ECO mode CHRYSLER CARAVAN 2003 Workshop Manual

(15) Install input clutch assembly to the Input
Clutch Pressure Fixture±Tool 8391 (Fig. 261).
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 262).(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
263). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005±0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90É apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB 5.837-5.937 mm (0.230-0.234 in.)
4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
Fig. 261 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 262 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 263 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
RS41TE AUTOMATIC TRANSAXLE21 - 223
INPUT CLUTCH ASSEMBLY (Continued)
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(33) Using moderate pressure, press down and
hold (near indicator) reverse clutch disc with screw-
driver or suitable tool and zero dial indicator (Fig.
276). When releasing pressure, indicator should
advance 0.005-0.010. as clutch pack relaxes.
(34) Apply 30 psi (206 kPa) air pressure to the
reverse clutch hose on Tool 8391. Measure and record
reverse clutch pack measurement in four (4) places,
90É apart.
(35) Take average of four measurements and com-
pare with reverse clutch pack clearance specification.
The reverse clutch pack clearance is 0.89-1.37
mm (0.035-0.054 in.).Select the proper reverse
clutch snap ring to achieve specifications:
REVERSE CLUTCH SNAP RING THICKNESS
4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.)
4412872 2.02-2.07 mm (0.080-0.082 in.)
4412873 2.27-2.32 mm (0.090-0.091 in.)(36) To complete the assembly, reverse clutch and
overdrive clutch must be removed.
(37) Install the #2 needle bearing (Fig. 277).
(38) Install the underdrive shaft assembly (Fig.
278).
Fig. 276 Press Down on Reverse Clutch and Zero
Indicator
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
Fig. 277 Install No. 2 Needle Bearing
1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
Fig. 278 Install Underdrive Shaft Assembly
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING
21 - 228 41TE AUTOMATIC TRANSAXLERS
INPUT CLUTCH ASSEMBLY (Continued)
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white letters. To remove the protective coating, apply
warm water and let it soak for a few minutes. After-
wards, scrub the coating away with a soft bristle
brush. Steam cleaning may also be used to remove
the coating.
CAUTION: DO NOT use gasoline, mineral oil, oil-
based solvent or a wire brush for cleaning.
WHEELS
DESCRIPTION - WHEEL
Original equipment wheels are designed for proper
operation at all loads up to the specified maximum
vehicle capacity.
All models use either steel or aluminum drop-cen-
ter wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety
humps (Fig. 28). Initial inflation of the tires forces
the bead over these raised sections. In case of air
loss, the safety humps hold the tire in position on the
wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights to fit on the flange of the rim (Fig. 29).
When wheel alignment is necessary on a vehicle
with cast aluminum wheels, special wheel clamps are
required to avoid damage to the wheel's finish.
The wheel studs and nuts are designed for specific
wheel applications and must be replaced with equiv-
alent parts.
All aluminum wheels have wheel mounting (lug)
nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
DIAGNOSIS AND TESTING - WHEEL
INSPECTION
Inspect wheels for:
²Excessive runout
²Dents, cracks or irregular bends
²Damaged wheel stud (lug) holes
²Air Leaks
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
If a wheel is damaged, an original equipment
replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load
carrying capacity. The diameter, width, offset, pilot
hole and bolt circle of the wheel should be the same
as the original wheel.
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE.
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING.
CLEANING - ALUMINUM WHEEL CARE
Chrome plated and painted aluminum wheels
should be cleaned regularly using mild soap and
water to maintain their luster and to prevent corro-
sion.
Fig. 28 Safety Rim
1 - TIRE
2 - WELL
3 - SAFETY HUMPS
4 - FLANGE
Fig. 29 Styled Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - STYLED WHEEL WEIGHT
22 - 18 TIRES/WHEELSRS
TIRES (Continued)
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INSTALLATION
NOTE: The crossbar assemblies are designed to be
installed in only one way. Check top and bottom
surfaces of the crossbar for the word FRONT and
directional arrows. The directional arrows must
point toward the front of the vehicle.
(1) Place crossbar in position on vehicle.
(2) Work from side to side sliding the crossbar
assembly back a little at a time to ensure it remains
perpendicular to the side rails.
