key CHRYSLER CARAVAN 2003 Owners Manual

INSTALLATION
(1) Engage clip into outside handle to hold lock
cylinder (Fig. 11).
(2) With link arm toward rear of vehicle, push lock
cylinder into door handle until clip snaps into place.
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install watershield and door trim panel.
TRIM PANEL
REMOVAL
(1) Remove the plug and remove screw attaching
door pull cup to inner door panel.
(2) Remove switch bezel and disconnect power win-
dow/memory switch.
(3) Remove screws attaching trim panel to door
from below map pocket.(4) If equipped, remove window crank. (Refer to 23
- BODY/DOOR - FRONT/WINDOW CRANK -
REMOVAL)
(5) Remove screw holding door trim to door panel
from behind inside latch release handle.
(6) Disengage clips attaching door trim to door
frame around perimeter of panel.
(7) Lift trim panel upward to disengage flange
from inner belt molding at top of door.
(8) Tilt top of trim panel away from door to gain
access to latch linkage.
(9) Disengage clip attaching linkage rod to inside
latch release handle (Fig. 12).
(10) Separate linkage rod from latch handle.
(11) Disconnect the power door switch, courtesy
lamp electrical connectors.
(12) Remove front door trim panel from vehicle.
INSTALLATION
(1) Hold top of trim panel away from door to gain
access to latch linkage.
(2) Place linkage rod in position on latch handle.
(3) Engage clip to hold linkage rod to inside latch
release handle.
(4) Place front door trim panel in position on door.
(5) Install trim panel into inner belt molding at
top of door.
Fig. 11 OUTSIDE DOOR HANDLE
1 - CLIP
2 - LOCK CYLINDER
3 - KEY CYLINDER TO LATCH LINK
4 - OUTSIDE HANDLE TO LATCH LINK5 - LOCK KNOB LINK
6 - FRONT DOOR
7 - KEY POSITION SWITCH
8 - OUTSIDE HANDLE
23 - 20 DOOR - FRONTRS
LOCK CYLINDER (Continued)
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EXTERIOR HANDLE
REMOVAL
(1) Roll door glass up.
(2) Remove the watershield as necessary to gain
access to the outside door handle. (Refer to 23 -
BODY/DOOR - FRONT/WATERSHIELD -
REMOVAL)
(3) Through access hole at rear of inner door
panel, disconnect Vehicle Theft Security System
(VTSS) switch connector from door harness, if
equipped.
(4) Disengage push in fasteners attaching VTSS
switch harness to inner door reinforcement bar, if
equipped.
(5) Disengage clip holding door latch linkage to
door latch (Fig. 11).
(6) Remove latch linkage from latch.
(7) Disengage clip holding door lock linkage to
door latch.
(8) Remove lock linkage from latch.
(9) Remove nuts holding outside door handle to
door outer panel.
(10) Remove outside door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary,
transfer lock cylinder from the original handle to the
new one.
(1) Place outside door handle in position on vehi-
cle.
(2) Install nuts attaching outside door handle to
door outer panel (Fig. 11). Tighten nuts to 6 N´m (50
in. lbs.).
(3) Insert lock linkage into door latch.
(4) Engage clip to hold door lock linkage to latch.
(5) Insert latch linkage into door latch.
(6) Engage clip to hold door latch linkage to latch.
(7) Install push-in fasteners to hold VTSS switch
harness to inner door reinforcement bar, if equipped.
(8) Connect VTSS switch connector into door har-
ness, if equipped.
(9) Verify door latch operation.
(10) Install sound shield and door trim panel.
WINDOW REGULATOR -
POWER
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Disconnect wire connector from power window
motor.
(5) Loosen screws attaching front and rear window
guide rails to inner door panel.
(6) Remove screw heads on guide rails from key
hole slots in inner door panel.
(7) Loosen screws attaching motor/housing to inner
door panel.
(8) Remove regulator from inner door panel.
