This bulletin involves installing an evaporator inlet flow straightener
Contents
1. 5 24 002 03 14 Remove the two screws that secure the upper half of the recirculation air door to the lower half of the door 15 Remove the upper half of the recirculation air door from the lower half of the door Fig 4 80aa7386 Fig 4 RECIRCULATION AIR DOOR TYPICAL 1 EVAPORATOR HOUSING 2 UPPER RECIRCULATION AIR DOOR 3 LOWER INTAKE AIR HOUSING 16 Remove the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half 17 Carefully separate and remove the upper half of the evaporator housing from the lower half Be certain not to loose 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 a notched area between the upper and lower housing halves Fig 5 24 002 03 6 Pin 2 d gt I Ypma 80aa503d Fig 5 EVAPORATOR HOUSING TYPICAL LOWER EVAPORATOR HOUSING UPPER EVAPORATOR HOUSING BLOWER WHEEL EVAPORATOR AA UO N 18 With the evaporator assembly removed from the evaporator housing install the rubber evaporator tube insert p n 05061454AA between the evaporator inlet and outlet tubes as shown Fig 5 24 002 03 A i oo avi ou EL aii 81133ab5 Fig 6 RUBBER EVAPORATOR INSERT PLACEMENT 1 EVAP2. 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 Refer to the service information available in the TechCONNECT MDS2 or the appropriate service manual Section 24 Heating amp Air Conditioning Plumbing Front Expansion Valve Removal 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 Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing Fig 2 24 002 03 4 DL eo Saas fe 80aa5095 Fig 2 HVAC HOUSING DISTRIBUTION HOUSING SCREWS 3 HVAC WIRING HARNESS ROUTING CLIP EVAPORATOR HOUSING a A O N 12 Pull the top of the distribution housing away from the evaporator housing far enough to disengage the two hook formations on the bottom of the distribution housing from the two receptacles on the evaporator housing Fig 3 80aa7305 Fig 3 UPPER INTAKE AIR HOUSING TYPICAL 1 EVAPORATOR HOUSING 2 UPPER INTAKE AIR HOUSING 3 RECIRCULATION AIR DOOR 4 BLOWER WHEEL 13 Remove the screw and washer from the upper pivot of the recirculation door
3. NUMBER 24 002 03 E SERVICE GROUP Heating and A C i BULLETIN DATE Apr 4 2003 SUBJECT Evaporator Hiss Sound OVERVIEW This bulletin involves installing an evaporator inlet flow straightener and a rubber evaporator insert between the evaporator tubes if necessary MODELS 2002 2003 RS Town amp Country Caravan Voyager SYMPTOM CONDITION Some customers may experience a hiss sound that originates from the Heating Ventilation Air Conditioning HVAC unit This may be most noticeable when operating between 18 C 27 C 65 F 80 F DIAGNOSIS Operate the vehicle in a moderate ambient temperature 18 C 27 C 65 F 80 F Run the HVAC system in recirculation panel mode A C off full heat high blower for 1 to 2 minutes to heat the evaporator Switch the HVAC system to outside air panel mode A C on full cool low blower and maintain a steady engine speed of approximately 2000 rpm Listen for a hiss that will occur when the A C clutch cycles on NOTE PERFORM THIS PROCEDURE AFTER EACH REPAIR TO THE HVAC SYSTEM TO VERIFY THE HISS IS NO LONGER PRESENT PARTS REQUIRED Description 04885713AA Flow Straightener Evaporator Inlet 05061454AA Rubber Evaporator Insert 05019220AD Seal Kit A C and Heater Unit Lo _ EQUIPMENT REQUIRED NPN Refrigerant Recovery Recycling Station Models Available through Pentastar Service Equipment DaimlerChrysler Corporation Dealer Technica
4. ORATOR 2 EVAPORATOR OUTLET TUBE 3 EXPANSION VALVE 4 EVAPORATOR INLET TUBE 5 RUBBER EVAPORATOR INSERT Assemble the HVAC housing as follows 19 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 20 Install and tighten the twelve screws around the perimeter of the evaporator housing that secure the upper housing half to the lower half Tighten the screws to 2 Nm 18 in lbs 21 Position the upper half of the recirculation air door onto the lower half of the door 22 Install and tighten the two screws that secure the upper half of the recirculation air door to the lower half of the door Tighten the screws to 2 Nm 18 in Ibs 23 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 24 Install and tighten the three 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 Tighten the screws to 2 Nm 18 in lbs 25 Install and tighten the two screws that s
