control panel. Rear zone control panel will then operate rear HVAC unit mode door and blower speed settings. FRONT A/C-HEATER UNIT Sunday, July 03, :58:31 2:59:33 PM Page Mitchell Repair Information Company, LLC.

2 Front Heater, Ventilation & Air Conditioning (HVAC) functions are electronically controlled by HVAC control module. HVAC control module is integral with A/C-heater control panel and is located in center of instrument panel, near radio. A/C-heater control panel consists of temperature controls, blower motor switch, A/C switch and airflow outlet mode selector to maintain climate of vehicle cabin. Additional switches for rear window defogger and recirculated or fresh air are also located on A/C-heater control panel. If equipped with rear HVAC, rear control and rear blower switch is located in front A/C-heater control panel. Rear control and rear blower switch overrides control of rear zone control panel. Rear climate settings will follow driver settings, except when switch is REAR position. See Fig. 1. In REAR position, rear zone control panel assumes control of rear climate settings. Outside air enters vehicle through cowl grille at base of windshield or air is recirculated within vehicle cabin by blower motor. Air temperature is modified by A/C evaporator core and/or heater core in HVAC plenum housing. Airflow is directed through HVAC plenum housing through of a series of pulse width modulated actuator driven mode doors, which are controlled by HVAC control module. Airflow is directed by position of blend, mode, and recirculation actuator doors through various air ducts to appropriate air outlet vents. REAR A/C-HEATER UNIT Rear Heater, Ventilation & Air Conditioning (HVAC) unit is located on passenger-side, in rear quarter panel area. Rear HVAC unit operates in conjunction with front HVAC system through rear control and rear blower switch on front A/C-heater control panel, or independently from rear zone control panel, when enabled. See Fig. 1. Rear HVAC unit contains a blower motor, evaporator core, expansion valve and heater core separate from front HVAC assembly. Rear blower motor draws in air through air intake grille on rear panel. Blower motor draws air through evaporator or heater core as directed by rear mode door actuator. Rear HVAC unit controls can be operated separately from rear zone control panel, when enabled. Rear zone control panel can be set to operate rear blower speed and rear zone temperature, in A/C or HEAT mode. For rear A/C operation, front A/C switch LED must be on, to engage A/C compressor. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

3 Fig. 1: Identifying Front & Rear Control Panels Of 3 Zone System Courtesy of CHRYSLER CORP. OPERATION AIR FILTER Vehicles equipped with dual zone front HVAC system include a dust and odor air filter located near evaporator. A door located below glove box, at base of dual zone HVAC plenum housing, provides easy access to air filter element. See Fig. 2 and Fig. 3. Air filter element is about same size as evaporator core. HVAC air filter replacement is recommended at 15,000 mile intervals. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

4 Fig. 2: Identifying HVAC Air Filter Door Courtesy of CHRYSLER CORP. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

5 Fig. 3: Removing HVAC Air Filter Element Courtesy of CHRYSLER CORP. A/C-HEATER CONTROL PANELS Single Zone (Standard) Control Panel A single temperature control lever identifies single zone (standard) HVAC system. Temperature lever position changes blend air door position and discharge air temperature from HVAC system. See Fig. 4. Manually moving lever to cold or hot position changes temperature inside entire vehicle cabin. When either A/C button is depressed or mode selector is in defrost position, A/C compressor engages. Dual Zone Temperature Control Panel Vehicle may be equipped with driver-side and passenger-side temperature control levers for independent control of driver and passenger climate zones (if equipped). See Fig. 4. Each front occupant can independently adjust outlet temperature for driver-side or passenger-side of vehicle from separate temperature control levers. DRIVER lever controls zone/driver mode door position, and PASS lever controls blend/passenger mode door position. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

