battery CHRYSLER VOYAGER 2004 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2004, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2004Pages: 2585, PDF Size: 62.54 MB
Page 2441 of 2585
(2) Engage the retainer features on the top of the
outlet housing with their receptacles at the top of the
center bezel, then roll the bottom of the outlet hous-
ing downwards towards the center bezel.
(3) Install the three screws that secure the bottom
of the outlet housing to the center bezel. Tighten the
screws to 2 N´m (17 in. lbs.).
(4) If the vehicle is equipped with the optional
ATC system, reconnect the ATC remote infrared tem-
perature sensor jumper harness to the sensor connec-
tor receptacle located on the bottom of the center
outlet housing.
(5) Reinstall the center bezel onto the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(6) Reconnect the battery negative cable.
INSTALLATION - DEMISTER OUTLET
(1) Position the demister outlet over the demister
duct opening in the instrument panel top pad.
(2) Using hand pressure, press the demister outlet
firmly and evenly into the instrument panel top pad
opening until the snap features on the outlet are
fully engaged.
INSTALLATION - INSTRUMENT PANEL OUTLET
(1) Position the instrument panel outlet into the
panel duct opening in the instrument panel top pad.
(2) Using hand pressure, press the instrument
panel outlet firmly and evenly into the instrument
panel top pad opening until the snap features on the
outlet are fully engaged.
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. 6). The
blower motor and wheel are located near the passen-
ger side end of the HVAC housing in the passenger
compartment below the instrument panel. The
blower motor and blower motor wheel are factory bal-
anced and cannot be adjusted or repaired. If faulty or
damaged, the blower motor and blower wheel must
be replaced as an assembly.
OPERATION
On models equipped with the manual heater-A/C
system, the blower motor will operate whenever the
ignition switch is in the On position and the blower
control switch is in any position except Off. On mod-
els equipped with the Automatic Temperature Con-
trol (ATC) system, the blower motor will operate
whenever the ignition switch is in the On position
and the A/C-heater control power is turned on.
The blower motor receives battery current when-
ever the front blower motor relay is energized. The
front blower motor relay output circuit is protected
by a fuse in the Integrated Power Module (IPM)
located in the engine compartment near the battery.
In the manual heater-A/C 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 motor
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
Fig. 5 Instrument Panel Outlet - Left Side Shown
1 - INSTRUMENT PANEL TOP PAD
2 - INSTRUMENT PANEL OUTLET
3 - TRIM STICK
Fig. 6 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
24 - 46 DISTRIBUTION - FRONTRS
AIR OUTLETS (Continued)
Page 2442 of 2585
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
HVAC housing by spinning the blower wheel within
the housing at the selected speed or, in the ATC sys-
tem, at the selected or programmed speed.
DIAGNOSIS AND TESTING - BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 10 - 40 ampere) in the
Integrated 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 A/C-heater 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, check the front blower motor relay.
(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 block (Manual
Temperature Control) or the front blower motor
power module (Automatic Temperature Control) from
the resistor or module connector receptacle. Recon-
nect the battery negative cable. Turn the ignition
switch to the On position. Be certain that the A/C-
heater 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 connec-
tor for the front blower motor resistor block (MTC) orthe front blower motor 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 block (MTC) or the front
blower motor 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 diagno-
sis of the front blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- FRONT/BLOWER MOTOR RESISTOR - DIAGNO-
SIS AND TESTING). If OK with ATC, use a DRBIII
scan tool to diagnose the front blower motor power
module. Refer to Body 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 for basic checks of the blower motor when a
vibration or noise is present (Fig. 7).
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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
NOTE: The blower motor is located on the passen-
ger side of the vehicle under the instrument panel.
The blower motor can be removed from the vehicle
without having to remove the HVAC housing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the passenger side door sill plate and
cowl panel.
(3) Pull back the carpet to access the front lower
air intake screw.
RSDISTRIBUTION - FRONT24-47
BLOWER MOTOR (Continued)
Page 2445 of 2585
(6) Install the four screws (from the bottom) that
secure the lower air inlet housing to the lower HVAC
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(7) Install the one screw (from the top) that
secures the lower air inlet housing to the upper air
intake housing. Tighten the screws to 2 N´m (17 in.
lbs.).
(8) Connect the blower motor pigtail harness con-
nector to the blower motor resistor block or power
module, depending how vehicle is equipped.
(9) Install the recirculation door actuator (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS/
RECIRCULATION DOOR ACTUATOR - INSTALLA-
TION).
(10) Install the recirculation door actuator wire
harness lead into the routing clip on the lower air
inlet housing.
(11) Reinstall the carpet.
(12) Install the passenger side door sill plate and
cowl panel.
(13) Reconnect the battery negative cable.
(14) 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).
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.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the defroster duct to the instrument
panel.
