shaft CHRYSLER CARAVAN 2002 Service Manual

bezel with the snap clip receptacles on the retainer
above the headliner.
(7) Using hand pressure, press the top edge of the
rear heater-A/C control bezel upward until the two
snap clips are fully seated in their receptacles.
(8) Reconnect the battery negative cable.
(9) Using the DRB-IIItreset the Rear Tempera-
ture Selector calibration values.
(10) Verify that the Actuator Calibration of the
Front Control has passed. If an Actuator Calibration
has not passed correct any errors before proceeding
further.
(11) Rotate the Rear Temperature Selector counter
clockwise to the Cold Position, allow the Selector to
remain in the Cold Position for 5 seconds.
(12) Rotate the Rear Temperature Selector Clock-
wise to the Hot Position, allow the Selector to remain
in the Cold Position for 5 seconds.
(13) calibration is now complete.
BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuator is a reversible, 12-volt
Direct Current (DC), servo motor (Fig. 3). The single
blend door actuator is located on the outboard side of
the rear heater-A/C unit housing, below the mode
door actuator. The blend door actuator is mechani-
cally connected to the blend air door. The blend door
actuator is interchangeable with the actuator for the
mode door. Each actuator is contained within an
identical black molded plastic housing with an inte-gral wire connector receptacle. Two integral mount-
ing tabs allow the actuator to be secured with two
screws to the rear heater-A/C unit housing. Each
actuator also has an identical output shaft with
splines that connects it to the pivot or linkage of the
proper door. The blend door actuator does not require
mechanical indexing to the blend air door pivot, as it
is electronically calibrated by the front heater-A/C
control module. The blend door actuator cannot be
adjusted or repaired and, if damaged or faulty, it
must be replaced.
OPERATION
The blend door actuator is connected to the front
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire take out and
connector of the rear HVAC wire harness. The blend
door actuator can move the blend air door in two
directions. When the front heater-A/C control module
pulls the voltage on one side of the motor connection
Fig. 2 Heater-A/C Control Bezel
1 - BEZEL
2 - SNAP CLIP (2)
3 - HEATER-A/C CONTROL
4 - SCREW (3)
5 - LOCATOR TAB (2)
Fig. 3 Blend Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 30 CONTROLS - REARRS
A/C-HEATER CONTROL (Continued)
ProCarManuals.com

high and the other connection low, the blend air door
will move in one direction. When the module reverses
the polarity of the voltage to the motor, the blend air
door moves in the opposite direction. When the mod-
ule makes the voltage to both connections high or
both connections low, the blend air door stops and
will not move. These same motor connections also
provide a feedback signal to the front heater-A/C con-
trol module. This feedback signal allows the module
to monitor the operation and relative positions of the
blend door actuator and the blend air door. The front
heater-A/C control module learns the blend air door
stop positions during the calibration procedure and
will store a Diagnostic Trouble Code (DTC) for any
problems it detects in the blend door actuator cir-
cuits. A DTC can be retrieved and the blend door
actuator can be diagnosed using a DRBIIItscan tool.
Refer to the appropriate diagnostic information.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(4) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar.
(5) Remove the screw that secures the front of the
rear heater-A/C unit housing to the right quarter
inner panel.
(6) Carefully pull the top of the rear heater-A/C
unit housing away from the right quarter inner panel
far enough to reach between the rear heater-A/C unit
housing and the quarter inner panel to access the
blend door actuator (Fig. 4).
(7) Remove the two screws that secure the blend
door actuator to the rear heater-A/C unit housing.
(8) Pull the blend door actuator away from the
rear heater-A/C unit housing far enough to disengage
the actuator output shaft from the blend air door
pivot.
(9) Raise the blend door actuator far enough to
access and disconnect the rear HVAC wire harness
connector for the actuator from the actuator connec-
tor receptacle.
(10) Remove the blend door actuator from between
the rear heater-A/C unit housing and the quarter
inner panel.
INSTALLATION
(1) Position the blend door actuator between the
rear heater-A/C unit housing and the quarter inner
panel.
(2) Reconnect the rear HVAC wire harness connec-
tor for the blend door actuator to the actuator con-
nector receptacle.
(3) Position the blend door actuator onto the rear
heater-A/C unit housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the blend air door pivot.
(4) Install and tighten the two screws that secure
the blend door actuator to the rear heater-A/C unit
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(5) Push the top of the rear heater-A/C unit hous-
ing back into position against the right quarter inner
panel.