5. all the evaporator inlet flow straightener P N 04885713AA Fig 1 Install the expansion valve 81183dce Fig 1 FLOW STRAIGHTENER INSTALLED 1 EVAPORATOR INLET 2 EVAPORATOR OUTLET 3 FLOW STRAIGHTENER 4 3 24 002 03 Perform the Diagnosis procedure If the hiss sound is no longer present no further action is necessary Return the vehicle to the customer If the hiss sound is still present proceed to the next step If the vehicle has a manual single zone HVAC unit built March 25 2002 MDH 0325XX through and including February 26 2003 MDH 0226XX or a manual dual zone HVAC unit built on or after July 22 2002 MDH 0722XxX through and including February 26 2003 MDH 0226XX a rubber insert that fits between the evaporator tubes needs to be installed Remove the HVAC unit housing Refer to the service information available in the TechCONNECT MDS2 or the appropriate service manual Section 24 Heating amp Air Conditioning Distribution Front HVAC Housing Removal Gain access to the evaporator inlet tubes within the HVAC housing as follows 6 Remove the heater core tubes from the heater core Refer to the service information available in the TechCONNECT MDS2 or the appropriate service manual Section 24 Heating amp Air Conditioning Plumbing Front Heater Core Removal Heater Core Tubes Remove and discard the foam seal from the HVAC housing seal flange around the fresh air inlet opening and the
6. ecure the upper intake air housing to the lower intake air housing Tighten the screws to 2 Nm 18 in lbs 24 002 03 8 26 Engage the two hook formations on the bottom of the distribution housing in the two receptacles on the evaporator housing 27 Roll the top of the distribution housing up into position against the evaporator housing 28 Install and tighten the three screws from the dash panel side of the unit that secure the top of the distribution housing to the inboard end of the evaporator housing Tighten the screws to 2 Nm 18 in lbs 29 Engage the HVAC wire harness in the routing clips molded into the outside of the HVAC housing components 30 Connect 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 31 Install the expansion valve onto the evaporator inlet and outlet tube fittings 32 Install a new foam seal from the A C Heater unit seal kit p n 05019220AD 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 33 Install the heater core tubes into the heater core 34 Install the HVAC unit housing into the vehicle 35 Run the HVAC Control Actuator Calibration procedure Refer to the service information available in the TechCONNECT MDS82 or the appropriate service manual Section 24 Heating amp Air Conditioning Diagn
7. l Operations 24 002 03 2 REPAIR PROCEDURE 1 Perform the A C Performance Test and the Refrigerant System Charge Level Test Refer to the service information available in the TechCONNECT MDS2 or the appropriate service manual Section 24 Diagnosis and Testing to determine if the vehicle has the proper refrigerant charge level If the charge level is incorrect repair any leaks which may have caused the HVAC system to lose refrigerant charge and add recharge as necessary to attain the proper charge level Perform the Diagnosis procedure If the hiss sound is no longer present no further action is necessary Return the vehicle to the customer In many cases low refrigerant is the cause of this sound If the hiss sound is still present proceed to the next step NOTE VEHICLES BUILT ON OR BEFORE MARCH 24 2002 MDH 0324XX OR ON OR AFTER JULY 22 2002 MDH 0722XX ALREADY HAVE EVAPORATOR INLET FLOW STRAIGHTENERS FOR THESE VEHICLES PROCEED TO STEP 5 If the vehicle has a manual single zone HVAC unit built on March 25 2002 MDH 0325XX through and including July 22 2002 MDH 0722XX an evaporator inlet flow straightener will need to be installed in the evaporator inlet Remove the expansion valve Refer to the service information available in the TechCONNECT MDS2 or the appropriate service manual Section 24 Heating amp Air Conditioning Plumbing Front Expansion Valve Removal to gain access to the evaporator inlet Inst
8. osis And Testing 36 Perform the Diagnosis procedure to insure the hiss sound is no longer present POLICY Reimbursable within the provisions of the warranty TIME ALLOWANCE Labor Operation Description No 24 65 02 90 Performance Test A C System 24 65 02 91 Performance Test A C System and Install Flow 1 0 Hrs Straightener 24 65 02 92 Performance Test A C System and Install A C 4 1 Hrs Coil Isolator 24 65 02 93 Performance Test A C System and Install A C 4 5 Hrs Coil Isolator and Flow Straightener FAILURE CODE eee
Download Pdf Manuals
Related Search