8e electrical CHRYSLER VOYAGER 2004 Service Manual

SUN VISOR SUPPORT
REMOVAL
(1) Disengage sun visor from support.
(2) Remove screw holding support to roof header
(Fig. 17).
(3) Remove sun visor support from vehicle.
INSTALLATION
(1) Place sun visor support in position on vehicle.
(2) Install screw holding support to roof header
(Fig. 17).
(3) Engage sun visor into support.
FLOOR CONSOLE TRAY
REMOVAL
(1) Remove the floor console. Refer to the Owner's
Manual for proper procedures.
(2) Remove the four screws and remove the tray.
INSTALLATION
(1) Install the floor console tray and install the
screws.
(2) Install the floor console. Refer to the Owner's
Manual for proper procedures.
FLOOR CONSOLE TRAY -
BRACKET ASSEMBLY
REMOVAL
(1) Remove the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
REMOVAL)
(2) Disconnect the electrical connector.
(3) Remove the four screws and remove the
bracket assembly.
INSTALLATION
(1) Install the bracket assembly and install the
four screws.
(2) Connect the electrical connector.
(3) Install the floor carpet. (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION)
Fig. 17 SUN VISOR SUPPORT
1 - OVERHEAD CONSOLE
2 - SUN VISOR SUPPORT
3 - HEADLINING
RSINTERIOR23-83

QUARTER WINDOW
REMOVAL
(1) Remove C-pillar trim.
(2) Open quarter glass to vent position.
(3) Disengage quarter window retainer from vent
motor arm.
(4) Remove nuts attaching quarter glass to C-pillar
(Fig. 5).
(5) Use magnetic socket to prevent dropping into
the pillar.
(6) Remove quarter glass from vehicle.
INSTALLATION
(1) Place quarter glass in position on vehicle.
(2) Install nuts attaching quarter glass to C-pillar.
(3) Engage quarter window retainer to vent motor
arm.
(4) Install screw attaching quarter window
retainer to vent motor arm.
(5) Close quarter glass.
(6) Install C-pillar trim.
REAR DOOR GLASS
REMOVAL
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
REAR WINDOW REMOVAL ± EXTERIOR METHOD
(1) Remove rear window wiper arm.
(2) Remove interior trim covers.
(3) Disconnect wires for electrically heated win-
dow, if equipped.(4) Using a sharp cold knife, cut urethane adhe-
sive attaching the rear window to the liftgate. A
power cutting device can be used if available (Fig. 1).
(5) Remove rear window from vehicle.
REAR WINDOW REMOVAL ± INTERIOR METHOD
(1) Remove rear window wiper arm.
(2) Remove interior trim covers.
(3) Disconnect wires for electrically heated win-
dow, if equipped.
(4) Using a reciprocating or oscillating power
knife, cut urethane adhesive holding the rear window
to the liftgate. Refer to instructions provided with
the equipment being used.
(5) Remove rear window from vehicle.
INSTALLATION
Refer to the Safety Precautions in this section for
description of tools and adhesive systems that are
recommended for use in this procedure.
CAUTION: Open the left front door glass before
installing rear window to avoid pressurizing the
passenger compartment. If a door is slammed
before urethane bonding is cured, water leaks can
result.
Allow the urethane at least 24 hours to cure before
returning the vehicle to use.
To avoid stressing the replacement rear window,
the urethane bonding material on the rear window
fence should be smooth and consistent to the
shape of the replacement glass.
(1) Place replacement glass into rear window open-
ing.
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement rear window. If not, the fence must be
formed to the shape of the new glass.
(3) Using a grease pencil, mark the glass and lift-
gate in several locations to aid installation.
(4) Remove replacement glass from liftgate open-
ing.
(5) Position the rear window inside up on a suit-
able work surface with two padded, wood 10 cm by
10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks,
placed parallel 75 cm (2.5 ft.) apart (Fig. 2).
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN REAR WINDOW BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(6) Clean inside of rear window with ammonia
based glass cleaner and lint-free cloth.