(2) Install the fasteners that secure the defroster
duct to the instrument panel armature.
(3) Reinstall the instrument panel in the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Reconnect the battery negative cable.
FLOOR DISTRIBUTION DUCTS
REMOVAL
(1) Roll back the carpet on the front floor from
under the instrument panel toward the rear of the
vehicle (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).
(2) Lift the center floor distribution duct upward
far enough to disengage its locator hole from the
weld stud on the front floor panel (Fig. 11).
(3) Pull the center floor distribution duct rearward
far enough to disengage it from the floor outlet of the
HVAC housing.
(4) Disassemble the right and/or left floor distribu-
tion ducts from the center floor distribution duct as
required.
INSTALLATION
(1) Assemble the right and/or left floor distribution
ducts onto the center floor distribution duct as
required.
(2) Slide the center floor distribution duct under
the instrument panel center stack far enough to
engage it to the floor outlet of the HVAC housing.
24 - 50 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)
Page 2446 of 2585
(3) Align the locator hole on the center floor distri-
bution duct with the weld stud on the front floor
panel.
(4) Using hand pressure, push the locator hole of
the center floor distribution duct down over the weld
stud on the front floor panel.
(5) Reinstall the carpet onto the front floor panel
and under the instrument panel (Refer to 23 - BODY/
INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).
HVAC HOUSING
REMOVAL
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) AND (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
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) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the windshield wiper module from the
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(5) Disconnect the liquid line and suction line from
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/LIQUID
LINE - REMOVAL) and (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/SUC-
TION LINE - REMOVAL).
(6) Disconnect the heater hoses from the heater
core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(7) On LHD models, remove the one bolt that
secures the HVAC housing to the dash panel (Fig.
12).
(8) Remove the three nuts that secure the HVAC
housing to the dash panel.
(9) Remove the instrument panel from the passen-
ger compartment (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(10) Remove the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
REMOVAL).
(11) Remove the bolt or bolts (depending on appli-
cation) that secure the HVAC housing to the passen-
ger compartment side of the dash panel (Fig. 13) or
(Fig. 14).
(12) Pull the HVAC housing rearward far enough
for the mounting studs to clear the dash panel and
remove the housing from the passenger compart-
ment.
DISSASEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).
Fig. 11 Floor Distribution Ducts - LHD Shown, RHD
Typical
1 - CENTER FLOOR DISTRIBUTION DUCT
2 - RIGHT FLOOR DISTRIBUTION DUCT
3 - LEFT FLOOR DISTRIBUTION DUCT
4 - WELD STUD
RSDISTRIBUTION - FRONT24-51
FLOOR DISTRIBUTION DUCTS (Continued)
Page 2449 of 2585
housing half to the lower half. Tighten the screws to
2 N´m (17 in. lbs.).
(3) Position the upper air inlet housing onto the
top of the HVAC housing over the recirculation air
door and the blower motor and wheel. Be certain
that the upper pivot of the recirculation air door is
captured in the pivot receptacle of the upper air inlet
housing.
(4) Install the three screws that secure the upper
air inlet housing to the top of the HVAC housing. Be
certain to install the screw located just inside the
inboard side of the fresh air intake opening. Tighten
the screws to 2 N´m (17 in. lbs.).
(5) Install the two screws that secure the upper air
inlet housing to the lower air inlet housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(6) Engage the two hook retainers on the bottom of
the distribution housing to the two receptacles on the
HVAC housing.
(7) Roll the top of the distribution housing up into
position against the HVAC housing.
(8) Install the three screws that secure the top of
the distribution housing to HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(9) Engage the HVAC wire harness in the routing
clips molded into the outside of the HVAC housing.
(10) Reconnect the HVAC wire harness connector
to the blower motor.
(11) Install the expansion valve onto the evapora-
tor inlet and outlet tube fittings (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
EXPANSION VALVE - INSTALLATION).
(12) Install a new foam seal onto the HVAC hous-
ing seal flange around the fresh air inlet opening and
the expansion valve/evaporator tube opening.
(13) Install the heater core tubes into the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
INSTALLATION - HEATER CORE TUBES).
(14) Install the HVAC housing into the vehicle
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION - FRONT/HVAC HOUSING -
INSTALLATION).
INSTALLATION
(1) Position the HVAC housing into the passenger
compartment with the mounting studs located in
their proper mounting holes in the dash panel.(2) Install the bolt or bolts (depending on applica-
tion) that secure the HVAC housing to the passenger
compartment side of the dash panel. Tighten the
bolt(s) to 3 N´m (26 in. lbs.).
(3) Install the three nuts that secure the HVAC
housing to the engine compartment side of the dash
panel. Tighten the nuts to 7 N´m (62 in. lbs.).
(4) On LHD models, install the one bolt that
secures the HVAC housing to the engine compart-
ment side of the dash panel. Tighten the bolt to 4
N´m (35 in. lbs.).