(3) Position first crossbar assembly crossbar at the
second most rearward locator holes. Press the top of
the stanchion lever to lock it into position.
(4) Position the second crossbar assembly in the
second hole from the front. Lock into place.
(5) Place luggage rack riser into position.
(6) Install two fasteners into riser. Tighten fasten-
ers to 4 mm (35 in. lbs.) torque.
REAR QUARTER PANEL/
FENDER AIR EXHAUSTER
DESCRIPTION
Air exhausters, designed to conform to the body
structure, allow air entering at the front of the vehi-
cle to flow out the back. By reducing air pressure
within the vehicle, the exhausters also reduce blower
noise at any given air flow level compared to operat-
ing without them and help reduce door closing effort.
They are located in the lower rear comers of the
body.
REMOVAL
SHORT WHEELBASE
(1) Remove the rear fascia from the body. (Refer to
13 - FRAMES & BUMPERS/BUMPERS/REAR FAS-
CIA - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 19).
(3) Remove the air exhauster from the hole in the
lower aperture panel.
LONG WHEELBASE
NOTE: Models with the optional rear heater and air
conditioner do not have an air exhauster on the
right side of the vehicle, but have a plastic plug
installed in the right lower aperture panel. This plug
is removed using the same procedure used toremove the air exhauster from the short wheelbase
model. Refer to SHORT WHEELBASE.
(1) Remove the quarter trim panel from the inside
of the left or right quarter inner panel (Refer to 23 -
BODY/INTERIOR/RIGHT QUARTER TRIM PANEL
- REMOVAL) or (Refer to 23 - BODY/INTERIOR/
LEFT QUARTER TRIM PANEL - REMOVAL).
(2) Using a trim stick or another suitable wide flat
bladed tool, carefully pry the air exhauster away
from the opening in the lower aperture panel until
the snap features release (Fig. 20).
(1) Remove the air exhauster from the hole in the
lower aperture panel.
Fig. 19 AIR EXHAUSTER - SWB
1 - LOWER APERTURE PANEL
2 - AIR EXHAUSTER
Fig. 20 AIR EXHAUSTER - LWB
1 - AIR EXHAUSTER
2 - PLUG
3 - LOWER APERTURE PANEL
23 - 56 EXTERIORRS
LUGGAGE RACK CROSSBAR (Continued)
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²air recirculation button. The Recirculate button
contains an LED that illuminates to show when the
function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²rotary knobs for front and rear fan speed selec-
tion.
²a rotary knob for mode control.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner has a rotary adjustment for temperature
and fan speed control of the rear unit by intermedi-
ate seat passengers when the front control rear knob
is set to the rear position.
DESCRIPTION - AUTOMATIC TEMPERATURE
CONTROL
The Automatic Temperature Control (ATC) allows
occupants to select a comfort temperature, which is
the perceived temperature level not the actual pas-
senger compartment air temperature.
The Automatic Temperature Control system
includes a dust and odor air filter. The filter element
is the same size as the air conditioning evaporator to
ensure ample capacity. A door at the base of the
heater and air conditioning housing below the glove
box provides easy access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the Programmable Communi-
cations Interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine RPM, vehicle speed and Man-
ifold Absolute Pressure information from the PCM.
²Coolant Temperature± ATC computer moni-
tors Coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors Ambient temperature from the Compass Mini
Trip Computer (CMTC) and converts it to degrees
Fahrenheit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors Barometric Pressure, Intake Air Temperature,
High Side Pressure and Methanol Content as broad-
cast by the PCM.²Door Ajar Status± The ATC computer moni-
tors Driver Front Door, Passenger Front Door, Left
Rear Door, Right Rear Door and Liftgate ajar infor-
mation, as identified by the Body Control Module
(BCM), to determine if all in-car temperatures should
be maintained.
