light CHRYSLER CARAVAN 2005 Service Manual

(1) Slide lower seat belt cover rearward to expose
anchor fastener.
(2) Remove bolt/nut attaching lower seat belt
anchor to floor.
(3) Remove upper B-pillar trim cover.
(4) Remove access panel from B-pillar trim (Fig.
3).
(5) Disengage hidden clips attaching lower trim
cover to B-pillar.
(6) Remove lower B-pillar trim cover from vehicle.
INSTALLATION
NOTE: The driver's side a double ended stud is
used. A nut has to be removed for the seat belt
anchor removal and the stud for the retractor
removal.
NOTE: On the passenger side there is a belt tension
sensor.
(1) On the passenger side secure grommet to seat
belt sensor connector into bottom of B-pillar lower
trim prior to install B-pillar lower trim cover.(2) Place lower B-pillar trim cover in position on
vehicle (Fig. 3).
(3) Insert seat belt through hole in lower B-pillar
trim.
(4) Engage hidden clips attaching lower trim cover
to B-pillar.
(5) Install access cover.
(6) Install upper B-pillar trim cover.
(7) Place seat belt anchor in position on floor so
webbing is pointed rearward and slightly outboard.
(8) Install bolt/nut attaching lower seat belt
anchor to floor. Tighten seat belt anchor bolt/nut to
39 N´m (29 ft. lbs.) torque.
(9) Verify that seat belt anchor does not interfere
with seat track travel.
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove bolt attaching lower seat belt anchor to
floor.
(2) Lower shoulder belt height adjuster to the bot-
tom of travel.
(3) Remove shoulder belt turning loop from height
adjuster.
(4) Use a Snap-ontTrim Pad Remover tool
(A179A), or equivalent, and remove shoulder belt
height adjuster knob.
(5) Remove shoulder belt bezel from trim cover
(Fig. 3).
(6) Remove screw attaching trim cover to B-pillar
from inside bezel cavity.
(7) Disengage hidden clips attaching trim cover to
B-pillar.
(8) Remove B-pillar trim cover from vehicle.
INSTALLATION
(1) Insert seat belt through B-pillar trim and web
guide (Fig. 3).
(2) Place B-pillar trim cover in position on vehicle.
(3) Engage hidden clips attaching trim cover to
B-pillar.
(4) Install shoulder belt bezel into trim cover.
(5) Install height adjuster knob.
(6) Install shoulder belt turning loop onto height
adjuster. Tighten bolt to 39 N´m (29 ft. lbs.) torque.
(7) Place seat anchor in position on floor so web-
bing is pointed rearward and slightly outboard or self
aligning tab on passenger side.
(8) Install bolt attaching lower seat belt anchor to
floor. Tighten seat belt bolt to 39 N´m (29 ft. lbs.)
torque.
Fig. 3 LOWER B-PILLAR TRIM COVER
1 - B-PILLAR UPPER TRIM
2 - B-PILLAR UPPER PLUG
3 - POWER SLIDING DOOR SWITCH AND BEZEL
4 - BELT ASSEMBLY
5 - B-PILLAR LOWER TRIM
23 - 80 INTERIORRS
B-PILLAR LOWER TRIM (Continued)

PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - COLOR CODE CHARTS . . 100
BASE COAT/CLEARCOAT FINISH
DESCRIPTION........................101
PAINT CODE
DESCRIPTION........................101PAINTED TOUCH-UP
DESCRIPTION........................101
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION........................101
PAINT
SPECIFICATIONS - COLOR CODE CHARTS
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
COLOR CODEEXTERIOR COLOR DAIMLERCHRYSLER
COLOR CODE
BRIGHT SILVER
METALLIC CLEAR
COATWS2 LIGHT KHAKI
METALLIC CLEAR
COATAJC
BRILLIANT BLACK
CRYSTAL PEARL
COATAXR LINEN GOLD PEARL
COATCYG
BUTANE BLUE
METALLIC CLEAR
COATABE MAGNESIUM PEARL
COATBPK
DARK KHAKI
METALLIC CLEAR
COATBJT MIDNIGHT BLUE
PEARL COATBB8
DEEP BERYL GREEN
PEARL COATCGV PATRIOT BLUE
PEARL COATWB7
DEEP LAVA RED
PEARL COATZMQ SATIN JADE PEARL
COATAP4
DEEP MOLTEN RED
PEARL COATBR8 SHALE GREEN
METALLIC CLEAR
COATWS2
GRAPHITE METALLIC
CLEAR COATZDR STONE WHITE CLEAR
COATSW1
INFERNO RED TINTED
PEARL COATWEL
23 - 100 PAINTRS

INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
COLOR CODEINTERIOR COLOR DAIMLERCHRYSLER
COLOR CODE
DARK KHAKI/LIGHT
GRAYSTONEJ1 MEDIUM SLATE
GRAYD5
KHAKI J3
BASE COAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clearcoat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents on
painted surfaces. Damage to finish or color can result.
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE -
DESCRIPTION). The paint code is also identified on
the Vehicle Safety Certification Label which is
located on the drivers door shut face. The first digit
of the paint code listed on the vehicle indicates the
sequence of application, i.e.: P = primary coat, Q =
secondary coat. The codes listed in the Color Code
Chart are used for manufacturing purposes.
PAINTED TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch Up Paints and Clear Top
Coat. (Refer to VEHICLE DATA/VEHICLE INFOR-
MATION/BODY CODE PLATE - DESCRIPTION).
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
TOUCH UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface.
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch up
paint. Do not overlap touch up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch up
paint to dry hard.
(5) On vehicles without clearcoat, the touch up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
CAUTION: Do not remove clearcoat finish, if
equipped. Basecoat paint must retain clearcoat for
durability.
RSPAINT23 - 101
PAINT (Continued)

MANUAL DUAL ZONE
²The two slide controls enable continuously vari-
able proportioning of the conditioned air.
²The mode control knob enables continuously
variable proportioning of air flow between modes and
has detents adjacent to each icon.
²The blower control provides four separate speeds
and an Off position.
²When the heater-A/C system is off, the HVAC
computer closes the recirculation door to prevent out-
side air from entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the A/C-
heater control.
²To reduce humidity for rapid defogging, the A/C
compressor runs automatically in modes from ªmixº
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off button.
MANUAL THREE ZONE
FRONT CONTROL PANEL
²Primary control of the rear heater-A/C system is
on the instrument panel. This control allows the
driver to set the rear compartment fan speed, to turn
the rear heater-A/C system off, or to give control to
the intermediate seat occupants by switching to the
Rear position. When the rear heater-A/C system is
controlled from the instrument panel, rear air tem-
perature is based on the driver-side temperature con-
trol position, and the mode (floor or overhead air) is
based on the front control's mode position.
²The mode control knob enables continuously
variable proportioning of air flow between modes but
has detents adjacent to each icon.
²The blower control provides four separate speeds
and an Off position. When the heater-A/C system is
off, the HVAC computer closes the recirculation door
to prevent outside air from entering the passenger
compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
REAR CONTROL PANEL
With the rear control active, temperature selection
dictates the air distribution mode (floor or overhead
air) of the rear unit: a cool temperature setting
directs flow to the overhead outlets and a warm tem-
perature setting to the floor.
AUTOMATIC TEMPERATURE CONTROL
Comfort temperature or perceived temperature is
affected by air flow, sun levels on exposed skin, etc.
The air temperature may be higher or lower than the
comfort temperature. The automatic temperature
control (ATC) system uses two infrared sensors in the
instrument panel center stack to measure the tem-
perature of the front occupants in order determine
their comfort level relative to their selected comfort
temperature. The integral HVAC computer adjusts
temperature and air flow rates to maintain the cus-
tomer-perceived comfort temperatures. The air tem-
perature in the passenger compartment may be
slightly higher or lower than the comfort tempera-
ture at any time. 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.
The Three-Zone ATC system uses the infrared sen-
sors located in the instrument panel center stack
along with an offset calibration strategy to meet the
comfort requirements of the rear seat occupants.
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.
²DEFROST± The defrost function must be man-
ually selected to direct air flow to the windshield to
remove fog or ice. The ATC system cannot automati-
cally sense the presence of fog or ice on the wind-
shield.
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 defog-
ger and side view mirror (if equipped) circuitry. The
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)

Condition Possible Causes Correction
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.1. Excessive refrigerant oil in
system.1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. Blend door actuator
improperly installed or faulty.2. See Blend Door Actuator in this group. Inspect
the actuator for proper operation and replace, if
required.
3. Blend door inoperative or
sealing improperly.3. See HVAC Housing in this group. Inspect the
blend door for proper operation and sealing.
Repair if required.
4. Blend door not in full cold
position.Use a DRBIII Scan Tool to check for DTCs and
blend door position. Refer to Body Diagnostic
Procedures.
The low side pressure is
normal or slightly low, and the
high side pressure is too low.1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Refrigerant flow through
the A/C evaporator is
restricted.2. See A/C Evaporator in this group. Replace the
restricted A/C evaporator, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.1. A/C condenser air flow
restricted.1. Check the A/C condenser for damaged fins,
foreign objects obstructing air flow through the
condenser fins, and missing or improperly
installed air seals. Clean, repair, or replace
components as required.
2. Refrigerant flow through
the receiver/drier is
restricted.2. See Receiver/Drier in this group. Replace the
restricted receiver/drier, if required.
3. Inoperative radiator
cooling fan.3. Test the radiator cooling fan and replace, if
required. Refer to Group 7.
4. Refrigerant system
overcharged.4. See Refrigerant System Charge in this group.
Recover the refrigerant from the refrigerant
system. Charge the refrigerant system to the
proper level, if required.
5. Air in the refrigerant
system.5. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
6. Engine overheating. 6. Test the engine cooling system and repair, if
required. Refer to Group 7.
The low side pressure is too
high, and the high side
pressure is too low.1. Accessory drive belt
slipping.1. Inspect the accessory drive belt condition and
tension. Tighten or replace the accessory drive
belt, if required. Refer to Group 7.
2. Faulty A/C expansion
valve.2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Faulty A/C compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
RSHEATING & AIR CONDITIONING24-9
HEATING & AIR CONDITIONING (Continued)

Condition Possible Causes Correction
The low side pressure is too
low, and the high side
pressure is too high.1. Restricted refrigerant flow
through the refrigerant lines.1. See Liquid Line, Suction Line and Discharge
Line in this group. Inspect the refrigerant lines for
kinks, tight bends or improper routing. Correct
the routing or replace the refrigerant line, if
required.
2. Restricted refrigerant flow
through the A/C expansion
valve.2. See A/C Expansion Valve in this group.
Replace the valve, if required.
3. Restricted refrigerant flow
through the A/C condenser.3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
HEATER PERFORMANCE TEST
WARNING: REVIEW SAFETY PRECAUTIONS AND
WARNINGS IN THIS GROUP BEFORE PERFORMING
THIS PROCEDURE (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING).
Check the coolant level, drive belt tension, radiator
air flow and fan operation. Start engine and allow to
warm up to normal operating temperature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
If vehicle has been run recently, wait 15 minutes
before removing the radiator cap. Place a rag overthe cap and turn it to the first safety stop. Allow
pressure to escape through the overflow tube. When
the system pressure stabilizes, remove the cap com-
pletely.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two heater hoses. With the engine idling at normal
operating temperature, set the temperature control
to maximum heat, the mode control to the floor posi-
tion, and the blower in the highest speed position.
Using a test thermometer, check the temperature of
the air being discharged from the floor outlets. Com-
pare the test thermometer reading to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE
Ambient Temperature Minimum Floor Outlet Temperature
Celsius Fahrenheit Celsius Fahrenheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
If the floor outlet air temperature is insufficient,
check that the cooling system is operating to specifi-
cations (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Both heater hoses should be
HOT to the touch (the coolant return hose should be
slightly cooler than the supply hose). If the coolant
return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction
in heater system.
OBSTRUCTED COOLANT FLOW Possible locations or causes
of obstructed coolant flow are as follows:
²Pinched or kinked heater hoses.
²Improper heater hose routing.²Plugged heater hoses or supply and return ports
at the cooling system connections.
²Plugged heater core.
If proper coolant flow through the cooling system is
verified, and heater outlet air temperature is insuffi-
cient, a mechanical problem may exist.
MECHANICAL PROBLEMS
Possible causes of insufficient heat due to mechan-
ical problems are as follows:
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend door not functioning properly.
24 - 10 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

(b) If the compressor clutch coil current reading
is four amperes or more, the coil is shorted and
must be replaced.
STANDARD PROCEDURE
CLUTCH INSPECTION
NOTE: The compressor clutch can be serviced in
the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley, or coil
replacement.
Examine the friction surfaces of the clutch pulley
and the clutch plate for wear. The pulley and plate
should be replaced if there is excessive wear or scor-
ing.
If the friction surfaces are oily, inspect the shaft
and nose area of the A/C compressor for refrigerant
oil. If refrigerant oil is found, the compressor shaft
seal is leaking and the A/C compressor must be
replaced.
Check the clutch pulley bearing for roughness or
excessive leakage of grease. Replace the pulley and
bearing assembly, if required.
A/C CLUTCH BREAK-IN
After a new A/C compressor clutch has been
installed, cycle the compressor clutch approximately
twenty times (five seconds on, then five seconds off).
During this procedure, set the A/C-heater controls to
the A/C Recirculation Mode, the blower motor in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces of the compressor
clutch, which provides optimum compressor clutch
torque capability.
REMOVAL
NOTE: The compressor clutch can be serviced in
the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley, or coil
replacement.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Raise and support the vehicle.
(4) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil pig-
tail wire connector on the top of the A/C compressor.
(5) On models with the 3.3L and 3.8L engines, dis-
engage the retainer on the engine wire harness com-pressor clutch coil take out from the bracket on the
top of the A/C compressor.
(6) On models with the 2.4L, 2.5L and 2.8L
engines, remove all of the compressor mounting bolts
except the upper left (rear of the A/C compressor),
which should only be loosened. Allow the front (pul-
ley end) of the A/C compressor to tilt downward far
enough to access the clutch for removal, then tighten
the loosened upper left compressor mounting bolt.
(7) On models with the 3.3L and 3.8L engines,
remove the two bolts and two nuts that secure the
A/C compressor to the engine. Disengage the mount-
ing ear at the front of the A/C compressor from the
stud on the engine, allow the front (pulley end) of the
A/C compressor to tilt downward far enough to access
the clutch for removal, then reinstall and tighten the
upper left compressor mounting bolt.
(8) Remove the compressor shaft bolt (Fig. 2). A
band-type oil filter wrench or a strap wrench may be
used to secure the clutch during bolt removal.
(9) Tap the clutch plate lightly with a plastic mal-
let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3).
NOTE: Use care not to lose any of the shim(s).
Fig. 2 A/C Compressor Shaft Bolt
1 - BOLT
2 - COMPRESSOR CLUTCH PLATE
RSCONTROLS - FRONT24-15
A/C COMPRESSOR CLUTCH/COIL (Continued)

REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 8).
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the IPM for A/C compressor
clutch relay identification and location.
(3) Remove the A/C compressor clutch relay from
the IPM.
INSTALLATION
NOTE: Refer to the fuse and relay map on the inner
surface of the cover of the integrated power module
(IPM) for A/C compressor clutch relay identification
and location.
(1) Position the A/C compressor clutch relay into
the proper receptacle in the IPM.
(2) Align the A/C compressor clutch relay termi-
nals with the terminal cavities in the IPM receptacle.
(3) Push down firmly on the A/C compressor clutch
relay until the terminals are fully seated in the ter-
minal cavities.
(4) Install the cover onto the IPM.
(5) Reconnect the negative battery cable.
A/C HEATER CONTROL
DESCRIPTION
The A/C-heater control is located at the center of
the instrument panel and uses electrical controls.
These controls provide the vehicle operator with a
number of setting options to help control the climate
and comfort within the vehicle. Refer to the owner's
manual in the vehicle glove box for more information
on the suggested operation and use of these controls.
The A/C-heater control cannot be repaired. If faulty
or damaged, the entire unit must be replaced. The
control knobs are available for service replacement.
STANDARD PROCEDURE
A/C-HEATER CONTROL CALIBRATION
The A/C-heater 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) If equipped with the manual temperature con-
trol (MTC) system, press and hold the Rear Wipe/
Wash and Recirculation buttoms for at least five
seconds. If equipped with the automatic temperature
control (ATC) systen, simultaneously press and hold
the Power and Recirculation buttons on the A/C-
heater control for at least five seconds. The MTC
A/C-heater control Rear Wipe/Wash Light Emitting
Diode (LED) and Recirculation LED, or the ATC A/C-
heater control Delay and Recirculation graphics will
begin to flash when the calibration procedure has
begun.
(3) The calibration procedure should take less than
two minutes to complete for the manual A/C-heater
control, and less than twenty seconds for the ATC
A/C-heater control. When the LEDs or graphics stop
flashing, the calibration procedure is complete.
(4) If the LEDs or graphics continue to flash
beyond the two minute (manual) or twenty second
(ATC) calibration time, it indicates that the A/C-
heater control has detected a failure and a Diagnostic
Trouble Code (DTC) has been set. Refer to Body
Diagnostic Procedures to perform further diagnosis.
The LEDs or graphics will continue to flash even
after the ignition switch is cycled Off and On, until a
successful calibration is completed or until the vehi-
cle has been driven about 13 kilometers (8 miles).
Fig. 8 A/C Compressor Clutch Relay
1 - INTEGRATED POWER MODULE (IPM)
2 - A/C COMPRESSOR CLUTCH RELAY
3 - FRONT CONTROL MODULE
RSCONTROLS - FRONT24-19
A/C COMPRESSOR CLUTCH RELAY (Continued)

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 two
blend door actuators. The single zone blend door
actuator is located on the driver's side end of the
HVAC housing, close to the middle of the distribution
housing. 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 sep-
arate blend door actuator is also located on the
driver side end of the HVAC housing, close to the
middle of the distribution housing, and is mechani-
cally connected to only the driver's 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 distri-
bution 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.
OPERATION
The blend door actuators are connected to the A/C-
heater control through the vehicle electrical system
by a dedicated two-wire lead and connector of the
HVAC wire harness. The blend door actuator(s) can
move the blend-air door(s) in two directions. When
the A/C-heater control pulls the voltage on one side
of the motor connection high and the other connec-
tion low, the blend-air door will move in one direc-
tion. When the A/C-heater control reverses the
polarity of the voltage to the motor, the blend-air
door moves in the opposite direction.
When the A/C-heater control makes the voltage to
both connections high or both connections low, the
blend-air door stops and will not move. The A/C-
heater control uses a feedback signal positioning sys-
tem to monitor the operation and relative position of
the blend door actuator(s) and the blend-air door(s).
The A/C-heater control learns the blend-air door stoppositions during the calibration procedure and will
store a diagnostic trouble code (DTC) for any prob-
lems it detects in the blend door actuator circuits.
The blend door actuators are diagnosed using a
scan tool (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING and to 24 -
HVAC Electrical Diagnostics for more information).
The blend door actuators cannot be adjusted or
repaired and, if faulty or damaged, they must be
replaced.
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.
NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. 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 procedures can be used for each of
these actuators.
(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 wire harness connector from the
blend door actuator(s) (Fig. 11).
(4) Remove the two screws that secure the blend
door actuator to the distribution housing.
(5) Remove the blend door actuator.
INSTALLATION
(1) Position the blend door actuator onto the distri-
bution 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 the two screws that secure the blend
door actuator to the housing. Tighten the screws to 2
N´m (17 in. lbs.).
24 - 22 CONTROLS - FRONTRS

INSTALLATION
(1) Position the mode door actuator onto the HVAC
distribution 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 the two screws that secure the mode
door actuator to the distribution housing. Tighten the
screws to 2 N´m (17 in. lbs.).
(3) Connect the wire harness connector to the
mode door actuator.
(4) Install the silencer under the driver side end of
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL SILENCER -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Perform the A/C-heater 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 - BLOWER
MOTOR
DESCRIPTION
A blower motor power module is used on this
model when it is equipped with the optional Auto-
matic Temperature Control (ATC) system. Models
equipped with the standard manual heater-A/C sys-
tem use a blower motor resistor block, instead of the
blower motor power module (Refer to 24 - HEATING
& AIR CONDITIONING/CONTROLS/BLOWER
MOTOR RESISTOR BLOCK - DESCRIPTION).
The blower motor power module is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The module
consists of a molded plastic mounting plate with two
integral connector receptacles. Concealed behind the
mounting plate is the power module electronic cir-
cuitry and a large finned, heat sink. The blower
motor power module is accessed for service by remov-
ing the glove box from the instrument panel.
OPERATION
The blower motor power module is connected to the
vehicle electrical system through a dedicated lead
and connector from the instrument panel wire har-
ness. A second connector receptacle receives a wire
lead connector from the blower motor. The blower
motor power module allows the microprocessor-based
Automatic Temperature Control (ATC) heater-A/C
control module to calculate and provide infinitely
variable blower motor speeds based upon either man-
ual blower switch input or the ATC programming
using a Pulse Width Modulated (PWM) circuit strat-
egy. The PWM voltage is applied to a comparator cir-
cuit 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 motor power module is diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: THE HEAT SINK FOR THE BLOWER
MOTOR POWER MODULE MAY GET VERY HOT
DURING NORMAL OPERATION. IF THE BLOWER
MOTOR WAS TURNED ON PRIOR TO SERVICING
THE BLOWER MOTOR POWER MODULE, WAIT
FIVE MINUTES TO ALLOW THE HEAT SINK TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
24 - 30 CONTROLS - FRONTRS
MODE DOOR ACTUATOR (Continued)