(9) Extract rear guide rail through inner door
panel rear access hole (Fig. 14).
(10) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.
(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 in
lbs).
(6) Tighten screws to attach motor/housing to
inner door panel to 2.8 N´m (25 in lbs).
(7) Connect wire connector into power window
motor.
(8) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(9) Verify door glass alignment and operation.
Fig. 14 FRONT DOOR POWER WINDOW - TYPICAL
1 - POWER WINDOW MOTOR
2 - FRONT DOOR
3 - GUIDE RAILS
23 - 22 DOOR - FRONTRS
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(10) Install inner belt molding (Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION)
(11) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Remove watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - REMOVAL)
(2) Remove inner belt molding.(Refer to 23 -
BODY/WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - REMOVAL)
(3) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL).
(4) Loosen screws attaching front and rear window
guide rails to inner door panel. (Fig. 15).
(5) Remove screw heads on guide rails from key
hole slots in inner door panel.
(6) Loosen screws attaching regulator to inner door
panel.
(7) Remove regulator from inner door panel.
(8) Extract rear guide rail through inner door
panel rear access hole.
(9) Extract front guide rail through front access
hole.
INSTALLATION
(1) Insert front guide rail through front access
hole.
(2) Insert rear guide rail through rear access hole.
(3) Place window regulator in position on inner
door panel.(4) Place screw heads on guide rails in position
through key hole slots in inner door panel.
(5) Tighten screws to attach front and rear guide
rails to inner door panel to 8.5±10.7 N´m (75±95 in
lbs).
(6) Tighten screws to attach regulator to inner
door panel to 2.8 N´m (25 in lbs).
(7) Install door glass. (Refer to 23 - BODY/DOOR -
FRONT/DOOR GLASS - INSTALLATION)
(8) Verify door glass alignment and operation.
(9) Install inner belt molding (Refer to 23 - BODY/
WEATHERSTRIP/SEALS/FDR INNER BELT
WEATHERSTRIP - INSTALLATION)
(10) Install watershield. (Refer to 23 - BODY/
DOOR - FRONT/WATERSHIELD - INSTALLATION)
Fig. 15 FRONT DOOR MANUAL WINDOW
REGULATOR - TYPICAL
1 - FRONT DOOR
2 - MANUAL WINDOW REGULATOR
3 - GUIDE RAILS
RSDOOR - FRONT23-23
WINDOW REGULATOR - POWER (Continued)
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(8) Install screw to hold top of inside release han-
dle to sliding door.
(9) Install screws to hold bottom of inside latch
handle to sliding door.
(10) Verify sliding door operation. Adjust as neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJUSTMENTS)
(11) Install sliding door trim panel.(Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
BELLCRANK
REMOVAL
(1) Remove stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - REMOVAL).
(2) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to gain
access to latch bellcrank.
(4) Disengage lock link (Fig. 21).
(5) Disengage link and sleeve
(6) Remove bellcrank by rotating bellcrank to
release it from door.
(7) Remove bellcrank from vehicle.
INSTALLATION
(1) Position bellcrank on vehicle.
(2) Rotate bellcrank into position.
(3) Place lock link into position and engage clip
(Fig. 21).
(4) Place link and sleeve into position and engage
clip.
(5) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(6) Install sliding door trim panel (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION).
(7) Install stop bumper (Refer to 23 - BODY/
DOORS - SLIDING/STOP BUMPER - INSTALLA-
TION).