(7) Apply Glass Prep adhesion promoter 25 mm (1
in.) wide around perimeter of rear window and wipe
Fig. 5 QUARTER GLASS
1 - VENT CONTROL
2 - QUARTER GLASS
3 - CLIP
RSSTATIONARY GLASS23 - 111

SUNROOF
TABLE OF CONTENTS
page page
SUNROOF
DESCRIPTION........................116
DIAGNOSIS AND TESTING - SUNROOF.....116
DRAIN TUBE
REMOVAL............................119
INSTALLATION........................120
GLASS PANEL
REMOVAL............................120
INSTALLATION........................120
ADJUSTMENTS
SUNROOF GLASS PANEL ADJUSTMENT . . 120
SUNROOF ASSEMBLY
REMOVAL............................120
INSTALLATION........................120
SUNSHADE
REMOVAL............................120INSTALLATION........................121
WIND DEFLECTOR
REMOVAL............................121
INSTALLATION........................121
WATER CHANNEL
REMOVAL............................121
INSTALLATION........................121
SUNROOF MOTOR
REMOVAL............................121
INSTALLATION........................121
ADJUSTMENTS
ADJUSTMENT.......................122
SUNROOF SWITCH
REMOVAL............................123
INSTALLATION........................123
SUNROOF
DESCRIPTION
WARNING: Keep fingers and other body parts out
of sunroof opening at all times.
The sun roof features consists of: (Fig. 1)
²Sun roof glass
²Sun roof sun shade
The sunroof power sliding glass panel and sun-
shade can be positioned anywhere along its travel,
rearward of glass panel front edge.
The sunroof is electrically operated from a switch
located in the overhead console. To operate the sun-
roof the ignition switch must be in the Accessory or
On/Run position. Both switchs are a rocker style
design that open or close the sunroof. When pressing
and releasing the open button once, the sunroof will
express open to the comfort stop and the wind deflec-
tor will raise. If the button is pressed a second time,
the sunroof will continue to open to full travel unless
the button is released, at which time it will stop in
that position. Pressing and holding the close button
will close the sunroof. If the close button is released
before the glass fully closes, the sunroof will stop in
that position. The vent switch operates in a similar
manor. The sunroof will also operate for up to fifteenminutes after the ignition key is turned off for cus-
tomer comfort and convenance while parking.
DIAGNOSIS AND TESTING - SUNROOF
Refer to Sunroof Diagnostic Chart for possible
causes. Before beginning sunroof diagnostics verify
that all other power accessories are in proper operat-
ing condition. If not, a common electrical problem
may exist. Refer to Wiring Diagrams, in this publica-
tion for circuit, splice and component descriptions.
Check the condition of the circuit protection (20 amp
circuit breaker in the Junction Block). Inspect all
wiring connector pins for proper engagement and
continuity. Check for battery voltage at the power
sunroof controller, refer to Wiring Diagrams, for cir-
cuit information. If battery voltage of more than 10
volts is detected at the controller, proceed with the
following tests (the controller will not operate at less
than 10 volts).
Before beginning diagnosis for wind noise or water
leaks, verify that the problem was not caused by
releasing the control switch before the sunroof was
fully closed. The sunroof module has a water-man-
agement system. If however, the sunroof glass is in a
partial closed position, high pressure water may be
forced beyond the water management system bound-
aries and onto the headlining.
23 - 116 SUNROOFRS

(5) Install the sunroof motor and verify proper
sunroof operation (Refer to 23 - BODY/SUNROOF/
DRIVE MOTOR - INSTALLATION).
(6) Install the sunroof glass, leaving the retaining
bolts loose.
(7) Install the sunroof assembly into the vehicle
(Refer to 23 - BODY/SUNROOF/MODULE ASSEM-
BLY - INSTALLATION).
(8) Flush the sunroof glass into the vehicle roof
opening and check sunroof glass alignment (Refer to
23 - BODY/SUNROOF/GLASS PANEL - ADJUST-
MENTS).
SUNROOF SWITCH
REMOVAL
(1) Disconnect the negative battery cable.
(2) Separate the overhead console from the head-
liner, by carefully pulling down on the front portion,
toward the windshield, to release the retaining clips
(Fig. 6).
(3) Release the sunroof switch retaining tab, dis-
connect the electrical connector and remove the
switch from the console (Fig. 6).