(6) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
Fig. 4 Mode Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
RSCONTROLS - REAR24-31
BLEND DOOR ACTUATOR (Continued)
ProCarManuals.com

INFRARED TEMPERATURE
SENSOR
DESCRIPTION
The rear infrared temperature sensor consists of
an infrared transducer that is concealed behind the
lens of the rear heater-A/C control in the headliner.
This sensor is used only on models equipped with the
optional Automatic Temperature Control (ATC) heat-
ing and air conditioning system. The rear infrared
temperature sensor is integral to the rear heater-A/C
control. The infrared sensor cannot be adjusted or
repaired and, if faulty or damaged, the rear heater-
A/C control unit must be replaced.
OPERATION
The rear infrared temperature sensor provides an
independent measurement input to the Automatic
Temperature Control (ATC) heater-A/C control mod-
ule that indicates the surface temperature of the rear
seat occupants. By using a surface temperature mea-
surement, rather than an air temperature measure-
ment, the ATC system is able to adjust itself to the
comfort level as perceived by the occupant. This
allows the system to detect and compensate for other
ambient conditions affecting comfort levels, such as
solar heat gain or evaporative heat loss. The ATC
system logic responds to the infrared sensor input by
calculating and adjusting the air flow temperature
and air flow rate needed to properly obtain and
maintain the selected comfort level temperatures for
the rear seat occupants. The ATC heater-A/C control
module continually monitors the infrared sensor cir-
cuit, and will store a Diagnostic Trouble Code (DTC)
for any problem it detects. This DTC information can
be retrieved and the infrared temperature sensor
diagnosed using a DRBIIItscan tool. Refer to the
appropriate diagnostic information.
MODE DOOR ACTUATOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(4) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar.(5) Remove the screw that secures the front of the
rear heater-A/C unit housing to the right quarter
inner panel.
(6) Carefully pull the top of the rear heater-A/C
unit housing away from the right quarter inner panel
far enough to reach between the rear heater-A/C unit
housing and the quarter inner panel to access the
mode door actuator (Fig. 10).
(7) Remove the two screws that secure the mode
door actuator to the rear heater-A/C unit housing.
(8) Pull the mode door actuator away from the
rear heater-A/C unit housing far enough to disengage
the actuator output shaft from the mode door link-
age.
(9) Raise the mode door actuator far enough to
access and disconnect the rear HVAC wire harness
connector for the actuator from the actuator connec-
tor receptacle.
Fig. 10 Blend Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 36 CONTROLS - REARRS
ProCarManuals.com

(10) Remove the mode door actuator from between
the rear heater-A/C unit housing and the quarter
inner panel.
INSTALLATION
(1) Position the mode door actuator between the
rear heater-A/C unit housing and the quarter inner
panel.
(2) Reconnect the rear HVAC wire harness connec-
tor for the mode door actuator to the actuator connec-
tor receptacle.
(3) Position the mode door actuator onto the rear
heater-A/C unit housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the mode door linkage.
(4) Install and tighten the two screws that secure
the mode door actuator to the rear heater-A/C unit
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(5) Push the top of the rear heater-A/C unit hous-
ing back into position against the right quarter inner
panel.
(6) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).
(7) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(8) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel. Tighten the screws to 1.7
N´m (15 in. lbs.).
(9) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(10) Reconnect the battery negative cable.
(11) Perform the heater-A/C control calibration
procedure. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION).
POWER MODULE
DESCRIPTION
A blower power module is used on this model when
it is equipped with the optional Automatic Tempera-
ture Control (ATC) (Fig. 11). Models equipped with
the standard manual heater-A/C control use a blower
motor resistor, instead of the blower power module.
The blower power module is installed in a mounting
hole in the back of the rear heater-A/C unit housing,
directly above the expansion valve. The module con-
sists of a molded plastic mounting plate with twointegral connector receptacles. Concealed behind the
mounting plate within the evaporator housing is the
power module electronic circuitry and a large finned,
heat sink. The module mounting plate is secured
with two screws to the rear heater-A/C unit housing
and is accessed for service by removing the right
quarter and D-pillar trim panels.