6 Three Zone Temperature Control Panel Three zone control panel allows for independent control of driver's zone, front passenger's zone and rear occupant climate zone. Rear control and rear blower switch identifies 3 zone system. See Fig. 4. Each front occupant can independently adjust their respective climates. A/C compressor cannot be engaged from rear control panel, front panel A/C button must be depressed for rear A/C operation. Rear control and rear blower switch at front control panel activates rear unit mode door and blower motor to follow driver's climate zone settings. Rear control switch at front panel overrides rear zone control panel from operating rear HVAC unit, except when rear control and rear blower switch is in REAR position. See Fig. 4. When in REAR position, rear zone control panel is enabled. When enabled, rear zone control panel settings determine rear HVAC unit blower motor and mode operation. FRONT HVAC SYSTEM A/C Button A/C button energizes A/C compressor. The front control panel blower switch must be in any position except OFF, before A/C compressor will be engaged. A/C button LED is illuminated when depressed. See Fig. 4. A/C button must be engaged for rear A/C system to function (if equipped). Front Blower Switch Front blower switch is a dial type switch to select blower speed setting. See Fig. 4. Blower switch uses variable resistors to control blower motor operation and speed. A/C compressor will not operate when blower motor is in OFF position. Mode Selector Front control panel mode selector dial allows operator to select various airflow mode settings. International Standards Organization (ISO) symbols for face, bi-level, floor, defog and defrost airflow mode settings. See Fig. 4. When mode selector dial is rotated to each detent between ISO symbols, HVAC control module will change position of pulse width modulated mode doors progressively to allow smooth changes between airflow mode settings. In each detent position, HVAC control module will send several voltage pulse signals to reposition actuator doors. HVAC control module will actuates airflow mode requests by changing mode door positions for desired air outlet vents. Rear Window Defogger Button Rear window heated back lamp (defogger) will be energized when rear window defogger (defrost) button is engaged. See Fig. 4. Defogger button LED indicator will illuminate when defogger button is depressed. Defogger button will automatically turn off after a predetermined time has elapsed or when ignition switch is turned off. Recirculation Button Recirculation button controls recirculation mode door position for recirculated air or outside air setting. See Fig. 4. When recirculated button is engaged, LED indicator will illuminate. When ignition is turned off, HVAC Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

7 control module will automatically default to outside air setting (factory programmed default setting). HVAC control module can be programmed to default to recirculation air setting, but it is not recommended. See RECIRCULATION PROGRAMMING under PROGRAMMING. Fig. 4: Identifying Front Control Panel Switches (3 Zone System Is Shown: Standard & Dual Zone Systems Are Similar) Courtesy of CHRYSLER CORP. REAR HVAC SYSTEM Rear HVAC Unit Rear Heater, Ventilation and Air Conditioning (HVAC) unit is mounted inside vehicle cabin in right rear quarter panel (if equipped). Rear HVAC unit houses a heater core, evaporator core, blower motor, mode doors and electronic door actuators. Plumbing for heater and evaporator is branched out from engine compartment and routed under passenger-side of vehicle to rear unit. In cool mode, air flows past rear unit evaporator core and out of upper outlet vents. In heater mode, air flows past rear unit heater core and out of heater floor outlets. Rear unit functions are controlled by HVAC control module. Rear unit can be operated from either front control panel rear control/rear blower switch, or from rear zone control panel located in center of headliner. See Fig. 1. When operated from front control panel, rear HVAC unit will follow front driver zone climate settings, except when switch is in REAR position. See Fig. 4. With rear control/blower switch in REAR position, rear zone control panel operation is enabled. A/C button on front control panel must be depressed for rear A/C system, A/C compressor can not be engaged from rear zone control panel. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

8 Rear Zone Control Panel Rear zone control panel allows control of rear HVAC unit blower speed and temperature mode doors, when enabled. Before rear zone controls will work, rear control/blower switch at front control panel must be in REAR position. Rear zone control panel allows rear occupants to control rear HVAC blower motor speed and airflow mode for rear passenger climate settings of vehicle. REFRIGERANT SYSTEM A/C Compressor Two models of compressors are used on this vehicle, depending upon type of A/C system used. Both compressors used are a Nippondenso 10S20H model compressor, and each are belt driven by engine. A/C compressor belt tension is not adjustable, and is regulated by belt tensioner. A/C compressor is engaged by electric clutch, pulley and clutch coil. Compressor is lubricated by refrigerant oil which circulates within refrigerant system. Compressor draws in low pressure refrigerant vapor from receiver-drier, compresses vapor and discharges it as high pressure refrigerant vapor to condenser. These compressors cannot be serviced. If faulty or damaged, compressor must be replaced. A/C Pressure Transducer The A/C pressure transducer monitors refrigerant system high-side pressure. The A/C pressure transducer turns off voltage to compressor clutch coil when refrigerant pressure drops to levels that could damage compressor. It also controls condenser fan, radiator fan and A/C compressor functions. The A/C pressure transducer is a factory calibrated unit and must be replaced if defective. Expansion Valve Expansion valve regulates A/C system refrigerant high-side pressure entering evaporator, which directly affects temperature of evaporator core. Expansion valve is located on high-pressure refrigerant line going from engine compartment through firewall. On models with rear HVAC unit, an additional expansion valve regulates highside pressure entering rear HVAC evaporator, and regulating temperature of rear evaporator core. Rear expansion valve is located in rear HVAC unit housing. High Pressure Relief Valve High pressure relief valve vents off a small amount of refrigerant, necessary to reduce system pressure, when high-side refrigerant pressure reaches more than psi ( kg/cm 2 ). High pressure relief valve resets itself when pressure decreases to normal operating parameters. High pressure relief valve is located near discharge port of A/C compressor. Sunday, July 03, :58:32 PM Page Mitchell Repair Information Company, LLC.

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