INSTALLATION
(1) Position the switch against the overhead con-
sole and push the switch to seat properly in retaining
clip.(2) Install the overhead console.
(3) Connect the negative battery cable.
Fig. 6 OVERHEAD CONSOLE
1 - OVERHEAD CONSOLE
2 - POWER SUNROOF SWITCH
3 - SUNROOF SWITCH RETAINING CLIP (PART OF CONSOLE)
4 - OVERHEAD CONSOLE RETAINING CLIPS
RSSUNROOF23 - 123
SUNROOF MOTOR (Continued)

A/C COMPRESSOR CLUTCH/
COIL
DESCRIPTION
The A/C compressor clutch assembly consists of a
stationary electromagnetic A/C clutch field coil with a
zener diode, a pulley bearing and pulley assembly,
and a clutch plate (Fig. 1). A/C clutch field coil and
the pulley bearing 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 compressor shaft, and secured with a nut or
bolt (depending on application). These components
provide the means to engage and disengage the com-
pressor from the engine serpentine accessory drive
belt.
The A/C compressor clutch and coil are available
for separate service replacement. The clutch coil
zener diode is integral to the clutch coil pigtail wire
and connector and, if faulty or damaged, the clutch
electromagnetic coil 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 windingsby 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 for automatic temperature
control (ATC) system or on the HVAC housing for
manual temperature control (MTC) system, the Pow-
ertrain Control Module (PCM) in the engine compart-
ment, and the compressor clutch relay in the
Integrated Power Module (IPM). The PCM may delay
compressor clutch engagement for up to thirty sec-
onds (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN CONTROL
MODULE - DESCRIPTION - PCM OPERATION).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
The air conditioning compressor clutch coil electri-
cal circuit is controlled by the powertrain control
module (PCM) through the A/C compressor clutch
relay, which is located in the integrated power mod-
ule (IPM) in the engine compartment. Begin testing
of a suspected compressor clutch coil problem by per-
forming the preliminary checks.
PRELIMINARY CHECKS
(1) If the compressor clutch will not engage, verify
the refrigerant charge level (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - FRONT/RE-
FRIGERANT - DIAGNOSIS AND TESTING -
REFRIGERANT CHARGE LEVEL). If the refriger-
ant charge level is OK, go to Step 2. If the refriger-
ant charge level is not OK, adjust the refrigerant
charge as required.
(2) If the A/C compressor clutch still will not
engage, disconnect the wire harness connector for the
A/C pressure transducer and check for battery cur-
rent at the connector with the engine running and
the A/C-heater control set to the A/C mode. If OK, go
to TESTS. If not OK, refer to Body Diagnostic Proce-
dures to perform further diagnosis.
TESTS
(1) Verify the battery state of charge (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY -
DIAGNOSIS AND TESTING).
Fig. 1 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 - FRONT24-15

(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the heater-A/C control in the A/C mode
and the blower at low speed, start the engine and
allow it to run at a normal idle speed.
(4) The compressor clutch should engage immedi-
ately, and the clutch coil voltage should be within
two volts of the battery voltage. If the coil voltage is
not within two volts of battery voltage, test the
clutch coil feed circuit for excessive voltage drop. If
the compressor clutch does not engage, refer to Body
Diagnostic Procedures to perform further diagnosis.
(5) Refer to the A/C Clutch Coil Current Draw
chart for the acceptable A/C clutch coil current draw
specifications. Specifications apply for a work area
temperature of 21É C (70É F). If voltage is more than
12.5 volts, add electrical loads by turning on electri-
cal accessories until voltage reads below 12.5 volts.
(a) If the compressor clutch coil current reading
is zero, the coil is open and must be replaced.
(b) If the compressor clutch coil current reading
is four amperes or more, the coil is shorted and
must be replaced.
A/C CLUTCH COIL CURRENT DRAW
Compressor Current Draw
Nippondenso - 10S20
(2.5L/3.3L/3.8L engines)
Nippondenso - 10S17
(2.4L engine)2.2 amps @ 11.5 - 12.5
volts
REMOVAL
NOTE: The compressor clutch can be serviced in
the vehicle. The refrigerant system can remain fully-
charged during compressor clutch, pulley, or coil
replacement.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
2.4L - REMOVAL) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3/3.8L -
REMOVAL).
(3) Raise and support the vehicle.
(4) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil pig-
tail wire connector on the top of the compressor.
(5) On models with the 3.3L and 3.8L engines, dis-
engage the retainer on the engine wire harness com-
pressor clutch coil take out from the bracket on the
top of the compressor.(6) On models with the 2.4L and 2.5L engines,
remove all of the compressor mounting bolts except
the upper left (rear of the compressor), which should
only be loosened. Allow the front (pulley end) of the
compressor to tilt downward far enough to access the
clutch for removal, then tighten the loosened upper
left compressor mounting bolt.
(7) On models with the 3.3L and 3.8L engines,
remove the two bolts and two nuts that secure the
compressor to the engine. Disengage the mounting
ear at the front of the compressor from the stud on
the engine, allow the front (pulley end) of the com-
pressor to tilt downward far enough to access the
clutch for removal, then reinstall and tighten the
upper left compressor mounting bolt.
(8) Remove the compressor shaft bolt (Fig. 2). A
band-type oil filter wrench or a strap wrench may be
used to secure the clutch during bolt removal.
(9) Tap the clutch plate lightly with a plastic mal-
let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
compressor shaft (Fig. 3).
NOTE: Use care not to lose any of the shim(s).
CAUTION: Do not pry between the clutch plate unit
and the pulley to remove the clutch plate from the
compressor shaft as this may damage the clutch
plate.
Fig. 2 Compressor Shaft Bolt and Clutch Plate
1 - COMPRESSOR SHAFT BOLT
2 - COMPRESSOR CLUTCH PLATE
24 - 16 CONTROLS - FRONTRS
A/C COMPRESSOR CLUTCH/COIL (Continued)

COOLING/ACCESSORY DRIVE/DRIVE BELTS -
3.3L/3.8L - INSTALLATION).
(15) Lower the vehicle.
(16) Reconnect the battery negative cable.
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C-heater control to the A/C
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The compressor clutch relay (Fig. 7) is a Interna-
tional Standards Organization (ISO) micro-relay.
Relays conforming to the ISO specifications have
common physical dimensions, current capacities, ter-
minal patterns, and terminal functions. The ISO
micro-relay terminal functions are the same as a con-
ventional ISO relay. However, the ISO micro-relay
terminal pattern (or footprint) is different, the cur-
rent capacity is lower, and the physical dimensions
are smaller than those of the conventional ISO relay.
The A/C compressor clutch relay is located in the
Integrated Power Module (IPM) in the engine com-
partment. See the fuse and relay layout map molded
into the inner surface of the IPM cover for A/C com-
pressor clutch relay identification and location.The black, molded plastic case is the most visible
component of the A/C compressor clutch relay. Five
male spade-type terminals extend from the bottom of
the base to connect the relay to the vehicle electrical
system, and the ISO designation for each terminal is
molded into the base adjacent to each terminal. The
ISO terminal designations are as follows:
²30 (Common Feed)- This terminal is con-
nected to the movable contact point of the relay.
²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.
²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
OPERATION
The A/C compressor clutch relay is an electrome-
chanical switch that uses a low current input from
the powertrain control module (PCM) to control the
high current output to the compressor clutch electro-
magnetic coil. The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. The resistor or diode is con-
nected in parallel with the relay coil in the relay, and
helps to dissipate voltage spikes and electromagnetic
interference that can be generated as the electromag-
netic field of the relay coil collapses.
The compressor clutch relay terminals are con-
nected to the vehicle electrical system through a
receptacle in the integrated power module (IPM). The
inputs and outputs of the A/C compressor clutch
relay include:
²The common feed terminal (30) receives a bat-
tery current input from a fuse in the IPM through a
fused B(+) circuit at all times.
²The coil ground terminal (85) receives a ground
input from the PCM through the compressor clutch
relay control circuit only when the PCM electroni-
cally pulls the control circuit to ground.
²The coil battery terminal (86) receives a battery
current input from the PCM through a fused ignition
switch output (run-start) circuit only when the igni-
tion switch is in the On or Start positions.
