wheel CHRYSLER CARAVAN 2003 Service Manual

damaged, the clutch electromagnetic coil unit must
be replaced.
OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and
drives the compressor shaft. When the coil is not
energized, the pulley freewheels on the clutch hub
bearing, which is part of the pulley.
A zener diode is connected in parallel with the
clutch electromagnetic coil. This diode controls the
dissipation of voltage induced into the coil windings
by the collapsing of the electromagnetic fields that
occurs when the compressor clutch is disengaged.
The zener diode dissipates this induced voltage by
regulating a current path to ground. This arrange-
ment serves to protect other circuits and components
from potentially damaging voltage spikes in the vehi-
cle electrical system that might occur if the voltage
induced in the clutch coil windings could not be dis-
sipated.
The compressor clutch engagement is controlled by
several components: the heater-A/C controls in the
passenger compartment, the A/C pressure transducer
on the liquid line, the evaporator temperature sensor
on the expansion valve, the Powertrain Control Mod-
ule (PCM) in the engine compartment, and the com-
pressor clutch relay in the Intelligent Power Module
(IPM). The PCM may delay compressor clutch
engagement for up to thirty seconds. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION - PCM OPERATION).
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between 0.5 and 0.9 mm
(0.020 and 0.035 in.), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
check that the compressor clutch coil is performing to
specifications. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH COIL - DIAGNOSIS AND TESTING). If
the clutch coil is performing to specifications, per-
form the compressor clutch break-in procedure. This
procedure (burnishing) will seat the opposing friction
surfaces and provide a higher compressor clutch
torque capability.
(1) Set the heater-A/C controls to the A/C mode,
with the blower switch in the highest speed position.
(2) Start the engine and hold the engine speed at
1500 to 2000 rpm.
(3) Cycle the compressor clutch On and Off about
twenty times (seven seconds On, then seven seconds
Off).
REMOVAL
The refrigerant system can remain fully charged
during compressor clutch, pulley, or coil replacement.
Although the compressor assembly must be removed
from its mounting, the compressor clutch can be ser-
vice with the compressor in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
Fig. 11 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (SOME MODELS)
3 - PULLEY AND BEARING
4 - CLUTCH COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
RSCONTROLS - FRONT24-17
COMPRESSOR CLUTCH (Continued)
ProCarManuals.com

door stop positions during the calibration procedure
and will store a Diagnostic Trouble Code (DTC) for
any problems it detects in the mode door actuator
circuits. The mode door actuator can be diagnosed
using a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
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 silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the HVAC wire harness connector
for the mode door actuator from the actuator connec-
tor receptacle (Fig. 21).(4) Remove the two screws that secure the mode
door actuator to the distribution housing.
(5) Remove the mode door actuator from the distri-
bution housing.
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 mode door actuator onto the heat-
er/AC housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the mode door linkage.
(2) Install and tighten the two screws that secure
the mode door actuator to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the mode door actuator to the actuator connector
receptacle.
(4) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL 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. 22). 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 evaporator housing, directly behind the
glove box opening of the instrument panel. The mod-
ule consists of a molded plastic mounting plate with
two integral connector receptacles. Concealed behind
Fig. 21 Mode Door Actuator
1 - CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
RSCONTROLS - FRONT24-25
MODE DOOR ACTUATOR (Continued)
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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 evaporator housing
and is accessed for service by rolling down the glove
box from the instrument panel.
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 instrument panel wire harness.
A second connector receptacle receives the pigtail
wire connector from the blower motor. The blower
power module allows the microprocessor-based Auto-
matic Temperature Control (ATC) heater-A/C control
module 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 voltage is applied to a comparator circuit
which compares the PWM signal voltage to the
blower motor feedback voltage. The resulting output
drives the power module circuitry, which adjusts the
voltage output received from the blower motor relay
to change or maintain the desired blower speed. The
blower power module is diagnosed using a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation.
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) 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 power module from the module con-
nector receptacle.
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the power module connector receptacle.
(6) Remove the two screws that secure the power
module to the evaporator housing.
(7) Remove the power module from the evaporator
housing.
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 power module into the evaporator
housing.
Fig. 22 Power Module
1 - POWER MODULE
2 - LOWER GLOVE BOX OPENING REINFORCEMENT
3 - EVAPORATOR HOUSING
24 - 26 CONTROLS - FRONTRS
POWER MODULE (Continued)
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(2) Install and tighten the two screws that secure
the power module to the evaporator housing. Tighten
the screws to 2 N´m (18 in. lbs.).
(3) Reconnect the blower motor pigtail wire con-
nector to the power module connector receptacle.
(4) Reconnect the instrument panel wire harness
connector for the power module to the module con-
nector 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.
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The recirculation door actuator is a reversible,
12-volt Direct Current (DC), servo motor (Fig. 23).
The single recirculation door actuator is located on
the passenger side end of the heater-A/C housing
unit, on the bottom of the lower intake air housing.
The recirculation door actuator is mechanically con-
nected to the recirculation air door. The recirculation
door actuator is interchangeable with the actuators
for the blend air door(s) and the mode door. Each
actuator is contained within an identical black
molded plastic housing with an integral wire connec-
tor receptacle. Two integral mounting tabs allow the
actuator to be secured with two screws to the lower
intake air housing. Each actuator also has an identi-cal output shaft with splines that connects it to the
linkage that drives the recirculation air door. The
recirculation door actuator does not require mechan-
ical indexing to the recirculation air door, as it is
electronically calibrated by the heater-A/C control
module. The recirculation door actuator cannot be
adjusted or repaired and, if damaged or faulty, it
must be replaced.
OPERATION
The recirculation door actuator is connected to the
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire take out and
connector of the HVAC wire harness. The recircula-
tion door actuator can move the recirculation door in
two directions. When the heater-A/C control module
pulls the voltage on one side of the motor connection
high and the other connection low, the recirculation
air door will move in one direction. When the module
reverses the polarity of the voltage to the motor, the
recirculation air door moves in the opposite direction.
When the module makes the voltage to both connec-
tions high or both connections low, the recirculation
air door stops and will not move. These same motor
connections also provide a feedback signal to the
heater-A/C control module. This feedback signal
allows the module to monitor the operation and rela-
tive position of the recirculation door actuator and
the recirculation air door. The heater-A/C control
module learns the recirculation air door stop posi-
tions during the calibration procedure and will store
a Diagnostic Trouble Code (DTC) for any problems it
detects in the recirculation door actuator circuits.
The recirculation door actuator can be diagnosed
using a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
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.
Fig. 23 Recirculation Door Actuator
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER EVAPORATOR HOUSING
RSCONTROLS - FRONT24-27
POWER MODULE (Continued)
ProCarManuals.com

