steering CHRYSLER VOYAGER 2001 Service Manual

(17) Remove the two steering column shroud
retaining screws. Separate the shrouds and remove
from vehicle.
(18) Disconnect the steering column wiring. There
are seven connectors and then unclip the harness
from the column.
(19) Disconnect the ORC harness connector.
(20) Remove the four nuts retaining the steering
column and lower to the floor.
(21) Remove the four nuts attaching the instru-
ment panel to the brake pedal support bracket.
(22) Loosen the left side roll down bolt.
(23) Remove the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(24) If equipped with a mechanical transmission
range indicator:
(a) Remove the indicator cable loop.
(b) Remove the clip holding gear shift cable end
to the gear selector adapter.
(c) Pull the cable end from gear selector.
(d) Disconnect the clip for the indicator cable
and guide tube from the shift cable bracket and
move out of the way.
(25) Remove the instrument panel top cover. Using
a trim stick or equivalent, gently pry up on the front
edge of the top cover, pull rearward and remove from
vehicle.
(26) Disconnect the right side wire connectors from
the HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(27) Remove the right end cover by pulling out-
board.
(28) Remove the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(29) Loosen the right side roll down bolt.
(30) Disconnect the two front window defroster
grid wire connectors. One on each side of vehicle.
(31) Remove both the left and right power mirrors:
(a) Using a trim stick or equivalent, gently pry
out on mirror trim cover.
(b) Open door and remove the three torx retain-
ing screws.
(c) Disconnect the wire connector and remove
mirror from the vehicle.
(32) Feed power mirror wire harness inboard
through the A-pillar.
(33) Remove the bolts holding the instrument
panel frame to the dash panel below windshield
opening.
(34) With the help of an assistant remove the
instrument panel from vehicle. Lift the instrument
panel up off the HVAC so you won't damage the seal-
ing surface of the distribution duct.
If the instrument panel is being replaced, transfer
all parts to the new instrument panel assembly.INSTALLATION
(1) With the help of an assistant place the instru-
ment panel into vehicle on roll down bolts. As you
roll the instrument panel up, lift the instrument
panel up so the duct work does not bind or bend and
you can set it down on the HVAC housing to get the
proper seal at the distribution duct. Get one bolt
started in the dash panel.
(2) Install the bolts holding the instrument panel
frame to the dash panel below windshield opening.
(3) Feed power mirror wire harness outboard
through the A-pillar.
(4) Install both the left and right power mirrors:
(a) Connect the wire connector and install the
mirror onto the vehicle.
(b) Install the three torx retaining screws.
(c) Using a firm push, snap the mirror trim
cover into place.
(5) Connect the two front window defroster grid
wire connectors. One on each side of vehicle.
(6) Tighten the right side roll down bolt.
(7) Install the right side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(8) Install the right end cover. Position over retain-
ing slots and firmly snap into place.
(9) Connect the right side wire connectors to the
HVAC behind the glove box area and the two
antenna connectors behind the glove box hinge.
(10) Install the instrument panel top cover. Slide
the front edge of the top cover toward dash panel,
and firmly snap down the rear edge of the to cover to
engage clips.
(11) If equipped with a mechanical transmission
range indicator:
(a) Connect the clip for the indicator cable and
guide tube to the shift cable bracket.
(b) Install the cable end to the gear selector.
(c) Install the clip holding the gear shift cable
end to the gear selector adapter.
(d) Install the indicator cable loop.
(12) Install the left side A-pillar retaining bolts.
There are two 13 mm bolts and one 10 mm bolt.
(13) Tighten the left side roll down bolt.
(14) Install the four nuts attaching the instrument
panel to the brake pedal support bracket.
(15) Install the four nuts retaining the steering
column and lower to the floor.
(16) Connect the ORC harness connector.
(17) Connect the steering column wiring. There
are seven connectors and then clip the harness to the
column.
(18) Connect the shrouds and install the two steer-
ing column shroud retaining screws.
(19) Install five screws to the left under column
instrument panel reinforcement brace.
23 - 204 INSTRUMENT PANELRS
INSTRUMENT PANEL ASSEMBLY (Continued)