The power module heat sink will get hot when in
use. Do not touch the heat sink if the blower motor
has been running. The blower power module cannot
be adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The blower power module is connected to the vehi-
cle electrical system through a dedicated take out
and connector of the rear HVAC wire harness. A sec-
ond connector receptacle receives the pigtail wire
connector from the blower motor. The blower power
module allows the microprocessor-based Automatic
Temperature Control (ATC) heater-A/C control mod-
ule to calculate and provide infinitely variable blower
motor speeds based upon either manual blower
switch input or the ATC programming using a Pulse
Width Modulated (PWM) circuit strategy. The PWM
Fig. 11 Power Module
1 - REAR HEATER-A/C UNIT HOUSING
2 - SCREW (2)
3 - D-PILLAR
4 - BLOWER PIGTAIL WIRE
5 - REAR HVAC WIRE HARNESS
6 - EXPANSION VALVE
7 - BLOWER POWER MODULE
RSCONTROLS - REAR24-37
MODE DOOR ACTUATOR (Continued)
ProCarManuals.com

INSTALLATION
INSTALLATION - CENTER BEZEL OUTLETS
(1) Position the center bezel outlets and housing
onto the center bezel as a unit.
(2) Engage the retainer features on the top of the
outlet housing with their receptacles at the top of the
center bezel, then roll the bottom of the outlet hous-
ing downwards towards the center bezel.
(3) Install and tighten the three screws that secure
the bottom of the outlet housing to the center bezel.
Tighten the screws to 2 N´m (17 in. lbs.).
(4) If the vehicle is equipped with the optional
ATC system, reconnect the ATC remote infrared tem-
perature sensor jumper harness to the sensor connec-
tor receptacle located on the bottom of the center
outlet housing.
(5) Reinstall the center bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(6) Reconnect the battery negative cable.
INSTALLATION - DEMISTER OUTLET
(1) Position the demister outlet over the demister
duct opening in the instrument panel top pad.
(2) Using hand pressure, press the demister outlet
firmly and evenly into the instrument panel top pad
opening until the snap features on the outlet are
fully engaged.
INSTALLATION - FRONT DOOR REAR OUTLET
(1) Position the front door rear outlet through the
outside of the front door trim panel outlet opening.
(2) While keeping the outlet aligned with the door
duct opening behind the trim panel, use hand pres-
sure to press the outlet firmly and evenly through
the outside of the front door trim panel outlet open-
ing until the four latch features (two top and two bot-
tom) that secure the outlet to the inside of the
opening are fully engaged.
(3) Reinstall the trim panel onto the front door
inner panel. (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - INSTALLATION).
(4) Reconnect the battery negative cable.
INSTALLATION - INSTRUMENT PANEL OUTLET
(1) Position the instrument panel outlet into the
panel duct opening in the instrument panel top pad.
(2) Using hand pressure, press the instrument
panel outlet firmly and evenly into the instrument
panel top pad opening until the snap features on the
outlet are fully engaged.
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 7). The
blower motor and wheel are located near the passen-
ger side end of the heater-A/C unit within the two
halves of the intake air housing in the passenger
compartment below the instrument panel. The
blower motor and blower motor wheel are a factory
balanced unit and cannot be adjusted or repaired. If
faulty or damaged, the blower motor and blower
wheel must be replaced as a unit.
OPERATION
The blower motor will operate whenever the igni-
tion switch is in the On position and the heater-A/C
control power is turned on. The blower motor can
only be turned off by turning off the power at the
heater-A/C control. The blower motor receives battery
current whenever the front blower motor relay is
energized. The front blower motor relay output cir-
cuit is protected by a fuse in the Intelligent Power
Module (IPM) located in the engine compartment
near the battery. In the Manual system, the blower
motor speed is controlled by regulating the path to
ground through the blower control switch and the
blower motor resistor. In the ATC system, the blower
motor speed is controlled by an electronic blower
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
blower motor to regulate the blower motor ground
Fig. 7 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-43
AIR OUTLETS (Continued)
ProCarManuals.com

A/C DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear air conditioning distribution duct
upwards far enough to disengage it from the outlet at
the top of the rear heater-A/C unit housing (Fig. 2).
(3) While pulling the lower end of the auxiliary air
conditioning distribution duct away from the rear
heater-A/C unit outlet, disengage the upper end of
the distribution duct from the headliner duct.
(4) Remove the auxiliary air conditioning distribu-
tion duct from the vehicle.
INSTALLATION
(1) Align the upper end of the rear air conditioning
distribution duct to the headliner duct.
(2) Slide the upper end of the rear air conditioning
distribution duct onto the headliner duct far enough
to align the lower end of the duct with the outlet at
the top of the rear heater-A/C unit housing.