Fig. 7 A/C Compressor Clutch Relay
RSCONTROLS - FRONT24-19
A/C COMPRESSOR CLUTCH/COIL (Continued)

²The normally open terminal (87) provides a bat-
tery current output to the compressor clutch coil
through the compressor clutch relay output circuit
only when the compressor clutch relay coil is ener-
gized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the compressor
clutch relay coil is de-energized.
The A/C compressor clutch relay cannot be
repaired and, if faulty or damaged, it must be
replaced. Refer to the appropriate wiring information
for diagnosis and testing of the micro-relay and for
complete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 8).
(3) Refer to the fuse and relay layout map on the
inner surface of the IPM cover for A/C compressor
clutch relay identification and location.
(4) Remove the A/C compressor clutch relay from
the IPM.
INSTALLATION
(1) Refer to the fuse and relay layout map on the
inner surface of the integrated power module (IPM)cover for A/C compressor clutch relay identification
and location.
(2) Position the A/C compressor clutch relay into
the proper receptacle in the IPM.
(3) Align the A/C compressor clutch relay termi-
nals with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the A/C compressor clutch
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.
(6) Reconnect the negative battery cable.
A/C HEATER CONTROL
DESCRIPTION
The A/C-heater control is located at the center of
the instrument panel and uses electrical controls.
These controls provide the vehicle operator with a
number of setting options to help control the climate
and comfort within the vehicle. Refer to the owner's
manual in the vehicle glove box for more information
on the suggested operation and use of these controls.
The A/C-heater control cannot be repaired. If faulty
or damaged, the entire unit must be replaced. The
control knobs and the illumination lamps are avail-
able for service replacement.
STANDARD PROCEDURE - A/C-HEATER
CONTROL CALIBRATION
The A/C-heater control module must be recali-
brated each time an actuator motor or the control
module is replaced. If the vehicle is so equipped, the
calibration procedure also includes rear HVAC posi-
tions for each actuator motor.
(1) Turn the ignition switch to the On position.
(2) If equipped with the manual temperature con-
trol (MTC) system, press and hold the Rear Wipe/
Wash and Recirculation buttoms for at least five
seconds. If equipped with the automatic temperature
control (ATC) systen, simultaneously press and hold
the Power and Recirculation buttons on the A/C-
heater control for at least five seconds. The MTC
A/C-heater control Rear Wipe/Wash Light Emitting
Diode (LED) and Recirculation LED, or the ATC A/C-
heater control Delay and Recirculation graphics will
begin to flash when the calibration procedure has
begun.
(3) The calibration procedure should take less than
two minutes to complete for the manual A/C-heater
control, and less than twenty seconds for the ATC
A/C-heater control. When the LEDs or graphics stop
flashing, the calibration procedure is complete.
(4) If the LEDs or graphics continue to flash
beyond the two minute (manual) or twenty second
(ATC) calibration time, it indicates that the A/C-
Fig. 8 Integrated Power Module (IPM)
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE (IPM)
3 - FRONT CONTROL MODULE
24 - 20 CONTROLS - FRONTRS
A/C COMPRESSOR CLUTCH RELAY (Continued)

heater control has detected a failure and a Diagnostic
Trouble Code (DTC) has been set. Refer to Body
Diagnostic Procedures to perform further diagnosis.
The LEDs or graphics will continue to flash even
after the ignition switch is cycled Off and On, until a
successful calibration is completed or until the vehi-
cle has been driven about 13 kilometers (8 miles).
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 -
REMOVAL).
(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 A/C-heater
control (Fig. 9).
(5) Remove the six screws that secure the A/C-
heater control to the back of the instrument panel
center bezel.
(6) Remove the A/C-heater control from the instru-
ment panel center bezel.
INSTALLATION
(1) Position the A/C-heater control onto the back of
instrument panel center bezel.
(2) Install the six screws that secure the A/C-
heater 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 A/C-heater control.(4) Install 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.
