Grand Caravan FWD V6-3.3L VIN 3 Flex Fuel (2002)
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DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION
FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA'S
EXHAUST FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY OR DEATH.
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ALLOW THE DCHA ASSEMBLY TO COOL BEFORE PERFORMING A COMPONENT INSPECTION/REPAIR/REPLACEMENT.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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ALWAYS DISCONNECT THE VEHICLE'S BATTERY PRIOR TO PERFORMING ANY TYPE OF WORK ON THE DCHA. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.
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NEVER ATTEMPT TO REPAIR THE DCHA HEATER MODULE OR ANY OF ITS INTERNAL COMPONENTS. ALWAYS PERFORM
DCHA COMPONENT REPLACEMENT IN ACCORDANCE WITH THE SERVICE INFORMATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY OR DEATH.
CAUTION:
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Do not actuate the DCHA Field Mode Test with the engine oft. Failure to follow these instructions may result in internal damage to the DCHA
Heater Module.
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Always Perform The Cabin Heater Pre-Test Prior To Performing Any Other Cabin Heater Test For The Test Result To Be Valid.
NOTE:
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Do not disconnect the vehicle's battery or the DCHA's main power-supply while the DCHA is in operation or in run-down mode. Failure to follow
these instructions may result in excess emissions from the DCHA Heater Module.
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Failure to prime the Dosing Pump after draining the DCHA fuel line will prevent DCHA heater activation during the first attempt to start the
heater. This will also set a Diagnostic Trouble Code (DTC) in the DCHA Control's memory. Do not perform the Dosing Pump Priming Procedure
if an attempt was made to start the DCHA without priming the Dosing Pump first. This will put excess fuel in the DCHA Heater Module and cause
smoke to emit from the DCHA exhaust pipe when heater activation occurs.
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Waxed fuel can obstruct the fuel line and reduce flow. Check for the appropriate winter grade fuel and replace as necessary.
Component Description and Operation
COMPONENT DESCRIPTION AND OPERATION
DCHA Assembly
The DCHA is a supplemental heater designed to pre-heat the engine's coolant in order to supply the vehicle's occupants with heat prior to the engine
reaching operating temperature. The DCHA assembly mounts underneath the vehicle on the left side floor pan near the front door opening. The
DCHA assembly connects to the vehicle's heater hoses and has a fuel supply line that connects to the vehicle's fuel tank.
The DCHA assembly consists of a:
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combustion air fan assembly
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burner housing
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burner insert
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control unit/heat exchanger
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combustion chamber
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dosing pump
Combustion Air Fan
The combustion air fan assembly includes the:
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combustion air fan
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combustion air fan inlet
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fuel supply inlet
The combustion air fan delivers the air required for combustion from the combustion air inlet to the burner insert.
Burner Housing
The burner housing includes the:
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coolant inlet
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coolant outlet
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exhaust outlet
The burner housing accommodates the burner insert and is combined with the control unit/heat exchanger as an assembly.
Burner Insert
The burner insert includes the:
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combustion pipe fuel cross section
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glow plug/flame sensor
Inside the burner insert, fuel is distributed across the combustion-pipe fuel cross section. Combustion of the fuel/air mixture takes place within the
combustion pipe to heat the exchanger. The glow plug/ flame sensor, located in the burner insert, ignites the fuel/air mixture during heater start up.