(20) Install the two screws to the hood release
handle.
(21) Connect the left side wiring:
(a) Brake switch.
(b) Main bulkhead connector.
(c) Five harness connectors.
(d) Driver airbag connector.
(22) Install one screw to the left side instrument
panel silencer.
(23) Clip the Data Link Connector (DLC) to the
instrument panel reinforcement.
(24) Install the eight screws to the plastic knee
blocker reinforcement.
(25) Install the four screws to the lower steering
column cover.
(26) Install the glove box:
(a) Install glove box into the vehicle. Line up the
hinges and firmly snap together.
(b) Push in on sides of glove box bin and raise
door.
(27) Install the both left and right side A-pillar
trim covers. Position trim cover over slots and firmly
snap into place.
(28) Install the two screws to each right and left
cowl trim covers.
(29) Connect the wire connectors to the Passenger
Airbag.
(30) Install the bolts holding the lower supports to
the floor pan.
(31) Install the bolts holding the lower supports to
the instrument panel frame.
(32) Install the lower console:
(a) Install lower console to vehicle.
(b) Connect the auxiliary power outlet.
(c) Install the six retaining screws.
(33) Connect the battery negative cable.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove cup holder. Refer to Body, Instrument
Panel, Cup Holder, Removal.
(3) Insert the trim stick (special tool #C-4755) or
equivalent between access cover and center bezel.
(4) Carefully pry the access cover from the instru-
ment panel.
(5) Remove the cup holder track. Refer to Body,
Instrument Panel, Cup Holder, Removal.
(6) Using a trim stick or equivalent, gently pry out
on the edge of the instrument panel center bezel and
pull outward.(7) Disconnect the wire connectors to the accessory
switches and HVAC control.
(8) Remove the instrument panel center bezel from
the vehicle.
INSTALLATION
(1) Install the instrument panel center bezel from
the vehicle.
(2) Connect the wire connectors to the accessory
switches and HVAC control.
(3) Position the center bezel over the retaining
slots and firmly snap the instrument panel center
bezel into place.
(4) Install the cup holder track. Refer to Body,
Instrument Panel, Cup Holder, Installation.
(5) Position the center bezel over the retaining
slots and firmly snap into place.
(6) Install cup holder. Refer to Body, Instrument
Panel, Cup Holder, Installation.
(7) Connect the battery negative cable.
INSTRUMENT PANEL END
COVER
REMOVAL
(1) Open passenger side front door.
(2) Place fingers in end cover grille, and with a
firm outboard pulling motion, disengage clips holding
end cover to instrument panel.
INSTALLATION
(1) Position end cover over retaining slots and
firmly snap into place.
(2) Close passenger side front door.
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Remove A-pillar trim. Using a trim stick (spe-
cial tool #C-4755) or equivalent, gently pry out and
remove.
(2) Using a trim stick, disengage clips holding rear
edge of top cover to instrument panel.
NOTE: The Instrument Panel Top Cover may be
hard to unsnap from the instrument panel. Be sure
not to mar, scuff, or damage the instrument panel
pad.
(3) Pull top cover rearward to disengage hooks
holding front of top cover to instrument panel.
(4) Remove top cover from vehicle.
RSINSTRUMENT PANEL23 - 205
INSTRUMENT PANEL ASSEMBLY (Continued)

INSTALLATION
(1) Place instrument panel top cover in position on
vehicle.
(2) Push top cover forward to engage hooks to hold
front of top cover to instrument panel.
(3) Engage clips to hold rear edge of top cover to
instrument panel.
(4) Pull top cover rearward.
(5) Install A-pillar trim.
KNEE BLOCKER
REINFORCEMENT
REMOVAL
(1) Remove lower steering column cover. Refer to
Body, Instrument Panel, Instrument Panel Lower
Steering Column Cover, Removal.
(2) Remove screws holding knee blocker reinforce-
ment to instrument panel.
(3) Remove knee blocker reinforcement from vehi-
cle.
INSTALLATION
(1) Install the knee blocker reinforcement into
vehicle.
(2) Install the screws holding knee blocker rein-
forcement to instrument panel.
(3) Install the lower steering column cover. Refer
to Body, Instrument Panel, Instrument Panel Lower
Steering Column Cover, Installation.
LOWER CONSOLE
REMOVAL
(1) Remove screws holding the lower console to
floor bracket and instrument panel.
(2) Slide lower console rearward from around
instrument panel supports.
(3) Disconnect the auxiliary power outlet wire con-
nector (if equipped).
(4) Remove lower console from vehicle.
INSTALLATION
(1) Connect the auxiliary power outlet wire con-
nector (if equipped).
(2) Install the lower console into the vehicle.
(3) Slide console forward around instrument panel
supports.
(4) Install the screws holding lower console to floor
bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Remove the right end cover.
(2) Remove the lower steering column cover.
(3) Remove the center bezel.
(4) Remove the lower console.
(5) Remove the cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Remove the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(10) Remove the lower instrument panel from
vehicle.
INSTALLATION
When servicing the lower instrument panel, refer
to Body, Instrument Panel, and then the appropriate
removal procedure.
(1) Install the lower instrument panel into the
vehicle.
(2) Install the eighteen screws holding the lower
instrument panel to the reinforcement frame.
(3) Install the glove box lamp.
(4) Install the glove box latch striker.
(5) Install the glove box.
(6) Install the cup holder and track.
(7) Install the lower console.
(8) Install the center bezel.
(9) Install the lower steering column cover.
(10) Install the right end cover.
LOWER STEERING COLUMN
COVER
REMOVAL
(1) Remove the four screws holding the lower
steering column cover to instrument panel.
(2) Remove the lower steering column cover from
the vehicle.
INSTALLATION
(1) Install the lower steering column cover into the
vehicle.
(2) Install the four screws holding the lower steer-
ing column cover to instrument panel.
23 - 206 INSTRUMENT PANELRS
INSTRUMENT PANEL TOP COVER (Continued)