(5) Reinstall the floor distribution duct (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/FLOOR DISTRIBUTION DUCTS -
INSTALLATION).
(6) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(7) Reconnect the heater hoses to the heater core
tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER HOSE -
INSTALLATION).
(8) Reconnect the suction line and liquid line to
the expansion valve (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT/SUCTION
LINE - INSTALLATION) and (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
LIQUID LINE - INSTALLATION).
(9) Install the windshield wiper module (Refer to 8
- ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(10) Reconnect the negative battery cable.
(11) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(12) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
24 - 54 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)
Page 2450 of 2585
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(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 demister
ducts to the instrument panel armature.
(5) Disengage the demister ducts from the demis-
ter outlets.
(6) Remove the demister ducts from the instru-
ment panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the demister ducts to the instrument
panel.(2) Engage the demister ducts to the demister out-
lets.
(3) Install the fasteners that secure the demister
ducts to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
INSTRUMENT PANEL DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(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 screws that secure the panel ducts
to the instrument panel armature.
(5) Disengage the panel ducts from the panel out-
lets.
(6) Remove the panel ducts from the instrument
panel.
INSTALLATION
(1) Position the panel ducts to the instrument
panel.
(2) Engage the panel ducts to the panel outlets.
(3) Install the screws that secure the panel ducts
to the instrument panel armature.
(4) Reinstall the instrument panel into the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
RSDISTRIBUTION - FRONT24-55
Page 2452 of 2585
DISTRIBUTION DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel and the right D pillaR (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
REMOVAL).
(2) Slide the rear distribution duct upwards far
enough to disengage it from the outlet at the top of
the rear HVAC housing (Fig. 2).
(3) While pulling the lower end of the rear distri-
bution duct away from the rear HVAC housing out-
let, disengage the upper end of the distribution duct
from the headliner duct.
(4) Remove the rea distribution duct from the
vehicle.
INSTALLATION
(1) Align the upper end of the rear distribution
duct to the headliner duct.
(2) Slide the upper end of the rear distribution
duct onto the headliner duct far enough to align the
lower end of the duct with the outlet at the top of the
rear HVAC housing.
(3) Slide the rear distribution duct downwards far
enough to engage it onto the outlet at the top of the
rear HVAC housing.
(4) Reinstall the trim onto the right quarter inner
panel and the right D pillar (Refer to 23 - BODY/IN-
TERIOR/RIGHT QUARTER TRIM PANEL -
INSTALLATION).
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. The blower motor
and wheel are located near the top of the rear HVAC
housing in the passenger compartment behind the
right rear wheel house. The rear HVAC housing must
be removed from the vehicle to access the blower
motor 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
On models equipped with the Manual Temperature
Control (MTC) system, the rear blower motor will
operate only whenever the ignition switch is in the
On position, the front blower control switch is in any
position except Off and the rear blower control switch
on the front A/C-heater control is in any position
except Off. On models equipped with the Automatic
Temperature Control (ATC) system, the blower motor
will operate whenever the ignition switch is in the
On position, the A/C-heater control power is turned
on and the rear blower control switch on the front
A/C-heater control is in any position except Off. The
rear blower motor can only be turned off by turning
off the rear system at the front A/C-heater control.
The rear blower motor receives battery current
whenever the rear blower motor relay is energized.
The rear blower motor relay output circuit is pro-
tected by a fuse in the Integrated Power Module
(IPM) located in the engine compartment near the
battery. In the MTC system, the rear 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 rear blower
motor speed is controlled by an electronic blower
motor power module, which uses a pulse width mod-
ulated input from the ATC control module and feed-
back from the rear blower motor to regulate the
blower motor ground path it provides. The rear
blower motor and wheel are used to control the veloc-
ity of air moving through the rear HVAC housing.
The rear blower motor controls the velocity of the air
flowing through the rear HVAC housing by spinning
the blower wheel within the housing at the selected
speed or, in the ATC system, at the selected or pro-
grammed speed.
Fig. 2 Rear Distribution Duct
1 - HEADLINER DUCT
2 - REAR DISTRIBUTION DUCT
3 - REAR HVAC HOUSING OUTLET
RSDISTRIBUTION - REAR24-57
Page 2453 of 2585
DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR
BLOWER MOTOR INOPERATIVE
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring, diagrams, proper wire and con-
nector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
BLOWER MOTOR ELECTRICAL DIAGNOSIS
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Integrated 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 rear A/C-heater control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, check the rear blower motor relay.