Fig. 19 SLIDING DOOR INSIDE HANDLE
1 - INSIDE ASSIST HANDLE
2 - SLIDING DOOR
3 - LATCH BELLCRANK
4 - INSIDE RELEASE HANDLE CABLE
Fig. 20 RELEASE HANDLE CABLE
1 - ASSIST HANDLE MECHANISM
2 - SLIDING DOOR INSIDE ASSIST HANDLE
3 - RELEASE HANDLE CABLE
Fig. 21 BELLCRANK
1 - LOCK LINK
2 - LATCH LINK
3 - LINK AND SLEEVE - OUTSIDE HANDLE
4 - BELLCRANK
5 - KEY CYLINDER LINK (IF EQUIPPED)
23 - 34 DOORS - SLIDINGRS
INSIDE LATCH HANDLE (Continued)
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OUTSIDE HANDLE
REMOVAL
(1) Remove sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL -
REMOVAL)
(2) Remove sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
REMOVAL)
(3) Peel watershield away from adhesive around
perimeter of inner door panel as necessary to access
outside release handle fasteners.
(4) Disengage clip attaching outside door handle
linkage to door cable.
(5) Remove linkage from outside door handle.
(6) Remove three nuts attaching outside door han-
dle to outer door panel (Fig. 22).
(7) Remove outside door handle from vehicle.
INSTALLATION
(1) Position outside door handle on vehicle.
(2) Install nuts attaching outside door handle to
outer door panel.
(3) Engage clip attaching linkage to outside door
handle.
(4) Engage rigging cam to latch/lock control mech-
anism.
(5) Move clip on latch/lock control to bottom of slot
and engage linkage to latch/lock control.
(6) Verify sliding door operation. Adjust as neces-
sary.(7) Place the watershield into position and press
securely to adhesive making sure to properly route
wiring and linkages.
(8) Install sliding door stop bumper. (Refer to 23 -
BODY/DOORS - SLIDING/STOP BUMPER -
INSTALLATION)
(9) Install sliding door trim panel. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
UPPER HINGE
REMOVAL
(1) Open sliding door, do not latch open.
(2) Remove screw attaching upper stop bracket to
upper roller bracket (Fig. 23).
(3) Remove stop bracket from vehicle.
(4) Place a padded block between the open sliding
door and the roof rail.
(5) Mark outline of upper hinge bracket on sliding
door.
(6) Remove bolts attaching upper roller to sliding
door (Fig. 24).
(7) Remove upper hinge from door.
(8) Slide roller out of rear end of roof upper chan-
nel.
(9) Remove upper hinge from vehicle.
INSTALLATION
(1) Place upper hinge in position on vehicle (Fig.
24).
(2) Slide roller into rear end of roof upper channel.
(3) Place upper hinge in position on door.
(4) Align outline marks on sliding door to upper
roller bracket
Fig. 22 SLIDING DOOR OUTSIDE LATCH RELEASE
HANDLE
1 - OUTSIDE DOOR PANEL
2 - LOCK LINK
3 - LATCH LINK
4 - LOCKING LINK AND SLEEVE LINK
5 - BELLCRANK
6 - KEY CYLINDER LOCK LINK (IF EQUIPPED)
7 - KEY CYLINDER (IF EQUIPPED)
Fig. 23 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
RSDOORS - SLIDING23-35
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INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten. Tighten
bolts to 13.5 N´m (120 in. lbs.) torque. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(4) Verify hood operation and alignment.
LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 4).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net
pierced tabs. If alignment is required, flatten or
grind tabs.
(5) Verify hood operation and alignment. Adjust as
necessary.(6) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.
LATCH RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 4).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
Fig. 2 HOOD
1 - HOOD
2 - HOOD LATCH STRIKER
3 - HOOD HALF OF HOOD HINGE
Fig. 3 HOOD LATCH
1 - HOOD RELEASE CABLE
2 - HOOD LATCH
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
Fig. 4 HOOD
1 - RELEASE CABLE CASE
2 - HOOD LATCH
3 - RELEASE CABLE END
23 - 60 HOODRS
HOOD (Continued)
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(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 5).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.
(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 5).(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching striker to inside of
hood.
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts attaching hood latch striker to
hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.Fig. 5 HOOD RELEASE CABLE ROUTING
1 - GROMMET
2 - HOOD RELEASE CABLE
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
RSHOOD23-61
LATCH RELEASE CABLE (Continued)
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SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................113
DIAGNOSIS AND TESTING - SUNROOF.....113
DRAIN TUBE
REMOVAL............................116
INSTALLATION........................117
GLASS PANEL
REMOVAL............................117
INSTALLATION........................117
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 117
SUNROOF ASSEMBLY
REMOVAL............................117
INSTALLATION........................117
SUNSHADE
REMOVAL............................117INSTALLATION........................118
WIND DEFLECTOR
REMOVAL............................118
INSTALLATION........................118
WATER CHANNEL
REMOVAL............................118
INSTALLATION........................118
SUNROOF MOTOR
REMOVAL............................118
INSTALLATION........................118
ADJUSTMENTS
ADJUSTMENT.......................119
SUNROOF SWITCH
REMOVAL............................120
INSTALLATION........................120
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteen
minutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING - SUNROOF
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
RSSUNROOF23 - 113
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fort temperature. For instance, on sunny summer
days the air flow will probably be cooler than the
comfort temperature; on cold or cloudy days and at
night it will probably be slightly warmer. Infrared
Three-Zone Temperature Control provides side-to-
side and front-to-rear variation in comfort tempera-
ture settings. The Infrared Three-Zone Automatic
Temperature Control fan provides a continuously
variable air flow rate to meet occupant comfort
requirements.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DE-FROST± The de-frost function is active
when the rear window defogger function is active or
when the defog/defrost mode is selected.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the Intelligent
Power Module which controls the Rear Window
Defogger and side view mirror (if equipped) circuitry.
The defogger function will be active for 10 minutes
and can be turned off by a switch press. The defogger
will function while the control is in the ON mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that function alone manual for
as long as the ignition is on. If only one is changed
manually, the other remains under automatic control.
Pressing the HI-AUTO/LO-AUTO rocker switch
restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, Defrost mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the a/c system is
operating properly, or use a DRBIIItscan tool to
24 - 4 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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REMOVAL
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.
WARNING: THE BLOWER MOTOR RESISTOR MAY
GET VERY HOT DURING NORMAL OPERATION. IF
THE BLOWER MOTOR WAS TURNED ON, WAIT
FIVE MINUTES TO ALLOW THE BLOWER MOTOR
RESISTOR TO COOL BEFORE PERFORMING DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THIS PRE-
CAUTION CAN RESULT IN PERSONAL INJURY.
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box downward.
(4) Reach through the glove box opening to access
and disconnect the instrument panel wire harness
connector for the blower motor resistor from the
resistor connector receptacle (Fig. 10).
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the resistor connector receptacle.
(6) Remove the two screws that secure the blower
motor resistor to the evaporator housing.
(7) Remove the blower motor resistor from the
evaporator housing.
INSTALLATION
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.(1) Position the blower motor resistor into the
evaporator housing.
(2) Install and tighten the two screws that secure
the blower motor resistor to the evaporator housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the blower motor pigtail wire con-
nector to the blower motor resistor connector recep-
tacle.
(4) Reconnect the instrument panel wire harness
connector for the blower motor resistor to the resistor
connector receptacle.
(5) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box upward.
(6) Close and latch the glove box.
(7) Reconnect the battery negative cable.
COMPRESSOR CLUTCH
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil with a zener diode, a hub
bearing and pulley assembly, and a clutch plate (Fig.
11). The electromagnetic coil unit and the hub bear-
ing and pulley assembly are each retained on the
nose of the compressor front housing with snap rings.
The clutch plate is keyed or splined to the compres-
sor shaft, and secured with a bolt.
The compressor clutch plate and pulley unit, or the
clutch coil are available for separate service replace-
ment. The clutch coil zener diode is integral to the
clutch coil pigtail wire and connector and, if faulty or
Fig. 10 Blower Motor Resistor
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING LOWER REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE
6 - EVAPORATOR HOUSING
24 - 16 CONTROLS - FRONTRS
BLOWER MOTOR RESISTOR (Continued)
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