OVER STEERING COLUMN
COVER
REMOVAL
(1) Taking a firm grasp of the over steering col-
umn cover front edge, give a quick upward pulling
motion to disengage the cover from the instrument
panel.(2) Remove the over steering column cover from
the vehicle.
INSTALLATION
(1) Place the over steering column cover into posi-
tion over the retaining slots and firmly snap into
place.
RSINSTRUMENT PANEL23 - 207

(3) The calibration procedure should take less than
three minutes to complete for the manual heater-A/C
control, and less than twenty seconds for the ATC
heater-A/C control. When the LEDs or graphics stop
flashing, the calibration procedure is complete.
(4) If the LEDs or graphics continue to flash
beyond the normal three minute (manual) or twenty
second (ATC) calibration time, it indicates that the
heater-A/C control has detected a failure and a Diag-
nostic Trouble Code (DTC) has been set. Use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information. The LEDs
or graphics will continue to flash even after the igni-
tion switch is cycled Off and On, until a successful
calibration is completed or until the vehicle has been
driven about 5 kilometers (3 miles).
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 center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) Place the instrument panel center bezel unit
face down on a suitable work surface. Take the
proper precautions to protect the center bezel from
cosmetic damage.
(4) If the vehicle is equipped with the optional
Automatic Temperature Control (ATC) system, dis-
connect the infrared sensor jumper harness connector
from the receptacle on the back of the heater-A/C
control (Fig. 1).
(5) Remove the six screws that secure the heater-
A/C control to the back of the instrument panel cen-
ter bezel.
(6) Remove the heater-A/C control from the instru-
ment panel center bezel.
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 heater-A/C control onto the back of
instrument panel center bezel (Fig. 1).
(2) Install and tighten the six screws that secure
the heater-A/C control to the back of the instrument
panel center bezel. Tighten the screws to 2 N´m (17
in. lbs.).
(3) If the vehicle is equipped with the optional
ATC system, reconnect the infrared sensor jumper
harness connector to the receptacle on the back of
the heater-A/C control.
(4) Reinstall the center bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(5) Reconnect the battery negative cable.
Fig. 1 Heater-A/C Control
1 - INFRARED SENSOR JUMPER CONNECTOR (ATC ONLY)
2 - INFRARED SENSOR JUMPER HARNESS (ATC ONLY)
3 - HEATER-A/C CONTROL
4 - SCREW (6)
5- INSTRUMENT PANEL CENTER BEZEL
RSCONTROLS - FRONT24-9
A/C-HEATER CONTROL (Continued)

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.
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. 5).
(4) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front 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. 6).
(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 (Fig. 6). 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 (Fig. 5). Be certain that the two loca-
tion tabs on the front of the shield are engaged in the
Fig. 5 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
24 - 12 CONTROLS - FRONTRS
BLEND DOOR ACTUATOR (Continued)

