heater CHRYSLER VOYAGER 2001 Service Manual

OPERATION
The rear expansion valve solenoid is designed to
control the flow of refrigerant to the rear evaporator.
The solenoid receives fused battery current through
the rear blower motor relay on a fused rear blower
motor relay output circuit, and receives a ground
feed from the front ATC heater-A/C control module
on a TXV solenoid feed circuit. The front ATC heater-
A/C control module is programmed to control solenoid
operation. When the solenoid blocks refrigerant flow
to the rear evaporator, the resulting increase in the
refrigerant circulation rate between the condenser
and the front evaporator provides improved A/C cool-
ing performance for the front seat occupants. The
solenoid may be diagnosed using a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
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 orrepaired 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
DESCRIPTION
Fig. 9 Expansion Valve Solenoid
1 - SOLENOID
2 - SOLENOID CONNECTOR
3 - SEALING PLATE
4 - EXPANSION VALVE
5 - SEALING PLATE
6 - HVAC CONNECTOR
Fig. 10 Mode Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
RSCONTROLS - REAR24-37
EXPANSION VALVE SOLENOID (Continued)

The mode door actuator is a reversible, 12-volt
Direct Current (DC), servo motor (Fig. 10). The sin-
gle mode door actuator is located on the outboard
side of the rear heater-A/C unit housing, above the
blend door actuator. The mode door actuator is
mechanically connected to the mode door linkage.
The mode door actuator is interchangeable with the
actuator for the blend air door. Each actuator is con-
tained within an identical black molded plastic hous-
ing with an integral wire connector receptacle. Two
integral mounting tabs allow the actuator to be
secured with two screws to the rear heater-A/C unit
housing. Each actuator also has an identical output
shaft with splines that connects it to the linkage or
pivot of the proper door. The mode door actuator does
not require mechanical indexing to the mode door
linkage, as it is electronically calibrated by the front
heater-A/C control module. The mode door actuator
cannot be adjusted or repaired and, if damaged or
faulty, it must be replaced.
OPERATION
The mode door actuator is connected to the front
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire take out and
connector of the rear HVAC wire harness. The mode
door actuator can move the mode door in two direc-
tions. When the controlling heater-A/C control mod-
ule pulls the voltage on one side of the motor
connection high and the other connection low, the
mode door will move in one direction. When the mod-
ule reverses the polarity of the voltage to the motor,
the mode door moves in the opposite direction. When
the module makes the voltage to both connections
high or both connections low, the mode door stops
and will not move. These same motor connections
also provide a feedback signal to the front heater-A/C
control module. This feedback signal allows the mod-
ule to monitor the operation and relative positions of
the mode door actuator and the mode door. The front
heater-A/C control module learns the mode door stop
positions during the calibration procedure and will
store a Diagnostic Trouble Code (DTC) for any prob-
lems it detects in the mode door actuator circuits. A
DTC can be retrieved and the mode door actuator
can be diagnosed using a DRBIIItscan tool. Refer to
the appropriate diagnostic information.
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. 11).
(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.
(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.
Fig. 11 Mode Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 38 CONTROLS - REARRS
MODE DOOR ACTUATOR (Continued)

(2) Reconnect the rear HVAC wire harness connec-
tor for the mode door actuator to the actuator connec-
tor receptacle (Fig. 11).
(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. 12). 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 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 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. 12 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 - EXPANSION VALVE SOLENOID
8 - BLOWER POWER MODULE
RSCONTROLS - REAR24-39
MODE DOOR ACTUATOR (Continued)

voltage is applied to a comparator circuit which com-
pares 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
(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) Disconnect the rear HVAC wire harness con-
nector for the blower power module from the resistor
connector receptacle (Fig. 13).
(4) Disconnect the blower motor pigtail wire con-
nector from the blower power module connector
receptacle.
(5) Remove the two screws that secure the blower
power module to the rear heater-A/C unit housing.
(6) Remove the blower power module from the rear
heater-A/C unit housing.
INSTALLATION
(1) Position the blower power module into the rear
heater-A/C unit housing (Fig. 13).
(2) Install and tighten the two screws that secure
the blower power module to the rear heater-A/C unit
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the blower motor pigtail wire to the
blower power module connector receptacle.
(4) Reconnect the rear HVAC wire harness connec-
tor for the blower power module to the module con-
nector receptacle.
(5) 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).
(6) Reconnect the battery negative cable.
Fig. 13 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 - EXPANSION VALVE SOLENOID
8 - BLOWER POWER MODULE
24 - 40 CONTROLS - REARRS
POWER MODULE (Continued)