(3) Slide the rear air conditioning distribution duct
downwards far enough to engage it onto the outlet at
the top of the rear heater-A/C unit housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar. (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 3). The
blower motor and wheel are located in a housing
near the top of the rear heater-A/C unit in the pas-
senger compartment behind the right rear wheel
house. The rear heater-A/C unit housing must be
removed from the vehicle to access the blower motor
and blower wheel for service. The blower motor and
blower motor wheel are a factory balanced unit and
cannot be adjusted or repaired. If faulty or damaged,
the blower motor and blower wheel must be replaced
as a unit.
OPERATION
The rear blower motor will operate whenever the
ignition switch is in the On position, the heater-A/C
control power is turned on, and the rear heater-A/C
Fig. 2 Rear A/C Distribution Duct
1 - HEADLINER DUCT
2 - REAR A/C DISTRIBUTION DUCT
3 - REAR HEATER-A/C UNIT OUTLET
Fig. 3 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
24 - 52 DISTRIBUTION - REARRS
ProCarManuals.com

ward far enough to disengage the engine compart-
ment ends of the tubes from the dash panel seal.
(14) Remove the heater core tubes and sealing
plate as a unit from beneath the instrument panel.
(15) Use absorbent toweling to clean up any
engine coolant spills from the preceding operation.
REMOVAL - HEATER CORE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the silencer boot fasteners located
around the base of the lower steering shaft from the
dash panel so that it may be pushed aside.
(4) Remove the brake lamp switch from its mount-
ing bracket. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
REMOVAL).
(5) Disconnect the power brake booster input rod
(push rod) from the pin on the brake pedal arm.
(Refer to 5 - BRAKES - ABS/HYDRAULIC/ME-
CHANICAL/POWER BRAKE BOOSTER - REMOV-
AL).
(6) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 17).
(7) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.(8) Remove the heater core shield from the distri-
bution housing.
(9) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-
ant and have absorbent toweling readily available to
mop up any spills.
(10) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 18).
Fig. 17 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 18 Heater Core
1 - SEALING PLATE
2 - SCREW
3 - SCREWS (2)
4 - HEATER CORE
5 - HEATER CORE TUBES
RSPLUMBING - FRONT24-75
HEATER CORE (Continued)
ProCarManuals.com

(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel.
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(10) Reconnect the heater hoses to the heater hose
tubes. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(11) Reconnect the battery negative cable.
(12) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
INSTALLATION - HEATER CORE
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) While pushing the brake pedal downward and
pulling the accelerator pedal upward far enough for
clearance, slide the heater core into the distribution
housing.
(2) Install and tighten the two screws that secure
the heater core mounting plate to the distribution
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Remove the plugs or tape from the heater core
tube fittings and both heater core ports.
(4) Position both heater core tubes and the sealing
plate simultaneously to the heater core supply and
return ports.
(5) The heater core tubes each have a slot that
must be indexed to a location tab within each of the
heater core ports. Adjust the position of the tubes as
required so that the sealing plate fits flush against
the heater core supply and return ports, which indi-
cates that the tubes are properly indexed.
(6) Install and tighten the screw that secures the
heater core tube sealing plate to the heater core sup-
ply and return ports. Tighten the screw to 3 N´m (27
in. lbs.).
(7) Position the heater core shield onto the distri-
bution housing. Be certain that the two location tabs
on the front of the shield are engaged in the recepta-
cles in the two lower finger formations of the evapo-
rator housing near the dash panel.
(8) Install and tighten the three screws that secure
the heater core shield to the left end of the HVAC
distribution housing. Tighten the screws to 2 N´m (17
in. lbs.).
(9) Reconnect the power brake booster input rod
(push rod) to the pin on the brake pedal arm(Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/POWER
BRAKE BOOSTER - INSTALLATION).
(10) Reinstall the brake lamp switch into its
mounting bracket(Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION).
(11) Reinstall the silencer boot around the base of
the lower steering shaft on the dash panel.
(12) Reconnect the battery negative cable.
(13) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(14) Operate system for two thermostat cycles to
assure elimination of air in the system.
RSPLUMBING - FRONT24-77
HEATER CORE (Continued)
ProCarManuals.com

The following is a list of the monitored compo-
nents:
²Comprehensive Components
²Oxygen Sensor Monitor
²Oxygen Sensor Heater Monitor
²Catalyst Monitor
COMPREHENSIVE COMPONENTS
Along with the major monitors, OBD II requires
that the diagnostic system monitor any component
that could affect emissions levels. In many cases,
these components were being tested under OBD I.