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) Disconnect the instrument panel wire harness
connector for the blower motor resistor and the
blower motor pigtail wire connector from the resistor
connector receptacles.
(3) Check for continuity between each of the
blower motor switch input terminals of the blower
motor resistor and the resistor output terminal. In
each case there should be continuity. If OK, repair
the instrument panel wire harness circuits between
the blower motor switch and the blower motor resis-
tor or the blower motor pigtail wires as required. If
not OK, replace the faulty blower motor resistor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENTDIAGNOSIS 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 BLOWER MOTOR RESISTOR MAY GET VERY
HOT DURING NORMAL OPERATION. IF THE
BLOWER MOTOR WAS TURNED ON, WAIT FIVE
MINUTES TO ALLOW THE BLOWER MOTOR RESIS-
TOR TO COOL BEFORE PERFORMING DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THIS PRECAU-
TION CAN RESULT IN PERSONAL INJURY.
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box downward.
(4) Reach through the glove box opening to access
and disconnect the instrument panel wire harness
connector for the blower motor resistor from the
resistor connector receptacle (Fig. 11).
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the resistor connector receptacle.
(6) Remove the two screws that secure the blower
motor resistor to the evaporator housing.
(7) Remove the blower motor resistor from the
evaporator housing.
INSTALLATION
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Position the blower motor resistor into the
evaporator housing (Fig. 11).
Fig. 10 Blower Motor Resistor - Typical
1 - MOUNTING PLATE
2 - RESISTOR WIRES
24 - 16 CONTROLS - FRONTRS
BLOWER MOTOR RESISTOR (Continued)

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the HVAC wire harness connector
for the mode door actuator from the actuator connec-
tor receptacle (Fig. 22).
(4) Remove the two screws that secure the mode
door actuator to the distribution housing.
(5) Remove the mode door actuator from the distri-
bution housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the mode door actuator onto the heat-
er/AC housing (Fig. 22). If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the mode door linkage.
(2) Install and tighten the two screws that secure
the mode door actuator to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the mode door actuator to the actuator connector
receptacle.
(4) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
POWER MODULE
DESCRIPTION
A blower power module is used on this model when
it is equipped with the optional Automatic Tempera-
ture Control (ATC) (Fig. 23). Models equipped with
the standard manual heater-A/C control use a blower
motor resistor, instead of the blower power module.
The blower power module is installed in a mounting
hole in the evaporator housing, directly behind the
glove box opening of the instrument panel. The mod-
ule consists of a molded plastic mounting plate with
two integral connector receptacles. Concealed behind
the mounting plate within the evaporator housing is
the power module electronic circuitry and a large
finned, heat sink. The module mounting plate is
secured with two screws to the evaporator housingFig. 22 Mode Door Actuator
1 - CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE-ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
24 - 26 CONTROLS - FRONTRS
MODE DOOR ACTUATOR (Continued)

and is accessed for service by rolling down the glove
box from the instrument panel.
The power module heat sink will get hot when in
use. Do not touch the heat sink if the blower motor
has been running. The blower power module cannot
be adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The blower power module is connected to the vehi-
cle electrical system through a dedicated take out
and connector of the instrument panel wire harness.
A second connector receptacle receives the pigtail
wire connector from the blower motor. The blower
power module allows the microprocessor-based Auto-
matic Temperature Control (ATC) heater-A/C control
module to calculate and provide infinitely variable
blower motor speeds based upon either manual
blower switch input or the ATC programming using a
Pulse Width Modulated (PWM) circuit strategy. The
PWM voltage is applied to a comparator circuit
which compares the PWM signal voltage to the
blower motor feedback voltage. The resulting output
drives the power module circuitry, which adjusts the
voltage output received from the blower motor relay
to change or maintain the desired blower speed. The
blower power module is diagnosed using a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box downward.
(4) Reach through the glove box opening to access
and disconnect the instrument panel wire harness
connector for the power module from the module con-
nector receptacle.
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the power module connector receptacle.
(6) Remove the two screws that secure the power
module to the evaporator housing.
(7) Remove the power module from the evaporator
housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the power module into the evaporator
housing.
Fig. 23 Power Module
1 - POWER MODULE
2 - LOWER GLOVE BOX OPENING REINFORCEMENT
3 - EVAPORATOR HOUSING
RSCONTROLS - FRONT24-27
POWER MODULE (Continued)

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. 25).
(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 (Fig. 25). If necessary,
rotate the actuator slightly to align the splines on
the actuator output shaft with those in the recircula-
tion 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. 25 Recirculation Door Actuator
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER EVAPORATOR HOUSING
RSCONTROLS - FRONT24-29
RECIRCULATION DOOR ACTUATOR (Continued)