wheel CHRYSLER VOYAGER 2001 Service Manual

HEADLINER
REMOVAL
(1) Remove sun visors and vanity mirrors.
(2) Remove sun visor center supports.
(3) If equipped, remove coat hooks.
(4) If equipped, remove roof rail modules.
(5) Remove A-pillar trim covers.
(6) Remove B-pillar upper trim covers.
(7) Remove C-pillar upper trim covers.
(8) Remove D-pillar upper trim covers.
(9) Remove liftgate opening header trim.
(10) If equipped, remove overhead console.
(11) If equipped, remove reading lamp.
(12) Remove dome lamp.
(13) Remove push in locking fasteners attaching
headlining to rear roof header and roof bows (Fig. 9)
or (Fig. 10).
(14) Remove headlining from roof.
(15) Extract headlining through liftgate opening.
INSTALLATION
(1) Insert headlining through liftgate opening.
(2) Place headlining in position on roof.
(3) Install left sun visor support.
(4) Install push in locking fasteners attaching
headlining to rear roof header and bows (Fig. 9) or
(Fig. 10).
(5) Install right sun visor support.
(6) Install sun visors and vanity mirrors.(7) If equipped, install roof rail modules.
(8) If equipped, install coat hooks.
(9) Install dome lamp.
(10) If equipped, install reading lamp.
(11) If equipped, install overhead console.
(12) Install liftgate opening header trim.
(13) Install D-pillar upper trim covers.
(14) Install C-pillar upper trim covers.
(15) Install B-pillar upper trim covers.
(16) Install A-pillar trim covers.
JACK STORAGE COVER
REMOVAL
LONG WHEEL BASE
(1) Depress latch handle at top of jack storage
cover.
(2) Pull outward at top of cover to disengage latch.
(3) Remove jack storage cover from vehicle.
SHORT WHEEL BASE
(1) Open quarter panel bin storage cover.
(2) Lift upward and rearward on jack storage cover
retaining latch to disengage.
(3) Remove jack storage cover from vehicle.
Fig. 9 Headlining ± SWB
1 - ROOF
2 - REAR HEADER TRIM
3 - PUSH-IN FASTENER
4 - HEADLINING
Fig. 10 Headlining ± LWB
1 - ROOF
2 - HEADLINING
3 - SUN VISOR SUPPORTS
4 - PUSH-IN FASTENERS
RSINTERIOR23 - 213

INSTALLATION
LONG WHEEL BASE
(1) Place jack storage cover in position on vehicle.
(2) Align guide pins.
(3) Push inward at top of cover to engage latch
and fastener.
SHORT WHEEL BASE
(1) Position jack storage cover to vehicle.
(2) Snap storage cover latch into position on quar-
ter trim panel.
(3) Close quarter trim panel bin storage cover.
LEFT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
(5) Remove jack storage cover.
(6) Remove screws attaching trim panel to D-pil-
lar.
(7) Disengage hidden clips attaching trim to D-pil-
lar.
(8) Disconnect speaker wire connector, if equipped.
(9) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(10) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Pass seat belt through slot in D-pillar trim
panel on short wheel base vehicle.
(2) Position D-pillar trim panel on vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim to D-pillar.
(7) Install jack storage cover.
(8) Install bolt attaching second row seat belt
lower anchor to quarter on short wheel base vehicle.
Tighten all seat belt bolts to 39 N´m (29 ft. lbs.).
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
LIFTGATE SCUFF PLATE
REMOVAL
(1) Disengage hidden clips holding sill plate to lift-
gate door opening sill (Fig. 11) .
(2) Remove sill plate from vehicle.
INSTALLATION
(1) Place sill plate in position on vehicle.
(2) Align locator rib into recess in liftgate sill.
(3) Engage hidden clips to hold sill plate to liftgate
door opening sill.
QUARTER TRIM BOLSTER
REMOVAL
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Disengage hidden clips attaching trim bolster
to quarter trim panel.
(2) Disengage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Remove quarter trim bolster from vehicle.
INSTALLATION
The speaker grille in the quarter trim bolster is
not removable. The trim bolster must removed to ser-
vice the speaker.
(1) Place quarter trim bolster in position on vehi-
cle.
(2) Engage hook retainer attaching front of trim
bolster to quarter trim panel, if applicable.
(3) Engage hidden clips attaching trim bolster to
quarter trim panel.
Fig. 11 Liftgate Sill Plate
1 - LIFTGATE SILL PLATE
2 - LIFTGATE SILL
23 - 214 INTERIORRS
JACK STORAGE COVER (Continued)