(2) Pull the carpet on the passenger side front
floor away from the dash panel far enough to access
the recirculation door actuator.
(3) Disconnect the HVAC wire harness connector
for the recirculation door actuator from the actuator
connector receptacle (Fig. 24).
(4) Remove the two screws that secure the recircu-
lation door actuator to the lower intake air housing.
(5) Remove the recirculation door actuator from
the lower intake air housing.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 recirculation door actuator onto
the lower intake air housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the recirculation air door.
(2) Install and tighten the two screws that secure
the recirculation door actuator to the lower intake air
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the recirculation door actuator to the actuator
connector receptacle.
(4) Reposition the carpet on the passenger side
front floor back up to the dash panel.
(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
Fig. 24 Recirculation Door Actuator
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER EVAPORATOR HOUSING
24 - 28 CONTROLS - FRONTRS
RECIRCULATION DOOR ACTUATOR (Continued)
ProCarManuals.com

and also houses the remote front infrared tempera-
ture sensors.
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 center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) Place the center bezel face down on a suitable
work surface. Be certain to take the proper precau-
tions to protect the face of the center bezel from cos-
metic damage.
(4) If the vehicle is equipped with the optional
ATC system, disconnect the ATC remote infrared
temperature sensor jumper harness from the sensor
connector receptacle located on the bottom of the cen-
ter outlet housing (Fig. 3).(5) Remove the three screws that secure the bot-
tom of the outlet housing to the center bezel.
(6) Roll the bottom of the outlet housing upwards
towards the top of the center bezel far enough to dis-
engage the retainer features on the top of the outlet
housing from their receptacles at the top of the cen-
ter bezel.
(7) Remove the center bezel outlets and housing
from the center bezel as a unit.
REMOVAL - DEMISTER OUTLET
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
demister outlet away from the instrument panel top
pad until the snap features on the outlet are released
(Fig. 4).
(2) Remove the demister outlet from the demister
duct opening in the instrument panel top pad.
REMOVAL - FRONT DOOR REAR OUTLET
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the trim panel from the front door
inner panel. (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - REMOVAL).
(3) Using a trim stick or another suitable wide
flat-bladed tool, depress the four latch features (two
top and two bottom) that secure the outlet to the
inside of the trim panel rear outlet opening and push
the outlet unit out through the opening (Fig. 5).
(4) Remove the front door rear outlet through the
outside of the front door trim panel outlet opening.
Fig. 3 Center Bezel Outlets
1 - CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - SCREW (3)
4 - INSTRUMENT PANEL SWITCH BANK
5 - CONNECTOR (ATC ONLY)
6 - JUMPER HARHESS (ATC ONLY)
Fig. 4 Demister Outlet
1 - DEMISTER OUTLET
2 - INSTRUMENT PANEL TOP PAD
3 - TRIM STICK
RSDISTRIBUTION - FRONT24-41
AIR OUTLETS (Continued)
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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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