The OBD I requirements focused mainly on testing
emissions-related components for electrical opens and
shorts.
However, OBD II also requires that inputs from
powertrain components to the PCM be tested for
rationality, and that outputs to powertrain compo-
nents from the PCM be tested forfunctionality.
Methods for monitoring the various Comprehensive
Component monitoring include:
(1) Circuit Continuity
²Open
²Shorted high
²Shorted to ground
(2) Rationality or Proper Functioning
²Inputs tested for rationality
²Outputs tested for functionality
NOTE: Comprehensive component monitors are
continuous. Therefore, enabling conditions do not
apply.
Input RationalityÐWhile input signals to the
PCM are constantly being monitored for electrical
opens and shorts, they are also tested for rationality.
This means that the input signal is compared against
other inputs and information to see if it makes sense
under the current conditions.
PCM sensor inputs that are checked for rationality
include:
²Manifold Absolute Pressure (MAP) Sensor
²Oxygen Sensor (O2S)
²Engine Coolant Temperature (ECT) Sensor
²Camshaft Position (CMP) Sensor
²Vehicle Speed Sensor
²Crankshaft Position (CKP) Sensor
²Intake/inlet Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Ambient/Battery Temperature Sensors
²Power Steering Switch
²Oxygen Sensor Heater
²Engine Controller
²Brake Switch
²Leak Detection Pump Switch (if equipped)
²P/N Switch
²Trans ControlsOutput FunctionalityÐPCM outputs are tested
for functionality in addition to testing for opens and
shorts. When the PCM provides a voltage to an out-
put component, it can verify that the command was
carried out by monitoring specific input signals for
expected changes. For example, when the PCM com-
mands the Idle Air Control (IAC) Motor to a specific
position under certain operating conditions, it expects
to see a specific (target) idle speed (RPM). If it does
not, it stores a DTC.
PCM outputs monitored for functionality include:
²Fuel Injectors
²Ignition Coils
²Torque Converter Clutch Solenoid
²Idle Air Control
²Purge Solenoid
²EGR Solenoid (if equipped)
²LDP Solenoid (if equipped)
²Radiator Fan Control
²Trans Controls
OXYGEN SENSOR (O2S) MONITOR
DESCRIPTIONÐEffective control of exhaust
emissions is achieved by an oxygen feedback system.
The most important element of the feedback system
is the O2S. The O2S is located in the exhaust path.
Once it reaches operating temperature 300É to 350ÉC
(572É to 662ÉF), the sensor generates a voltage that
is inversely proportional to the amount of oxygen in
the exhaust. When there is a large amount of oxygen
in the exhaust caused by a lean condition, the sensor
produces a low voltage, below 450 mV. When the oxy-
gen content is lower, caused by a rich condition, the
sensor produces a higher voltage, above 450mV.
The information obtained by the sensor is used to
calculate the fuel injector pulse width. The PCM is
programmed to maintain the optimum air/fuel ratio.
At this mixture ratio, the catalyst works best to
remove hydrocarbons (HC), carbon monoxide (CO)
and nitrous oxide (NOx) from the exhaust.
The O2S is also the main sensing element for the
EGR (if equipped), Catalyst and Fuel Monitors.
The O2S may fail in any or all of the following
manners:
²Slow response rate (Big Slope)
²Reduced output voltage (Half Cycle)
²Heater Performance
Slow Response Rate (Big Slope)ÐResponse rate
is the time required for the sensor to switch from
lean to rich signal output once it is exposed to a
richer than optimum A/F mixture or vice versa. As
the PCM adjusts the air/fuel ratio, the sensor must
be able to rapidly detect the change. As the sensor
ages, it could take longer to detect the changes in the
oxygen content of the exhaust gas. The rate of
change that an oxygen sensor experiences is called
25 - 2 EMISSIONS CONTROLRS
EMISSIONS CONTROL (Continued)
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Effective control of exhaust emissions is achieved
by an oxygen feedback system. The most important
element of the feedback system is the O2S. The O2S
is located in the exhaust path. Once it reaches oper-
ating temperatures of 300É to 350ÉC (572 É to 662ÉF),
the sensor generates a voltage that is inversely pro-
portional to the amount of oxygen in the exhaust.
