Rear A/C - Poor Performance/Low Output
NUMBER: 24-003-02GROUP: Heating & A/C
DATE: Mar. 18, 2002
SUBJECT:
Poor Rear A/C Performance - Low Output From Headliner Vents
OVERVIEW:
This bulletin involves attaching the headliner ducts to the rear A/C crossover tube with screws, installing foam blocks between the front headliner ducts and the roof panel, and removing the turning vanes from the front headliner vent outlets.
MODELS:
2001 - 2002 (RS) Town & Country/Caravan
2001 - 2002 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO RS VEHICLES BUILT BEFORE SEPTEMBER 24, 2001 AND RG VEHICLES BUILT BEFORE OCTOBER 1, 2001 AND EQUIPPED WITH REAR AIR CONDITIONING (SALES CODE HBB).
SYMPTOM/CONDITION:
The vehicle operator may complain that the rear A/C does not provide adequate cooling, or that there is low air flow volume from the headliner vents.
DIAGNOSIS:
Insure the front A/C system is operating properly. Turn the front A/C system blower to the 3rd speed setting for manual systems, and the 6th speed (6th LED) setting for A/C systems. Turn the rear A/C blower to the highest setting. Use your hand to check the cool air output at the rear and front headliner vents. If the air flow volume is low as compared to the front dash panel A/C vents, perform the Repair Procedure.
PARTS REQUIRED
EQUIPMENT REQUIRED
REPAIR PROCEDURE:
1. Open both sliding doors, the liftgate, and fold down the rear seat back.
2. Remove both headliner vents located above the 2nd row seats by using a trim stick and gently prying on the thumb wheel end of the vent outlet.
3. Using a trim stick, remove the turning vanes from the headliner duct openings as shown in (Fig. 1). Discard the headliner outlet turning vanes.
4. Install the vent outlets to the headliner.
5. Remove the 2nd and 3rd row seat belt anchor bolts (4) from the C and D pillars.
6. Remove both 2nd seat grab handles from the headliner, if equipped.
7. Remove all coat hooks from the headliner.
8. Remove the liftgate sill plate.
9. Remove the rear headliner trim cover.
10. Remove the linkage from the power liftgate motor to the liftgate, if equipped.
11. Remove both D-pillar trim panels.
12. Remove A/C duct from right D-pillar.
13. Remove the three black push pins from the rear of the headliner.
14. Starting a the rear center of the headliner, remove the three rear beige pushpins from the headliner.
15. Loosen top of both C-pillar trim panels away from headliner. Do not remove C-pillar trim panels.
16. Put rear seat back in upright position.
17. Lower rear of headliner to rest on rear seat head rests.
NOTE:
IF REAR SEAT IS REMOVED FROM VEHICLE, HAVE AN ASSISTANT HOLD THE HEADLINER STATIONARY WHILE PERFORMING STEP 18 AND 19.
18. Press down on the rear left side of the headliner to access the crossover duct and headliner duct. Pressing the crossover tube and headliner duct together, use a right angle drill to install the two self tapping screws as shown in (Fig. 2).
NOTE:
MAKE SURE THERE IS COMPLETE SEALING BETWEEN THE CROSSOVER TUBE AND THE HEADLINER DUCT BEFORE DRILLING IN SCREWS.
19. Perform step 18 on the other side of the headliner.
20. From the left sliding door area, locate the headliner air vent above the 2nd row seat. Pull the headliner down just forward of the vent to access the front of the headliner duct. Remove backing from foam block (p/n 05086279M) and place the foam block, adhesive side down, over the headliner duct as shown in (Fig. 3).
21. Perform step 20 on the right side of the headliner.
22. Place headliner into position and install three new beige push pins, p/n TY98TL2AA to the center of the headliner.
23. Install three new black push pins, p/n 06501916 across rear of the headliner.
24. Install both C-pillar trim panels.
25. Install the A/C duct to the right D-pillar and install both D-pillar trim panels.
26. Install the power liftgate link rod bolt to liftgate and torque to 28 N.m (250 in. lbs.).
27. Install the rear headliner trim cover.
28. Install the rear liftgate sill plate.
29. Install all coat hooks.
30. Install both grab handles to headliner, if equipped.
31. Install the four seat belt anchor bolts and torque to 39 N.m (29 ft. lbs.).
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE