service CHRYSLER CARAVAN 2003 Service Manual
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Page 2040 of 2177
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
path it provides. The blower motor and wheel areused to control the velocity of air moving through the
heater-A/C unit housing. The blower motor controls
the velocity of the air flowing through the heater-A/C
housing by spinning the blower wheel within the
housing at the selected speed or, in the ATC system,
at the selected or programmed speed.
DIAGNOSIS AND TESTING - BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
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) Check the fuse (Fuse 10 - 40 ampere) in the
Intelligent Power Module (IPM). If OK, go to Step 2.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
(2) Turn the ignition switch to the On position. Be
certain that the heater-A/C control power is turned
on. Check for battery voltage at the fuse (Fuse 10 -
40 ampere) in the IPM. If OK, go to Step 3. If not
OK, proceed to diagnosis of the front blower motor
relay. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/BLOWER MOTOR
RELAY - DIAGNOSIS AND TESTING).
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the front HVAC wire harness connector
for the front blower motor resistor (Manual Temper-
ature Control) or the front blower power module
(Automatic Temperature Control) from the resistor or
module connector receptacle. Reconnect the battery
negative cable. Turn the ignition switch to the On
position. Be certain that the heater-A/C control
power is turned on. Check for battery voltage at the
fused front blower motor relay output circuit cavity
of the front HVAC wire harness connector for the
front blower motor resistor (MTC) or the front blower
power module (ATC). If OK, go to Step 4. If not OK,
repair the open fused front blower motor relay output
circuit to the IPM as required.
Fig. 7 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-43
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REMOVAL
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Disconnect the blower motor pigtail harness
connector from the connector receptacle of either the
blower motor resistor or power module, depending
how vehicle is equipped (Fig. 9).
(2) Remove the HVAC assembly from the vehi-
cle(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).(3) Remove the two screws that secure the recircu-
lation door actuator and disengage the wire harness
from the routing clips molded into the bottom of the
lower air intake housing.
(4) Remove the one screw (from the top) that
secures the lower air intake housing to the upper air
intake housing.
(5) Remove the four screws (from the bottom) that
secures the lower air intake housing to the lower half
of the evaporator housing and the upper air intake
housing.
(6) Push the rubber grommet on the blower motor
pigtail wires through the hole in the lower intake air
housing (Fig. 10).
(7) Feed the blower motor pigtail wires and electri-
cal connector through the grommet hole in the lower
intake air housing.
(8) Relocate the recirculation air door as necessary
to access and remove the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing (Fig. 11).
(9) Gently flex the recirculation air door far
enough to remove the blower motor and blower wheel
from the blower housing in the lower half of the
evaporator housing.
INSTALLATION
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
Fig. 9 Lower Intake Air Housing
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION AIR DOOR ACTUATOR
3 - BLOWER MOTOR PIGTAIL WIRE CONNECTOR
4 - RUBBER GROMMET
5 - BLOWER MOTOR RESISTOR/POWER MODULE
6 - LOWER EVAPORATOR HOUSING
7 - UPPER INTAKE AIR HOUSING
8 - RECIRCULATION AIR DOOR
Fig. 10 Rubber Grommet - Typical
1 - BLOWER MOTOR PIGTAIL WIRE GROMMET
24 - 46 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)
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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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Gently flex the recirculation air door far
enough to position the blower motor and blower
wheel into the blower housing in the lower half of the
evaporator housing.
(2) Install and tighten the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing. Tighten the screws to
2 N´m (18 in. lbs.).
(3) Feed the blower motor pigtail wires and electri-
cal connector through the grommet hole in the lower
intake air housing and seat the rubber grommet.
(4) Position the recirculation door in the lower air
inlet housing and place in position.
(5) Install and tighten the four screws (from the
bottom) that secure the lower air intake housing to
the lower half of the evaporator housing. Tighten the
screws to 2 N´m (18 in. lbs.).
(6) Install and tighten the one screw that secures
the upper intake air housing to the lower intake air
housing. Tighten the screws to 2 N´m (18 in. lbs.).(7) Install the recirculation actuator making cer-
tain that the splines are aligned and secure the
actuator with two screws and torque the to 2 N´m (18
in. lbs.). Route the wiring into the molded inn rout-
ing clips.
(8) Install the HVAC unit in the vehicle(Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - INSTALLATION).
(9) Connect the blower motor pigtail wire harness
electrical connector back into either the power mod-
ule or resistor receptacle.
(10) Run the Heater-A/C Calibration procedure(Re-
fer to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C HEATER CONTROL - STANDARD
PROCEDURE).
(11) Run the HVAC Control Cool down test(Refer
to 24 - HEATING & AIR CONDITIONING - DIAG-
NOSIS AND TESTING).
DEFROSTER DUCT
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the defroster
duct to the instrument panel armature.
(5) Remove the defroster duct from the instrument
panel.
Fig. 11 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-47
BLOWER MOTOR (Continued)
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INSTALLATION
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) Position the defroster duct to the instrument
panel.
(2) Install the fasteners that secure the defroster
duct to the instrument panel armature.
(3) Reinstall the instrument panel in the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Reconnect the battery negative cable.
DEMISTER DUCTS
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.(4) Remove the fasteners that secure the demister
ducts to the instrument panel armature.
(5) Disengage the demister ducts from the demis-
ter outlets.
(6) Remove the demister ducts from the instru-
ment panel.
INSTALLATION
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) Position the demister ducts to the instrument
panel.
(2) Engage the demister ducts to the demister out-
lets.
(3) Install the fasteners that secure the demister
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 12).
(3) Pull the floor distribution duct assembly rear-
ward far enough to disengage the center floor distri-
bution duct from the outlet on the bottom of the
heater-A/C housing unit.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
24 - 48 DISTRIBUTION - FRONTRS
DEFROSTER DUCT (Continued)
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INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required.
(2) Slide the floor distribution duct assembly
under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.
(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
REMOVAL
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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (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) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Remove the windshield wiper module from the
vehicle(Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
Fig. 12 Floor Distribution Ducts
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-49
FLOOR DISTRIBUTION DUCTS (Continued)
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Page 2048 of 2177
(8) Install the windshield wiper module(Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(9) Reconnect the battery negative cable.
(10) Refill the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(11) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(12) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
PANEL DUCTS
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the panel
ducts to the instrument panel armature.
(5) Disengage the panel ducts from the panel out-
lets.
(6) Remove the panel ducts from the instrument
panel.
INSTALLATION
(1) Position the panel ducts to the instrument
panel.
(2) Engage the panel ducts to the panel outlets.
(3) Install the fasteners that secure the panel
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
RSDISTRIBUTION - FRONT24-51
HVAC HOUSING (Continued)
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DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION.........................52
REMOVAL.............................52
INSTALLATION.........................52
A/C DISTRIBUTION DUCT
REMOVAL.............................53
INSTALLATION.........................53
BLOWER MOTOR
DESCRIPTION.........................53
OPERATION...........................54DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................54
REMOVAL.............................56
INSTALLATION.........................56
REAR HEATER-A/C HOUSING
REMOVAL.............................56
INSTALLATION.........................58
REAR HEATER DISTRIBUTION DUCT
REMOVAL.............................59
INSTALLATION.........................59
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear heater-A/C unit housing through
one or a combination of the two main housing out-
lets: air conditioner, or heater. Once the conditioned
air exits the unit housing, it is directed through
molded plastic ducts to the various outlets in the
vehicle interior. These outlets and their locations are
as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear heater distribution duct to the intermediate and
rear seat occupants. The floor outlets are integral to
the right quarter trim panel and, if faulty or dam-
aged, the quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear A/C distribution
duct and the headliner ducts to the intermediate and
rear seat occupants. The headliner ducts are integral
to the headliner panel. Each overhead outlet is
housed in a headliner bezel. The two forward head-
liner bezels also feature a courtesy lamp, a fold-away
coat hook, and a fold-away assist handle. The over-
head outlets can be removed from the headliner
bezels individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel.