DISTRIBUTION - FRONT
TABLE OF CONTENTS
page page
AIR FILTER
DESCRIPTION...........................41
REMOVAL..............................41
INSTALLATION...........................41
AIR OUTLETS
DESCRIPTION...........................42
REMOVAL..............................42
INSTALLATION...........................44
BLOWER MOTOR
DESCRIPTION...........................45
OPERATION.............................45
DIAGNOSIS AND TESTING.................45
BLOWER MOTOR......................45
REMOVAL..............................48
INSTALLATION...........................48DEFROSTER DUCT
REMOVAL..............................49
INSTALLATION...........................50
DEMISTER DUCTS
REMOVAL..............................50
INSTALLATION...........................50
FLOOR DISTRIBUTION DUCTS
REMOVAL..............................50
INSTALLATION...........................51
HVAC HOUSING
REMOVAL..............................51
INSTALLATION...........................52
PANEL DUCTS
REMOVAL..............................52
INSTALLATION...........................53
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 conditionerevaporator 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. 1).
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.
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
RSDISTRIBUTION - FRONT24-41

(3) With the latch still positioned against its
opened stop, reinstall the air filter door onto the
lower evaporator housing air filter opening (Fig. 2).
(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
or damaged, the instrument panel top cover must be
replaced.
²Demister Outlets- There are two side window
demisters that aid in defogging and defrosting the
front door windows. One demister outlet is located at
each outboard end of the instrument panel top pad,
near the belt line at the A-pillars. The demister out-
lets can be removed from the top pad individually for
service replacement.²Instrument Panel Outlets- There are five
panel outlets in the instrument panel, one located
near each outboard end of the instrument panel fac-
ing the rear of the vehicle, and three located near the
top of the instrument panel center bezel. On models
with manual temperature control, all five of these
outlets are fully adjustable. On models with Auto-
matic Temperature Control (ATC), the center outlet
in the center bezel has fixed vanes because it also
houses the remote infrared temperature sensors for
the front seat positions. The outboard outlets can be
removed individually for service replacement. The
center bezel outlets are serviced as a gang of three
outlets and, on models with ATC, also includes the
infrared sensors.
²Front Door Rear Outlets- A fully adjustable
outlet located at the rear of each front door trim
panel supplies only cooled air to the intermediate
seat passengers. Air is supplied to these outlets from
the instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. The door ducts are integral to the front
door trim panels. These outlets also incorporate a red
reflector to improve the safety and visibility of an
opened front door to traffic approaching the vehicle
from the rear at night. These outlets can be removed
from the door trim panels for service replacement.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel below the instrument panel. These out-
lets are integral to the front heater-A/C unit distri-
bution housing.
²Rear Floor Outlets- Wide rear floor outlets
located under each front seat have integral, fixed
directional dividers to distribute heated air across
the floor for intermediate seat passengers. These out-
lets are integral to the floor distribution ducts routed
under the front floor carpet from an outlet nozzle on
the bottom of the front heater-A/C unit distribution
housing.
REMOVAL - CENTER BEZEL OUTLETS
The three outlets located near the top of the
instrument panel center bezel are serviced only as a
gang of all three outlets. If the vehicle is equipped
with the optional Automatic Temperature Control
(ATC) system, the center outlet of the three has fixed
vanes and also houses the remote front infrared tem-
perature sensors.
Fig. 2 Air Filter Door
1 - AIR FILTER DOOR
2-LATCH
3 - CLOSED STOP
4 - LOWER EVAPORATOR HOUSING
5 - OPENED STOP
24 - 42 DISTRIBUTION - FRONTRS
AIR FILTER (Continued)

BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 7). The
blower motor and wheel are located near the passen-
ger side end of the heater-A/C unit within the two
halves of the intake air housing in the passenger
compartment below the instrument panel. The
instrument panel must be rolled rearward to access
the blower motor and blower wheel for service. The
blower motor and blower motor wheel are a factory
balanced unit and cannot be adjusted or repaired. If
faulty or damaged, the blower motor and blower
wheel must be replaced as a unit.
OPERATION
The blower motor will operate whenever the igni-
tion switch is in the On position and the heater-A/C
control power is turned on. The blower motor can
only be turned off by turning off the power at the
heater-A/C control. The blower motor receives battery
current whenever the front blower motor relay is
energized. The front blower motor relay output cir-
cuit is protected by a fuse in the Intelligent Power
Module (IPM) located in the engine compartment
near the battery. In the Manual system, the blower
motor speed is controlled by regulating the path to
ground through the blower control switch and the
blower motor resistor. In the ATC system, the blower
motor speed is controlled by an electronic blower
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
blower motor to regulate the blower motor ground
path it provides. The blower motor and wheel 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 - FRONT 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.
Fig. 7 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-45

(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 thefront 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).
24 - 46 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)

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) Roll the instrument panel rearward. (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/HVAC HOUSING - REMOVAL).
(2) Disconnect the blower motor pigtail wire har-
ness connector from the connector receptacle of either
the blower motor resistor or power module, as the
vehicle is equipped (Fig. 9).(3) Disengage the HVAC wire harness take out for
the recirculation air door actuator from the routing
clips molded into the bottom of the lower intake air
housing.
(4) Remove the two screws that secure the upper
intake air housing to the lower intake air housing.
(5) Remove the three screws that secure the lower
air intake housing to the lower half of the evaporator
housing.
(6) Push the rubber grommet on the blower motor
pigtail wires through the hole in the lower intake air
housing (Fig. 10).
(7) Remove the lower intake air housing from the
evaporator housing and upper intake air housing.
(8) Feed the blower motor pigtail wires and har-
ness connector through the grommet hole in the
lower intake air housing.
(9) Relocate the recirculation air door as necessary
to access and remove the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing (Fig. 11).
(10) Gently flex the recirculation air door far
enough to remove the blower motor and blower wheel
from the blower housing in the lower half of the
evaporator housing.
INSTALLATION
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
Fig. 9 Lower Intake Air Housing
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION AIR DOOR ACTUATOR
3 - BLOWER MOTOR PIGTAIL WIRE CONNECTOR
4 - RUBBER GROMMET
5 - BLOWER MOTOR RESISTOR/POWER MODULE
6 - LOWER EVAPORATOR HOUSING
7 - UPPER INTAKE AIR HOUSING
8 - RECIRCULATION AIR DOOR
Fig. 10 Rubber Grommet - Typical
1 - BLOWER MOTOR PIGTAIL WIRE GROMMET
24 - 48 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)

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 (Fig. 9).
(2) Relocate the recirculation air door as necessary
to install and tighten the three screws that secure
the blower motor to the blower housing in the lower
half of the evaporator housing (Fig. 11). Tighten the
screws to 2 N´m (18 in. lbs.).
(3) Reach through the fresh air intake opening to
access and engage the upper pivot receptacle of the
recirculation air door with the pivot post of the upper
intake air housing.
(4) Feed the blower motor pigtail wires and har-
ness connector through the grommet hole in the
lower intake air housing and seat the rubber grom-
met (Fig. 10).
(5) Position the lower intake air housing onto the
evaporator housing and upper intake air housing. Be
certain that the splined output shaft of the recircula-
tion air door actuator is properly engaged with the
splined receptacle on the bottom of the recirculation
air door.(6) Install and tighten the three screws 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.).
(7) Install and tighten the two screws that secure
the upper intake air housing to the lower intake air
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(8) Engage the HVAC wire harness take out for
the recirculation air door actuator with the routing
clips molded into the bottom of the lower intake air
housing.
(9) Reconnect the blower motor pigtail wire har-
ness connector to the connector receptacle of either
the blower motor resistor or power module, as the
vehicle is equipped.
(10) Reinstall the instrument panel into the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION - FRONT/HVAC HOUSING -
INSTALLATION).
DEFROSTER DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Place the instrument panel face down on a
suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.
(4) Remove the fasteners that secure the defroster
duct to the instrument panel armature.
(5) Remove the defroster duct from the instrument
panel.
Fig. 11 Blower Motor Mounting Tabs
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-49
BLOWER MOTOR (Continued)