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector
from the rear blower motor resistor block (Manual
Temperature Control) or the rear blower motor power
module (Automatic Temperature Control). Reconnect
the battery negative cable. Turn the ignition switch
to the On position. Be certain that the rear A/C-
heater control power is turned on. Check for battery
voltage at the fused rear blower motor relay output
circuit cavity of the rear HVAC wire harness connec-
tor for the rear blower motor resistor block (MTC) or
the rear blower motor 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 rear blower motor pigtail wire connec-
tor from the rear HVAC wire harness (MTC) or the
rear blower power module (ATC). Use jumper wires
to connect a battery and ground feeds to the blower
motor pigtail wire connector. The rear blower motor
should operate. If OK with MTC, proceed to diagno-
sis of the rear blower motor resistor block (Refer to
24 - HEATING & AIR CONDITIONING/CONTROLS
- REAR/BLOWER MOTOR RESISTOR - DIAGNOSIS
AND TESTING). If OK with ATC, use a DRBIII scan
tool to diagnose the rear blower motor power module.
Refer to the appropriate diagnostic information. If
not OK with MTC or ATC, replace the faulty rear
blower motor.BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart for basic checks of the blower motor when a
vibration or noise is present (Fig. 3).
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the rear HVAC housing from the vehi-
cle (Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control sys-
tem, the blower motor pigtail wire is connected to a
take out and connector of the rear HVAC wire har-
ness. With the Automatic Temperature Control sys-
tem , the blower pigtail wire is connected to a
receptacle on the blower motor power module.
(3) Remove the three screws that secure the rear
blower motor to the outboard side of the rear HVAC
housing (Fig. 4).
(4) Remove the rear blower motor from the rear
HVAC housing.
INSTALLATION
(1) Position the rear blower motor into the rear
HVAC housing.
(2) Install the three screws that secure the blower
motor to the rear HVAC housing. Tighten the screws
to 2 N´m (17 in. lbs.).
(3) Reconnect the rear blower motor pigtail wire
connector.
NOTE: With the Manual Temperature Control system
, the blower pigtail wire is connected to a take out
and connector of the rear HVAC wire harness. With
the Automatic Temperature Control system, the
blower pigtail wire is connected to a receptacle on
the blower motor power module.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)
Page 2455 of 2585
(4) Install the rear HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
HVAC HOUSING
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - WARNING - A/C PLUMBING) and (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/REFRIGERANT - STAN-
DARD PROCEDURE - REFRIGERANT
RECOVERY).(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the battery negative
cable.
(4) Raise and support the vehicle.
(5) Disconnect the underbody refrigerant line seal-
ing plate from the rear evaporator extension line
sealing plate that extends through the rear floor
panel behind the right rear wheel housing (Fig. 5).
(6) Remove the seals from the liquid line and suc-
tion line fittings and discard.
(7) Install plugs in, or tape over the opened liquid
line and suction line fittings and both ports in the
evaporator extension line sealing plate.
(8) Remove the three nuts that secure the rear
HVAC housing mounting studs to the rear floor panel
behind the right rear wheel housing (Fig. 6).
Fig. 4 Rear Blower Motor
1 - REAR HVAC HOUSING
2 - REAR BLOWER MOTOR
3 - SCREW (3)
4 - BLOWER MOTOR PIGTAIL WIRE
Fig. 5 Underbody Refrigerant Lines
1 - REFRIGERANT LINE SEALING PLATE
Fig. 6 Rear HVAC Housing Mounting Studs
1 - REAR HVAC HOUSING MOUNTING STUDS
24 - 60 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)
Page 2457 of 2585
(16) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid line and
suction line fittings.
(17) Reconnect the underbody refrigerant line seal-
ing plate to the evaporator extension line sealing
plate.
(18) Install the screw that secures the underbody
refrigerant line sealing plate to the evaporator exten-
sion line sealing plate. Tighten the screw to 23 N´m
(17 ft. lbs.).
(19) Lower the vehicle.
(20) Reconnect the battery negative cable.
(21) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(22) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(23) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(24) Run the HVAC Cooldown test to verify proper
operation (Refer to 24 - HEATING & AIR CONDI-
TIONING - DIAGNOSIS AND TESTING).
REAR FLOOR HEAT DUCT
REMOVAL
(1) Remove the trim from the right quarter inner
panel (Refer to 23 - BODY/INTERIOR/RIGHT
QUARTER TRIM PANEL - REMOVAL).
(2) Remove the two screws that secure the rear
floor heat duct to the right quarter inner panel (Fig.
8).
(3) Slide the rear floor heat duct forward far
enough to disengage it from the outlet on the front of
the rear HVAC housing.
(4) Remove the rear floor heat duct from the vehi-
cle.
Fig. 7 Rear HVAC Housing
1 - U-NUT (3)
2 - REAR HVAC HOUSING
3 - SCREW (3)
4 - EXPANSION VALVE5 - STUD (3)
6 - HEATER LINES
7 - NUT (5)
8 - STUD (2)
24 - 62 DISTRIBUTION - REARRS
HVAC HOUSING (Continued)