A/C PRESSURE TRANSDUCER
DESCRIPTION
The A/C pressure transducer is a switch that is
installed on a fitting located on the refrigerant liquid
line between the receiver/drier and the expansion
valve in the right rear corner of the engine compart-
ment. An internally threaded hex fitting on the
transducer connects it to the externally threaded
Schrader-type fitting on the liquid line. A rubber
O-ring seals the connection between the transducer
and the liquid line fitting. Three terminals within a
molded plastic connector receptacle on the top of the
transducer connect it to the vehicle electrical system
through a wire lead and connector of the headlamp
and dash wire harness.
The A/C pressure transducer cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
OPERATION
The A/C pressure transducer monitors the pres-
sures in the high side of the refrigerant system
through its connection to a fitting on the liquid line.
The transducer will change its internal resistance in
response to the pressures it monitors. The power-
train control module (PCM) provides a five volt ref-
Fig. 9 A/C-Heater Control
1 - INFRARED SENSOR CONNECTOR (ATC ONLY)
2 - INFRARED SENSOR HARNESS (ATC ONLY)
3 - A/C-HEATER CONTROL AREA
4 - SCREW (6)
5- INSTRUMENT PANEL CENTER BEZEL
RSCONTROLS - FRONT24-21
A/C HEATER CONTROL (Continued)

BLEND DOOR ACTUATOR
DESCRIPTION
The blend door actuators are reversible, 12-volt
Direct Current (DC), servo motors. Models with the
single zone heater and air conditioner system have a
single blend air door, which is controlled by a single
blend door actuator. Models with the optional dual
zone front heater and air conditioner system have
dual blend air doors, which are controlled by two
blend door actuators. The single zone blend door
actuator is located on the driver's side end of the
HVAC housing, close to the middle of the distribution
housing. In the dual zone system, the same blend
door actuator used for the single zone system
becomes the passenger blend door actuator, and is
mechanically connected to only the passenger side
blend air door. In the dual zone system, a second sep-
arate blend door actuator is also located on the
driver side end of the HVAC housing, close to the
middle of the distribution housing, and is mechani-
cally connected to only the driver's side blend air
door.
The blend door actuators are interchangeable with
each other, as well as with the actuators for the
mode door and the recirculation air door. Each actua-
tor is contained within an identical black molded
plastic housing with an integral wire connector
receptacle. Two integral mounting tabs allow the
actuator to be secured with two screws to the distri-
bution housing. Each actuator also has an identical
output shaft with splines that connects it to the link-
age that drives the proper blend air door. The blend
door actuators do not require mechanical indexing to
the blend door linkage, as they are electronically cal-
ibrated by the heater-A/C control module.
OPERATION
Each blend door actuator is connected to the A/C-
heater control through the vehicle electrical system
by a dedicated two-wire lead and connector from the
HVAC wire harness. The blend door actuator can
move the blend-air door in two directions. When the
A/C-heater control pulls the voltage on one side of
the motor connection high and the other connection
low, the blend-air door will move in one direction.
When the A/C-heater control reverses the polarity of
the voltage to the motor, the blend-air door moves in
the opposite direction. When the A/C-heater control
makes the voltage to both connections high or both
connections low, the blend-air door stops and will not
move. The motor connections also provide a feedback
signal to the A/C-heater control. This feedback signal
allows the A/C-heater control to monitor the opera-
tion and relative positions of the blend door actuator
and the blend-air door. The A/C-heater control learnsthe blend 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 Body Diagnostic Proce-
dures for more information. The blend door actuators
cannot be adjusted or repaired and, if damaged or
faulty, they must be replaced.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The single zone heating and air conditioning
system is equipped with a single blend door actua-
tor. The dual zone system has two blend door
actuators, one for the driver side blend air door and
one for the passenger side blend air door. The
same service procedures can be used for each of
these actuators.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(3) Disconnect the wire harness connector from the
blend door actuator(s) (Fig. 11).
(4) Remove the two screws that secure the blend
door actuator to the distribution housing.
(5) Remove the blend door actuator.
INSTALLATION
(1) Position the blend door actuator onto the distri-
bution housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the blend air door linkage.
(2) Install the two screws that secure the blend
door actuator to the housing. Tighten the screws to 2
N´m (17 in. lbs.).
RSCONTROLS - FRONT24-23