RIGHT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the battery negative cable.
Damage to accessory feed circuit can result.
(1) Remove first row seat.
(2) Remove second row seat, if equipped.
(3) Remove sliding door sill trim panel.
(4) Remove quarter trim bolster.
(5) Remove C-pillar trim panel.
(6) Remove D-pillar trim panel.
(7) Remove first row seat belt anchor.
(8) Remove second row seat belt anchor on long
wheel base vehicle.
(9) Remove screws attaching quarter trim to quar-
ter panel from bolster area.
(10) Remove screws attaching rear edge of quarter
trim to attaching bracket.
(11) Disengage hidden clips holding front of quar-
ter trim to quarter panel rearward of sliding door
opening.
(12) Remove quarter trim from quarter panel.
(13) Disconnect wire connector from accessory
power outlet, if equipped.
(14) Pass second row seat belt through slot in trim
panel on long wheel base vehicle.
(15) Pass first row seat belt through slot in trim
panel.
(16) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass first row seat belt through slot in trim
panel.
(3) Pass second row seat belt through access hole
in trim panel on long wheel base vehicle.
(4) Connect wire connector into accessory power
outlet, if equipped.
(5) Align locating pins on backside of trim panel to
mating holes in inner quarter panel.
(6) Engage hidden clips attaching front of quarter
trim to quarter panel rearward of sliding door open-
ing.
(7) Install screws attaching rear edge of quarter
trim to attaching bracket.
(8) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(9) Install second row seat belt anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (29 ft. lbs.) torque.
(10) Install first row seat belt anchor.
(11) Install D-pillar trim panel.
(12) Install C-pillar trim panel.
(13) Install quarter trim bolster.(14) Install sliding door sill trim panel.
(15) Install second row seat, if equipped.
(16) Install first row seat.
(17) Connect the battery negative cable.
LEFT QUARTER TRIM PANEL
REMOVAL
CAUTION: Disconnect the negative cable clamp
from battery post. Damage to accessory feed circuit
can result.
(1) Remove first row seat.
(2) Remove second row seat, if equipped.
(3)
Remove front door sill plate on three door vehicle.
(4) Remove sliding door sill plate on four door
vehicle.
(5) Remove left quarter trim bolster.
(6) Remove upper left B-pillar trim on three door
vehicle.
(7) Remove C-pillar trim panel.
(8) Remove left D-pillar trim panel.
(9) Remove first row seat belt anchor.
(10) Remove second row seat belt anchor on long
wheel base vehicle.
(11) Remove left front seat belt opening bezel from
quarter trim on three door vehicle.
(12) Remove screws attaching quarter trim to
quarter panel in B-pillar area on three door vehicle.
(13) Remove screws attaching quarter trim to
quarter panel from bolster area.
(14)
Remove screws attaching rear edge of quarter
trim to attaching bracket or inner quarter trim panel.
(15) Remove screws attaching top of trim panel to
inner sheet metal between B-pillar and C-pillar on
three door vehicle.
(16) Disconnect wire connector from accessory
power outlet, if equipped.
(17) Remove quarter trim from quarter panel.
(18) Pass front seat belt and turning loop through
slot in quarter trim panel on three door vehicle.
(19) Pass first row seat belt through slot in quar-
ter trim panel.
(20) Pass second row seat belt, if equipped,
through slot in quarter trim panel on long wheel
base vehicle.
(21) Remove quarter trim panel from vehicle.
INSTALLATION
(1) Position quarter trim panel on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in quarter trim panel on long wheel base vehicle.
(3) Pass first row seat belt through slot in quarter
trim panel.
RSINTERIOR23 - 215

(4) Pass front seat belt through slot in quarter
trim panel on three door vehicle.
(5) Connect wire connector into accessory power
outlet, if equipped.
(6) Align locating pins on backside of trim panel to
mating holes in inner panels.
(7) Position quarter trim panel on inner quarter
panel.
(8) Install screws attaching top of trim panel to
inner sheet metal between B-pillar and C-pillar on
three door vehicle.
(9) Install screws attaching rear edge of quarter
trim to attaching bracket or inner quarter panel.
(10) Install screws attaching quarter trim to inner
quarter panel in bolster area.
(11) Install screws attaching quarter trim to inner
quarter panel in B-pillar area on three door vehicle.
(12) Install left front seat belt opening bezel into
quarter trim on three door vehicle.
(13) Install second row seat belts anchor on long
wheel base vehicle. Tighten all seat belt bolts to 39
N´m (28 in. lbs.) torque.
(14) Install first row seat belt anchor.
(15) Install left D-pillar trim panel.
(16) Install C-pillar trim panel.
(17) Install upper left B-pillar trim on three door
vehicle.
(18) Install left quarter trim bolster.
(19)
Install front door sill plate on three door vehicle.
(20) Install sliding door sill plate on four door
vehicle.
(21) Install second row seat, if equipped.
(22) Install first row seat.
(23) Connect the battery negative cable.
REAR HEADER TRIM
REMOVAL
(1) Disengage hidden clips holding trim to rear
header (Fig. 12).
(2) Separate rear header trim from vehicle.
INSTALLATION
(1) Place rear header trim in position on vehicle.
(2) Align guide pins on trim to holes in header.
(3) Engage hidden clips to hold trim to rear
header.
REAR HVAC LOUVER
REMOVAL
(1) Using a trim stick (C-4755), pry edge of louver
from bezel.
(2) Remove HVAC louver from bezel.(3) Using a trim stick, pry lower edge of HVAC
bezel away from headlining (Fig. 13) .
(4) Remove louver from vehicle.INSTALLATION
(1) Place bezel in position in HVAC duct opening.
Fig. 12 REAR HEADER TRIM
1 - REAR HEADER
2 - GUIDE PINS
3 - CLIPS
Fig. 13 Rear HVAC Louver
1 - HEVAC DUCT
2 - REAR HEVAC LOUVER
3 - HEADLINING
4 - CLIP
23 - 216 INTERIORRS
LEFT QUARTER TRIM PANEL (Continued)

