CHRYSLER VOYAGER 2005 Service Manual

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 PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG
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/INSTRU-
MENT PANEL ASSEMBLY - INSTALLATION).
(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.
(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 PRECAU-
TIONS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
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
24 - 50 DISTRIBUTION - FRONTRS
DEFROSTER DUCT (Continued)

(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 nuts that secure the HVAC hous-
ing to the dash panel in the engine compartment.(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).
(2) Remove the heater core tubes from the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inlet
opening and the expansion valve/evaporator tube
opening.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - FRONT/
EXPANSION VALVE - REMOVAL).
Fig. 12 HVAC Housing Retainers - RS Shown
1 - HVAC HOUSING
2 - DASH PANEL
3 - STUD (3 RS models, 4 RG models)
4 - NUT (3 RS models, 4 RG models)
5 - BOLT (RS only)
Fig. 13 HVAC Housing - LHD Models
1 - HVAC HOUSING
2 - BOLT
3 - BRACKET
4 - DASH PANEL
RSDISTRIBUTION - FRONT24-51
HVAC HOUSING (Continued)

(5) Disconnect the HVAC wire harness connector
from the blower motor.
(6) Disengage the HVAC wire harness from the
routing clips molded into the outside of the HVAC
housing.
(7) Remove the four screws that secure the top of
the distribution housing to the HVAC housing (Fig.
15).(8) Pull the top of the distribution housing away
from the HVAC housing far enough to disengage the
two hook retainers on the bottom of the distribution
housing from the two receptacles on the HVAC hous-
ing (Fig. 16).
(9) Remove the two screws that secure the upper
air inlet housing to the lower air inlet housing.
(10) Remove the three screws that secure the
upper air inlet housing to the top of the HVAC hous-
ing. Be certain to remove the screw located just
inside the inboard side of the fresh air intake open-
ing.
(11) Remove the upper air inlet housing from the
top of the HVAC housing to expose the recirculation
air door and the blower motor and wheel (Fig. 17).
Fig. 15 Distribution Housing - LHD Shown,
RHD Typical
1 - DISTRIBUTION HOUSING
2 - SCREWS (3)
3 - HVAC WIRING HARNESS
4 - ROUTING CLIP
5 - HVAC HOUSING
Fig. 14 HVAC Housing - RHD Models
1 - BOLT (2)
2 - RETAINER CLIP
3 - BOLT
4 - HVAC HOUSING
Fig. 16 Distribution Housing Retainers - Typical
1 - HVAC HOUSING RECEPTACLES
2 - DISTRIBUTION HOUSING RETAINERS
Fig. 17 Upper Intake Air Housing - LHD Shown,
RHD Typical
1 - HVAC HOUSING
2 - UPPER AIR INLET HOUSING
3 - RECIRCULATION AIR DOOR
4 - BLOWER MOTOR AND WHEEL
24 - 52 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

(12) Remove the screw and washer from the upper
pivot of the recirculation door.
(13) Remove the twelve screws that secure the
upper HVAC housing half to the lower half.
(14) Carefully separate and remove the upper half
of the HVAC housing from the lower half. Be certain
not to lose the rubber grommet for the HVAC wire
harness evaporator temperature sensor take out.
This grommet is located on the inboard side of the
flange around the expansion valve/evaporator tube
opening, where it is captured in a notched area
between the upper and lower HVAC housing halves
(Fig. 18).
INSTALLATION
ASSEMBLY
(1) Position the upper half of the HVAC housing
onto the lower half. Be certain that the rubber grom-
met and the HVAC wire harness take out for the
evaporator temperature sensor are captured in the
notched area between the upper and lower HVAC
housing halves.
(2) Install the twelve screws around the perimeter
of the HVAC housing that secure the upper HVAC
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. Becertain 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 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).
Fig. 18 HVAC Housing - LHD Shown, RHD Typical
1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR AND WHEEL
4 - A/C EVAPORATOR
RSDISTRIBUTION - FRONT24-53
HVAC HOUSING (Continued)

(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).
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.
24 - 54 DISTRIBUTION - FRONTRS
HVAC HOUSING (Continued)

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

DISTRIBUTION - REAR
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION.........................56
REMOVAL.............................56
INSTALLATION.........................56
DISTRIBUTION DUCT
REMOVAL.............................57
INSTALLATION.........................57
BLOWER MOTOR
DESCRIPTION.........................57
OPERATION...........................57DIAGNOSIS AND TESTING
REAR BLOWER MOTOR................58
REMOVAL.............................58
INSTALLATION.........................60
HVAC HOUSING
REMOVAL.............................60
INSTALLATION.........................62
REAR FLOOR HEAT DUCT
REMOVAL.............................63
INSTALLATION.........................63
AIR OUTLETS
DESCRIPTION
Based upon the system mode selected, conditioned
air can exit the rear HVAC housing through one or a
combination of the two main housing outlets: air con-
ditioner, or heater. Once the conditioned air exits the
unit housing, it is directed through molded plastic
ducts to the various outlets in the vehicle interior.
These outlets and their locations are as follows:
²Floor Outlets- Three floor outlets with fixed
vanes are located in the right quarter trim panel,
near the floor. These outlets distribute air from the
rear floor heat duct to the intermediate and rear seat
occupants. The floor outlets are integral to the right
quarter trim panel and, if faulty or damaged, the
quarter trim panel must be replaced.
²Overhead Outlets- Four (two right side and
two left side) fully adjustable outlets along the roof
rails distribute air from the rear distribution duct
and the headliner ducts to the intermediate and rear
seat occupants. The headliner ducts are integral to
the headliner panel. Each overhead outlet is housed
in a headliner bezel. The two forward headliner
bezels also feature a courtesy lamp, a fold-away coat
hook, and a fold-away assist handle. The overhead
outlets can be removed from the headliner bezels
individually for service replacement.
REMOVAL
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the thumb wheel end of
the overhead outlet away from the pivot pin in the
headliner bezel until one end of the outlet is released
(Fig. 1).(2) Pull the opposite end of the overhead outlet
away from its pivot pin in the headliner bezel until
that end of the outlet is released.
(3) Remove the overhead outlet from the opening
in the headliner bezel.
INSTALLATION
(1) Position the overhead outlet into the opening in
the headliner bezel.
(2) Slide the non-thumb wheel end of the outlet
onto the pivot pin in the headliner bezel. Using hand
pressure, push the thumb wheel end outboard onto
the pivot pin until it fully seats.
Fig. 1 Overhead Outlet
1 - HEADLINER BEZEL
2 - OVERHEAD OUTLET
3 - TRIM STICK
4 - COURTESY LAMP
5 - COAT HOOK
6 - ASSIST HANDLE
24 - 56 DISTRIBUTION - REARRS

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

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.
24 - 58 DISTRIBUTION - REARRS
BLOWER MOTOR (Continued)

Fig. 3 Blower Motor Noise/Vibration Diagnosis
RSDISTRIBUTION - REAR24-59
BLOWER MOTOR (Continued)