Grand Caravan V6-3.3L VIN R (2005)
Upper Air Inlet Housing
9. Carefully cut the foam seal along the parting line of the upper air inlet housing. If the seal is deformed or damaged, it must be replaced.
10. Remove the three screws that secure the upper air inlet housing to HVAC housing.
11. Remove the upper air inlet housing and recirculation-air door from the HVAC housing.
12. If required, remove the screw that secures the recirculation-air door to the upper air inlet housing and remove the air door.
INSTALLATION
NOTE: The air inlet housing must be removed from HVAC housing for service of the recirculation-air door.
1. If removed, install the recirculation-air door into the upper air inlet housing and install the retaining screw. Tighten the screw to 2 N.m (17 in.
lbs.).
2. Position the air inlet housing and recirculation-air door onto the HVAC housing.
CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seats.
3. Install the three screws that secure the upper air inlet housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
4. Inspect the foam seal along the parting line. If the seal is deformed or damaged, it must be replaced.
5. Feed the blower motor wire lead through the opening in the lower air inlet housing and seat the rubber grommet into the lower air inlet housing.
6. Position the recirculation-air door pivot into the lower air inlet housing.
7. Install the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and the lower HVAC housing.
Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.).
9. Connect the blower motor wire lead connector to the blower motor resistor or power module, depending on application.
10. Install the recirculation door actuator wire lead into the routing clip located on the lower air inlet housing.
11. Install the recirculation door actuator.
12. Install the HVAC housing assembly.
Front HVAC Housing Removal and Installation
REMOVAL
WARNING:
-
REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING
OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY
OR DEATH.
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ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY
TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL