Evap CHRYSLER TOWN AND COUNTRY 2002 Workshop Manual

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.
(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 recirculationdoor 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
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)
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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.
(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)
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INFRARED TEMPERATURE
SENSOR
DESCRIPTION
The rear infrared temperature sensor consists of
an infrared transducer that is concealed behind the
lens of the rear heater-A/C control in the headliner.
This sensor is used only on models equipped with the
optional Automatic Temperature Control (ATC) heat-
ing and air conditioning system. The rear infrared
temperature sensor is integral to the rear heater-A/C
control. The infrared sensor cannot be adjusted or
repaired and, if faulty or damaged, the rear heater-
A/C control unit must be replaced.
OPERATION
The rear infrared temperature sensor provides an
independent measurement input to the Automatic
Temperature Control (ATC) heater-A/C control mod-
ule that indicates the surface temperature of the rear
seat occupants. By using a surface temperature mea-
surement, rather than an air temperature measure-
ment, the ATC system is able to adjust itself to the
comfort level as perceived by the occupant. This
allows the system to detect and compensate for other
ambient conditions affecting comfort levels, such as
solar heat gain or evaporative heat loss. The ATC
system logic responds to the infrared sensor input by
calculating and adjusting the air flow temperature
and air flow rate needed to properly obtain and
maintain the selected comfort level temperatures for
the rear seat occupants. The ATC heater-A/C control
module continually monitors the infrared sensor cir-
cuit, and will store a Diagnostic Trouble Code (DTC)
for any problem it detects. This DTC information can
be retrieved and the infrared temperature sensor
diagnosed using a DRBIIItscan tool. Refer to the
appropriate diagnostic information.
MODE DOOR ACTUATOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(4) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar.(5) Remove the screw that secures the front of the
rear heater-A/C unit housing to the right quarter
inner panel.
(6) Carefully pull the top of the rear heater-A/C
unit housing away from the right quarter inner panel
far enough to reach between the rear heater-A/C unit
housing and the quarter inner panel to access the
mode door actuator (Fig. 10).
(7) Remove the two screws that secure the mode
door actuator to the rear heater-A/C unit housing.
(8) Pull the mode door actuator away from the
rear heater-A/C unit housing far enough to disengage
the actuator output shaft from the mode door link-
age.
(9) Raise the mode door actuator far enough to
access and disconnect the rear HVAC wire harness
connector for the actuator from the actuator connec-
tor receptacle.
Fig. 10 Blend Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 36 CONTROLS - REARRS
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(10) Remove the mode door actuator from between
the rear heater-A/C unit housing and the quarter
inner panel.
INSTALLATION
(1) Position the mode door actuator between the
rear heater-A/C unit housing and the quarter inner
panel.
(2) Reconnect the rear HVAC wire harness connec-
tor for the mode door actuator to the actuator connec-
tor receptacle.
(3) Position the mode door actuator onto the rear
heater-A/C unit housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the mode door linkage.
(4) Install and tighten the two screws that secure
the mode door actuator to the rear heater-A/C unit
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(5) Push the top of the rear heater-A/C unit hous-
ing back into position against the right quarter inner
panel.
(6) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).
(7) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(8) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel. Tighten the screws to 1.7
N´m (15 in. lbs.).
(9) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(10) Reconnect the battery negative cable.
(11) Perform the heater-A/C control calibration
procedure. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL 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. 11). 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 back of the rear heater-A/C unit housing,
directly above the expansion valve. The module con-
sists of a molded plastic mounting plate with twointegral connector receptacles. Concealed behind 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 rear heater-A/C unit housing
and is accessed for service by removing the right
quarter and D-pillar trim panels.
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 rear HVAC wire harness. A sec-
ond connector receptacle receives the pigtail wire
connector from the blower motor. The blower power
module allows the microprocessor-based Automatic
Temperature Control (ATC) heater-A/C control mod-
ule 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
Fig. 11 Power Module
1 - REAR HEATER-A/C UNIT HOUSING
2 - SCREW (2)
3 - D-PILLAR
4 - BLOWER PIGTAIL WIRE
5 - REAR HVAC WIRE HARNESS
6 - EXPANSION VALVE
7 - BLOWER POWER MODULE
RSCONTROLS - REAR24-37
MODE DOOR ACTUATOR (Continued)
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AIR FILTER
DESCRIPTION
A dust and odor air filter is standard equipment on
models equipped with the dual zone or three zone
temperature control systems (Fig. 1). The filter ele-
ment is the same size as the front air conditioner
evaporator to ensure ample filtering capacity. A
removable door on the bottom of the front heater-A/C
unit housing below the glove box provides easy access
to the filter element for replacement. Filter replace-
ment is recommended at 24,000 kilometer (15,000
mile) intervals.
REMOVAL
(1) Locate the air filter door on the bottom of the
lower evaporator housing just outboard of the pas-
senger side of the instrument panel center stack (Fig.
2).
(2) Slide the air filter door latch toward the rear of
the vehicle until it engages the opened stop on the
door.
(3) Pull the air filter door straight downward to
disengage it from the air filter opening of the lower
evaporator housing.
(4) Use your fingers to reach through the air filter
opening of the lower evaporator housing far enough
to grasp the air filter.
(5) Pull the air filter straight down and out of the
evaporator housing (Fig. 2).
INSTALLATION
(1) Note the ªAirflowº directional arrow imprinted
on the foam seal around the frame of the air filter.
This arrow should always be oriented towards the
center of the vehicle.
(2) With the air filter ªAirflowº arrow properly ori-
ented, carefully slide the filter fully upward into the
evaporator housing through the air filter opening.
(3) With the latch still positioned against its
opened stop, reinstall the air filter door onto the
lower evaporator housing air filter opening.
(4) Slide the air filter door latch toward the front
of the vehicle until it hits the closed stop on the door.
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the front heater-A/C unit housing
through one or a combination of the four main hous-
ing outlets: defrost, demist, panel, or floor. Once the
conditioned air exits the unit housing, it is directed
through molded plastic ducts to the various outlets in
the vehicle interior. These outlets and their locations
are as follows:
²Defroster Outlet- A single, centrally mounted
outlet delivers air for defrosting the large windshield.
Because outlet vanes are not needed to direct flow, a
simple, integral grid is molded into the center of the
instrument panel top cover to prevent objects from
falling into the duct. If the defroster outlet is faulty
Fig. 1 Air Filter
1 - LOWER EVAPORATOR HOUSING
2 - LOWER EDGE OF INSTRUMENT PANEL
3 - AIR FILTER
4 - INSTRUMENT PANEL CENTER FLOOR BRACKET COVER
5 - FOAM SEAL
6 - AIR FILTER OPENING
Fig. 2 Air Filter Door
1 - AIR FILTER DOOR
2-LATCH
3 - CLOSED STOP
4 - LOWER EVAPORATOR HOUSING
5 - OPENED STOP
24 - 40 DISTRIBUTION - FRONTRS
ProCarManuals.com

path it provides. The blower motor and wheel are
used 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.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.Disconnect the front blower motor pigtail wire con-
nector from the connector receptacle of the front
blower motor resistor (MTC) or the front blower
power module (ATC). Use jumper wires to connect a
battery and ground feeds to the blower motor pigtail
wire connector. The blower motor should operate. If
OK with MTC, proceed to diagnosis of the front
blower motor resistor. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS - FRONT/BLOWER
MOTOR RESISTOR - DIAGNOSIS AND TESTING).
If OK with ATC, use a DRBIII scan tool to diagnose
the front blower power module. Refer to the appropri-
ate diagnostic information. If not OK with MTC or
ATC, replace the faulty front blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart (Fig. 8).
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 lower right trim panel and roll
back the carpet.
(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).
24 - 44 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)
ProCarManuals.com

(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 securethe 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.
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 four 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.
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
Fig. 11 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
24 - 46 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)
ProCarManuals.com

(4) Position the upper pivot of the recirculation
door into the opening at the top of the air inlet hous-
ing an dhold in place while the lower air inlet hous-
ing is placed in position.
(5) Install and tighten the three 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) Position the carpet into location and install the
lower right trim panel.
(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 Cooldown test(Refer to
24 - HEATING & AIR CONDITIONING - DIAGNO-
SIS 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 properprecautions 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.
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.
RSDISTRIBUTION - FRONT24-47
BLOWER MOTOR (Continued)
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INSTALLATION
(1) Position the blower motor and blower wheel
onto the outboard side of the rear heater-A/C unit
housing.
(2) Install and tighten the three screws that secure
the blower motor to the rear heater-A/C unit housing.
Tighten the screws to 2 N´m (18 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(4) Reinstall the rear heater-A/C unit housing into
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - INSTALLATION).
REAR HEATER-A/C HOUSING
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Raise and support the vehicle.
(5) Disconnect the underbody refrigerant line seal-
ing plate from the rear heater-A/C unit evaporator
extension line sealing plate that extends through the
rear floor panel behind the right rear wheel housing
(Fig. 6).
(6) Remove the seals from the liquid line and suc-
tion line fittings and discard.
(7) Install plugs in, or tape over the opened liquid
line and suction line fittings and both ports in the
evaporator extension line sealing plate.
Fig. 5 Blower Motor
1 - REAR HEATER-A/C UNIT HOUSING
2 - BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER PIGTAIL WIRE
Fig. 6 Refrigerant Lines
1 - UNDERBODY REFRIGERANT LINE SEALING PLATE
RSDISTRIBUTION - REAR24-55
BLOWER MOTOR (Continued)
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(8) Remove the three nuts that secure the rear
heater-A/C unit mounting studs to the rear floor
panel behind the right rear wheel housing (Fig. 7).
(9) Lower the vehicle.
(10) Remove the right quarter trim panel and
right D-pillar trim panel from the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - REMOVAL).
(11) Remove the rear A/C distribution duct from
the rear heater-A/C unit and the rear roof duct.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - REAR/AUXILIARY A/C DISTRI-
BUTION DUCT - REMOVAL).
(12) Disconnect the body wire harness connector
for the rear heater-A/C unit housing from the rear
HVAC wire harness connector located near the
expansion valve at the back of the unit.
(13) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(14) Remove the two screws that secure the bottom
of the quarter trim panel attaching bracket to the
rear heater-A/C unit housing.
(15) Remove the rear heater distribution duct from
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
REMOVAL).
(16) Take the proper precautions to protect the
carpeting below the rear heater core from spilled
engine coolant and have absorbent toweling readily
available to clean up any spills.
(17) Disconnect the heater hoses at the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - REMOV-
AL).(18) Install plugs in, or tape over the opened
heater core fittings and both heater hoses.
(19) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
(20) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar
(Fig. 8).
(21) Remove the screw that secures the front of
the rear heater-A/C unit housing to the right quarter
inner panel.
(22) Lift the rear heater-A/C unit housing up far
enough for the lower mounting studs and the evapo-
rator extension lines to clear the mounting holes in
the rear floor panel.
(23) Remove the rear heater-A/C unit housing from
the vehicle.
(24) Use absorbent toweling to mop up any engine
coolant spills from the preceding operation.
INSTALLATION
NOTE: If the rear heater core or the rear heater-A/C
housing have been removed from the vehicle for
service, the rear heater core may be pre-filled with
the proper engine coolant mixture prior to recon-
necting the heater hoses to the heater core hose fit-
tings. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - REAR/HEATER CORE - STANDARD
PROCEDURE - HEATER CORE FILLING).
(1) Position the rear heater-A/C unit housing into
the vehicle with the evaporator extension line sealing
plate inserted into the rectangular hole in the rear
floor panel behind the right rear wheel house.
(2) Align the rear heater-A/C unit housing lower
mounting studs with the mounting holes in the rear
floor panel and lower the unit to the floor.
(3) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).
(4) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(5) Remove the plugs or tape from both heater core
fittings and both heater hoses.
(6) Reconnect the heater hoses to the rear heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - REAR/HEATER HOSE - INSTAL-
LATION).
(7) Reinstall the rear heater distribution duct onto
the right quarter inner panel. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION -
REAR/REAR HEATER DISTRIBUTION DUCT -
INSTALLATION).
Fig. 7 Rear Heater-A/C Unit Mounting Studs
1 - REAR HEATER-A/C UNIT MOUNTING STUDS
24 - 56 DISTRIBUTION - REARRS
REAR HEATER-A/C HOUSING (Continued)
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