The information obtained by the sensor is used to
calculate the fuel injector pulse width. This main-
tains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture
ratio, the catalyst works best to remove hydrocarbons
(HC), carbon monoxide (CO) and nitrogen oxide
(NOx) from the exhaust.
The voltage readings taken from the O2S are very
temperature sensitive. The readings are not accurate
below 300ÉC. Heating of the O2S is done to allow the
engine controller to shift to closed loop control as
soon as possible. The heating element used to heat
the O2S must be tested to ensure that it is heating
the sensor properly.
The O2S circuit is monitored for a drop in voltage.
The sensor output is used to test the heater by iso-
lating the effect of the heater element on the O2S
output voltage from the other effects.
EGR MONITOR (if equipped)
The Powertrain Control Module (PCM) performs
an on-board diagnostic check of the EGR system.
The EGR monitor is used to test whether the EGR
system is operating within specifications. The diag-
nostic check activates only during selected engine/
driving conditions. When the conditions are met, the
EGR is turned off (solenoid energized) and the O2S
compensation control is monitored. Turning off the
EGR shifts the air fuel (A/F) ratio in the lean direc-
tion. The O2S data should indicate an increase in the
O2 concentration in the combustion chamber when
the exhaust gases are no longer recirculated. While
this test does not directly measure the operation of
the EGR system, it can be inferred from the shift in
the O2S data whether the EGR system is operating
correctly. Because the O2S is being used, the O2S
test must pass its test before the EGR test. Also
looks at EGR linear potentiometer for feedback.
MISFIRE MONITOR
Excessive engine misfire results in increased cata-
lyst temperature and causes an increase in HC emis-
sions. Severe misfires could cause catalyst damage.
To prevent catalytic convertor damage, the PCM
monitors engine misfire.
The Powertrain Control Module (PCM) monitors
for misfire during most engine operating conditions
(positive torque) by looking at changes in the crank-
shaft speed. If a misfire occurs the speed of the
crankshaft will vary more than normal.FUEL SYSTEM MONITOR
To comply with clean air regulations, vehicles are
equipped with catalytic converters. These converters
reduce the emission of hydrocarbons, oxides of nitro-
gen and carbon monoxide. The catalyst works best
when the air fuel (A/F) ratio is at or near the opti-
mum of 14.7 to 1.
The PCM is programmed to maintain the optimum
air/fuel ratio. This is done by making short term cor-
rections in the fuel injector pulse width based on the
O2S output. The programmed memory acts as a self
calibration tool that the engine controller uses to
compensate for variations in engine specifications,
sensor tolerances and engine fatigue over the life
span of the engine. By monitoring the actual air-fuel
ratio with the O2S (short term) and multiplying that
with the program long-term (adaptive) memory and
comparing that to the limit, it can be determined
whether it will pass an emissions test. If a malfunc-
tion occurs such that the PCM cannot maintain the
optimum A/F ratio, then the MIL will be illuminated.
CATALYST MONITOR
To comply with clean air regulations, vehicles are
equipped with catalytic converters. These converters
reduce the emission of hydrocarbons, oxides of nitro-
gen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a
catalyst to decay. A meltdown of the ceramic core can
cause a reduction of the exhaust passage. This can
increase vehicle emissions and deteriorate engine
performance, driveability and fuel economy.
The catalyst monitor uses dual oxygen sensors
(O2S's) to monitor the efficiency of the converter. The
dual O2S's strategy is based on the fact that as a cat-
alyst deteriorates, its oxygen storage capacity and its
efficiency are both reduced. By monitoring the oxy-
gen storage capacity of a catalyst, its efficiency can
be indirectly calculated. The upstream O2S is used to
detect the amount of oxygen in the exhaust gas
before the gas enters the catalytic converter. The
PCM calculates the A/F mixture from the output of
the O2S. A low voltage indicates high oxygen content
(lean mixture). A high voltage indicates a low content
of oxygen (rich mixture).
When the upstream O2S detects a lean condition,
there is an abundance of oxygen in the exhaust gas.
A functioning converter would store this oxygen so it
can use it for the oxidation of HC and CO. As the
converter absorbs the oxygen, there will be a lack of
oxygen downstream of the converter. The output of
the downstream O2S will indicate limited activity in
this condition.
As the converter loses the ability to store oxygen,
the condition can be detected from the behavior of
the downstream O2S. When the efficiency drops, no
RSEMISSIONS CONTROL25-7
EMISSIONS CONTROL (Continued)
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