²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the VF tube icons if the manual
motor calibration or manual cool down tests have
failed. Flashing of the display icons will cease when
the vehicle odometer is greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for Evaporator Temperature too
Low, Fan Blower Relay status, Evaporator Sensor
Failure, Rear Window Defogger Relay and A/C Select.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²A power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²Three rocker switches that select comfort tem-
peratures from 15É to 30É C (59É to 85É F), which are
shown in the vacuum-fluorescent digital control dis-
play. If the set temp is 59 and the down button is
pressed, the set temp value will become 55 but the
display will show LO. If the set temp is 85 and the
up button is pressed, the set temp value will become
90 but the display will show HIGH. Temperatures
can be displayed in either metric or Fahrenheit,
which is controlled from the overhead console.
²A rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²A defroster button which turns on the defroster
independently during full automatic control. A
defroster symbol illuminates in the display when the
button is pressed.
24 - 2 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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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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CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION................8
REMOVAL.............................9
INSTALLATION..........................9
A/C PRESSURE TRANSDUCER
DESCRIPTION - A/C PRESSURE
TRANSDUCER.......................10
OPERATION...........................10
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................10
REMOVAL.............................10
INSTALLATION.........................11
BLEND DOOR ACTUATOR
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
BLOWER MOTOR RELAY
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY.......................14
REMOVAL.............................14
INSTALLATION.........................14
BLOWER MOTOR RESISTOR
DESCRIPTION.........................14
OPERATION...........................15
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR....................15
REMOVAL.............................16
INSTALLATION.........................16
COMPRESSOR CLUTCH
DESCRIPTION.........................16
OPERATION...........................17
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP.....................17STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN....................17
REMOVAL.............................17
INSPECTION - COMPRESSOR CLUTCH/COIL . 18
INSTALLATION.........................19
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL........................20
COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY......................22
REMOVAL.............................22
INSTALLATION.........................22
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................22
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................23
OPERATION...........................24
MODE DOOR ACTUATOR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................25
INSTALLATION.........................25
POWER MODULE
DESCRIPTION.........................25
OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................26
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION
The heater-A/C control module must be recali-
brated each time an actuator motor or the control
module is replaced. If the vehicle is so equipped, the
calibration procedure also includes rear HVAC posi-
tions for each actuator motor.(1) Turn the ignition switch to the On position.
(2) Simultaneously depress and hold the Power
and Recirculation buttons on the heater-A/C control
for at least five seconds. The manual heater-A/C con-
trol power Light Emitting Diode (LED) and Recircu-
lation LED, or the Automatic Temperature Control
24 - 8 CONTROLS - FRONTRS
ProCarManuals.com

(2) Disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer from
the transducer connector receptacle (Fig. 3).
(3) Using an open end wrench, unscrew the A/C
pressure transducer from the fitting on the liquid
line between the filter-drier and the expansion valve.
(4) Remove the seal from the A/C pressure trans-
ducer fitting and discard.
INSTALLATION
(1) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the A/C pressure
transducer fitting.
(2) Using an open end wrench, install and tighten
the A/C pressure transducer onto the fitting on the
liquid line between the filter-drier and the expansion
valve.
(3) Reconnect the headlamp and dash wire harness
connector for the A/C pressure transducer to the
transducer connector receptacle.
(4) Reconnect the battery negative cable.
BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors. Models with the
single zone heater and air conditioner system have a
single blend air door, which is controlled by a single
blend door actuator. Models with the optional dual
zone front heater and air conditioner system have
dual blend air doors, which are controlled by twoblend door actuators. The single zone blend door
actuator is located on the driver side end of the heat-
er-A/C housing unit, close to the dash panel. In the
dual zone system, the same blend door actuator used
for the single zone system becomes the passenger
blend door actuator, and is mechanically connected to
only the passenger side blend air door. In the dual
zone system, a second separate blend door actuator is
also located on the driver side end of the heater-A/C
housing unit close to the instrument panel, and is
mechanically connected to only the driver side blend
air door.
The blend door actuators are interchangeable with
each other, as well as with the actuators for the
mode door and the recirculation air door. Each actua-
tor is contained within an identical black molded
plastic housing with an integral wire connector
receptacle. Two integral mounting tabs allow the
actuator to be secured with two screws to the heater-
A/C unit housing. Each actuator also has an identical
output shaft with splines that connects it to the link-
age that drives the proper blend air door. The blend
door actuators do not require mechanical indexing to
the blend door linkage, as they are electronically cal-
ibrated by the heater-A/C control module. The blend
door actuators cannot be adjusted or repaired and, if
damaged or faulty, they must be replaced.
OPERATION
Each blend door actuator is connected to the heat-
er-A/C control module through the vehicle electrical
system by a dedicated two-wire take out and connec-
tor of the HVAC wire harness. The blend door actua-
tor can move the blend air door in two directions.
When the heater-A/C control module pulls the volt-
age on one side of the motor connection 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 module makes
the voltage to both connections high or both connec-
tions low, the blend air door stops and will not move.
These same motor connections also provide a feed-
back signal to the heater-A/C control 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 heater-A/C con-
trol 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 circuits. The blend
door actuator can be diagnosed using a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
Fig. 3 A/C Pressure Transducer
1 - RIGHT FRONT STRUT TOWER
2 - CONNECTOR
3 - A/C PRESSURE TRANSDUCER
4 - RIGHT WIPER MODULE DRAIN TUBE
5 - HIGH SIDE SERVICE PORT
6 - LIQUID LINE
RSCONTROLS - FRONT24-11
A/C PRESSURE TRANSDUCER (Continued)
ProCarManuals.com

REMOVAL
The single zone heating and air conditioning sys-
tem is equipped with a single blend door actuator.
The dual zone system has two blend door actuators,
one for the driver side blend air door and one for the
passenger side blend air door. The same service pro-
cedures can be used for each of these actuators.
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) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 4).
(4) Pull the heater core shield rearward far enough
to disengage the two location tabs that position thefront of the shield to the receptacles in the two lower
finger formations of the heater/ air conditioner hous-
ing near the dash panel.
(5) Remove the heater core shield from the distri-
bution housing.
(6) Disconnect the HVAC wire harness connector
for the blend door actuator from the actuator connec-
tor receptacle (Fig. 5).
(7) Remove the two screws that secure the blend
door actuator to the distribution housing.
(8) Remove the blend door actuator from the dis-
tribution housing.
INSTALLATION
(1) Position the blend door actuator onto the heat-
er/air conditioner housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the blend air door linkage.
(2) Install and tighten the two screws that secure
the blend 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 blend door actuator to the actuator connector
receptacle.
(4) 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.
(5) Install and tighten the three screws that secure
the heater core shield to the left end of the heater/air
Fig. 4 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 5 Blend 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)
24 - 12 CONTROLS - FRONTRS
BLEND DOOR ACTUATOR (Continued)
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on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices, and grounds.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RELAY
The front blower motor relay (Fig. 7) is located in
the Intelligent Power Module (IPM), which is in the
engine compartment near the battery. See the fuse
and relay layout map molded into the inner surface
of the IPM cover for front blower motor relay identi-
fication and location. Remove the relay from the IPM
to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, use a DRBIIItscan tool to perform
further diagnosis of the relay circuits. Refer to the
appropriate diagnostic information. If not OK,
replace the faulty relay.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unlatch and remove the cover from the Intelli-
gent Power Module (IPM) (Fig. 8).(3) See the fuse and relay layout map molded into
the inner surface of the IPM cover for front blower
motor relay identification and location.
(4) Remove the front blower motor relay from the
IPM by pulling the relay straight up.
INSTALLATION
(1) See the fuse and relay layout map molded into
the inner surface of the Intelligent Power Module
(IPM) cover for front blower motor relay identifica-
tion and location.
(2) Position the front blower motor relay to the
proper receptacle in the IPM.
(3) Align the front blower motor relay terminals
with the terminal cavities in the IPM relay recepta-
cle.
(4) Push down firmly on the front blower motor
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install and latch the cover onto the IPM.
(6) Reconnect the battery negative cable.
BLOWER MOTOR RESISTOR
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C control
(Fig. 9). Models equipped with the optional Auto-
matic Temperature Control (ATC) use a blower power
Fig. 7 Blower Motor Relay - Terminal Legend
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 8 Intelligent Power Module
1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
24 - 14 CONTROLS - FRONTRS
BLOWER MOTOR RELAY (Continued)
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