(2) Push inward on bezel until clips snap in place.
Verify that all four clips have been engaged to the
bezel and that the bezel is flush to the headlining
(3) Position HVAC louver to bezel.
(4) Snap both ends of the louver into HVAC bezel.
REAR VIEW MIRROR
REMOVAL
(1) If equipped, disconnect mirror harness connec-
tor (Fig. 14).
(2) Loosen the mirror base set screw (Fig. 15).
(3) Slide the mirror base upward and off the
bracket.
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten the setscrew 1 N´m (15 in. lbs.) torque.
(3) If equipped, connect mirror harness connector.
RIGHT D-PILLAR TRIM PANEL
REMOVAL
(1) Remove rear header trim cover.
(2) Remove liftgate sill plate.
(3) Remove second row seat belt turning loop on
long wheel base vehicle.
(4) Remove bolt attaching second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle.
(5) Remove quarter trim bolster on short wheel
base vehicle.
(6) Remove screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Disengage hidden clips attaching trim to D-pil-
lar.
(8) Remove D-pillar trim panel from D-pillar.
(9) Disconnect speaker wire connector, if equipped.
(10) Pass second row seat belt, if equipped,
through slot in trim panel on short wheel base vehi-
cle.
(11) Remove D-pillar trim from vehicle.
INSTALLATION
(1) Position D-pillar trim on vehicle.
(2) Pass second row seat belt, if equipped, through
slot in trim panel on short wheel base vehicle.
(3) Connect speaker wire connector to speaker, if
equipped.
(4) Align locating pins on backside of trim panel to
mating holes in D-pillar.
(5) Engage hidden clips attaching trim to D-pillar.
(6) Install screws attaching trim panel to attach-
ing bracket on short wheel base vehicle.
(7) Install quarter trim bolster on short wheel base
vehicle.
(8) Install bolt to attach second row seat belt, if
equipped, anchor to quarter on short wheel base
vehicle. Tighten all seat belt bolts to 39 N´m (29 ft.
lbs.) torque.
(9) Install second row seat belt turning loop on
long wheel base vehicle.
(10) Install liftgate sill plate.
(11) Install rear header trim cover.
Fig. 14 Rear View Mirror Assembly
1 - HEADLINER
2 - WIRE COVER
3 - MIRROR
4 - MIRROR ASSEMBLY
5 - WIRE CONNECTOR
6 - WINDSHIELD
Fig. 15 Rear View Mirror
1 - MIRROR
2 - WINDSHIELD
RSINTERIOR23 - 217
REAR HVAC LOUVER (Continued)

(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)

(2) Install and tighten the two screws that secure
the blower motor resistor to the evaporator housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the blower motor pigtail wire con-
nector to the blower motor resistor connector recep-
tacle.
(4) Reconnect the instrument panel wire harness
connector for the blower motor resistor to the resistor
connector 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.
COMPRESSOR CLUTCH
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil with a zener diode, a hub
bearing and pulley assembly, and a clutch plate (Fig.
12). The electromagnetic coil unit and the hub bear-
ing and pulley assembly are each retained on the
nose of the compressor front housing with snap rings.
The clutch plate is keyed or splined to the compres-
sor shaft, and secured with a bolt.
The compressor clutch plate and pulley unit, or the
clutch coil are available for separate service replace-
ment. The clutch coil zener diode is integral to the
clutch coil pigtail wire and connector and, if faulty ordamaged, the clutch electromagnetic coil unit must
be replaced.
OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and
drives the compressor shaft. When the coil is not
energized, the pulley freewheels on the clutch hub
bearing, which is part of the pulley.
A zener diode is connected in parallel with the
clutch electromagnetic coil. This diode controls the
dissipation of voltage induced into the coil windings
by the collapsing of the electromagnetic fields that
occurs when the compressor clutch is disengaged.
The zener diode dissipates this induced voltage by
regulating a current path to ground. This arrange-
ment serves to protect other circuits and components
from potentially damaging voltage spikes in the vehi-
cle electrical system that might occur if the voltage
induced in the clutch coil windings could not be dis-
sipated.
The compressor clutch engagement is controlled by
several components: the heater-A/C controls in the
passenger compartment, the A/C pressure transducer
on the liquid line, the evaporator temperature sensor
on the expansion valve, the Powertrain Control Mod-
ule (PCM) in the engine compartment, and the com-
pressor clutch relay in the Intelligent Power Module
(IPM). The PCM may delay compressor clutch
engagement for up to thirty seconds. (Refer to 8 -
Fig. 11 Blower Motor Resistor
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING LOWER REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE
6 - EVAPORATOR HOUSING
Fig. 12 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (SOME MODELS)
3 - PULLEY AND BEARING
4 - CLUTCH COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
RSCONTROLS - FRONT24-17
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)