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
24 - 52 DISTRIBUTION - REARRS
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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.
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
RSDISTRIBUTION - REAR24-53
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Page 2055 of 2177
INSTALLATION
NOTE: If the rear heater core or the rear heater-A/C
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Position the rear heater-A/C unit housing into
the vehicle with the evaporator extension line sealing
plate inserted into the rectangular hole in the rear
floor panel behind the right rear wheel house.
(2) Align the rear heater-A/C unit housing lower
mounting studs with the mounting holes in the rear
floor panel and lower the unit to the floor.
(3) 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.).(4) 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.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Reinstall the rear heater distribution duct onto
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
INSTALLATION).
(8) Install and tighten the two screws that secure
the bottom of the quarter trim panel attaching
bracket to the rear heater-A/C unit housing. Tighten
the screws to 1.7 N´m (15 in. lbs.).
(9) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel.
Fig. 8 Rear Heater-A/C Housing
1 - U-NUT (3)
2 - REAR HEATER-A/C HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
24 - 58 DISTRIBUTION - REARRS
REAR HEATER-A/C HOUSING (Continued)
ProCarManuals.com
Page 2057 of 2177
PLUMBING - FRONT
TABLE OF CONTENTS
page page
PLUMBING - FRONT
WARNING
WARNING...........................61
WARNING - A/C PLUMBING.............61
CAUTION - A/C PLUMBING...............61
A/C COMPRESSOR
DESCRIPTION.........................63
OPERATION...........................63
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS....................63
REMOVAL
REMOVAL - COMPRESSOR - 2.4/3.3/3.8L
ENGINES............................64
REMOVAL - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE...............65
INSTALLATION
INSTALLATION - COMPRESSOR..........65
INSTALLATION - COMPRESSOR
MOUNTING BRACKET - 2.4L ENGINE......66
CONDENSER
DESCRIPTION.........................66
OPERATION...........................66
REMOVAL.............................66
INSTALLATION.........................67
DISCHARGE LINE
REMOVAL.............................68
INSTALLATION.........................69
EVAPORATOR
DESCRIPTION.........................69
OPERATION...........................70
REMOVAL.............................70
INSTALLATION.........................71
EXPANSION VALVE
DESCRIPTION.........................72
OPERATION...........................72
DIAGNOSIS AND TESTING - EXPANSION
VALVE ..............................72
REMOVAL.............................73
INSTALLATION.........................74
HEATER CORE
DESCRIPTION.........................74
OPERATION...........................74
REMOVAL
REMOVAL- HEATER CORE EXTENSION
TUBES.............................75REMOVAL - HEATER CORE.............76
INSTALLATION
INSTALLATION- HEATER CORE
EXTENSION TUBES...................77
INSTALLATION - HEATER CORE..........78
HEATER HOSE
REMOVAL.............................78
INSTALLATION.........................80
LIQUID LINE
REMOVAL.............................80
INSTALLATION.........................82
RECEIVER/DRIER
DESCRIPTION.........................83
OPERATION...........................84
REMOVAL.............................84
INSTALLATION.........................84
REFRIGERANT
DESCRIPTION.........................85
OPERATION...........................85
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM CHARGE LEVEL...............85
DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS......................86
STANDARD PROCEDURE
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT..........87
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE.....................88
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE...................89
STANDARD PROCEDURE - REFRIGERANT
RECOVERY..........................89
REFRIGERANT OIL
DESCRIPTION.........................90
OPERATION...........................90
STANDARD PROCEDURE - REFRIGERANT
OIL LEVEL...........................90
SUCTION LINE
REMOVAL.............................90
INSTALLATION.........................91
SERVICE PORTS
REMOVAL.............................92
INSTALLATION.........................93
24 - 60 PLUMBING - FRONTRS
ProCarManuals.com