Module CHRYSLER VOYAGER 2005 Service Manual

DESCRIPTION FIGURE
FUEL TANK SUPPORT AND TIRE STOWAGE - SHORT WHEEL BASE ONLY 119
INNER SIDE SILLS - SHORT WHEEL BASE ONLY 120
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 121
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE ONLY 122
WHEELHOUSES - SHORT WHEEL BASE ONLY 123
FRONT SEAT CROSS MEMBER - SHORT WHEELBASE, ALL WHEEL DRIVE ONLY 124
FLOOR PAN SIDE RAIL - LONG WHEEL BASE ONLY 125
INNER BODY SIDE SILL REINFORCEMENTS 126
TOE BOARD CROSS MEMBER 127
FRONT SIDE RAIL - SHORT WHEEL BASE ONLY 128
DASH PANEL REINFORCEMENT 129
LOWER COWL PLENUM 130
UPPER COWL PLENUM SUPPORT 131
UPPER DASH PANEL 132
COWL SIDE PANELS 133
INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 134
INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL 135
STRUT TOWER BRACKET AND COWL PLENUM 136
FRONT SIDE RAILS TO LOWER DASH PANEL 137
INNER BODY SIDE SILL TO LOWER DASH PANEL 138
FRONT HINGE TAPPING PLATE 139
FRONT HINGE PILLAR 140
INNER WINDSHIELD FRAME 141
WINDSHIELD FRAME 142
FENDER BRACKET 143
INNER B-PILLAR 144
STRIKER LATCH AND TAPPING PLATES 145
RIGHT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 146
RIGHT REAR INNER QUARTER PANEL/OUTER WHEELHOUSE - LONG WHEEL BASE
ONLY147
RIGHT REAR BODY SIDE APERTURE - LONG WHEEL BASE ONLY 148
STRIKER LATCH REINFORCEMENT - LONG WHEEL BASE ONLY 149
BELT TAPPING PLATE - LONG WHEEL BASE ONLY 150
C-PILLAR REINFORCEMENT - LONG WHEEL BASE ONLY 151
OUTER WHEELHOUSE - LONG WHEEL BASE ONLY 152
C AND D-PILLAR INNER REINFORCEMENTS - LONG WHEEL BASE ONLY 153
LEFT REAR INNER QUARTER PANEL - LONG WHEEL BASE ONLY 154
OUTER WHEELHOUSE EXTENSION - LONG WHEEL BASE ONLY 155
TAIL LAMP - LONG WHEEL BASE ONLY 156
SLIDING DOOR LATCH - LONG WHEEL BASE ONLY 157
ROOF BOW EXTENSION - LONG WHEEL BASE ONLY 158
RIGHT REAR INNER QUARTER PANEL - SHORT WHEEL BASE ONLY 159
RSBODY STRUCTURE23 - 235
WELD LOCATIONS (Continued)

Fig. 135 INSTRUMENT PANEL, DASH PANEL, ACM MODULE AND ACCELERATOR PEDAL
Fig. 136 STRUT TOWER BRACKET AND COWL PLENUM
23 - 282 BODY STRUCTURERS
WELD LOCATIONS (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM
REQUIREMENTS.......................1
HEATER AND AIR CONDITIONER..........1
MANUAL SINGLE ZONE.................2
MANUAL DUAL ZONE...................2
MANUAL THREE ZONE..................2
AUTOMATIC TEMPERATURE CONTROL....3
OPERATION
HEATER AND AIR CONDITIONER..........4
MANUAL SINGLE ZONE.................4
MANUAL DUAL ZONE...................5
MANUAL THREE ZONE..................5AUTOMATIC TEMPERATURE CONTROL....5
DIAGNOSIS AND TESTING
A/C COOL DOWN TEST.................6
A/C PERFORMANCE TEST...............7
HEATER PERFORMANCE TEST..........10
SPECIFICATIONS
A/C SYSTEM.........................11
CONTROLS - FRONT.....................13
CONTROLS - REAR......................33
DISTRIBUTION - FRONT...................42
DISTRIBUTION - REAR....................56
PLUMBING - FRONT.....................64
PLUMBING - REAR......................98
CABIN HEATER........................113
HEATING & AIR
CONDITIONING
DESCRIPTION
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or condenser will
reduce the performance of the air conditioning and
engine cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to Cooling for more information before
opening or attempting any service to the engine cool-
ing system.
HEATER AND AIR CONDITIONER
A manually controlled single zone type heating-air
conditioning system, manually controlled dual zone
type heating-air conditioning system, manually con-
trolled three zone type heating-air conditioning sys-
tem or an automatic controlled three zone type
heating-air conditioning system is available on this
model.
All vehicles are equipped with a common heater,
ventilation and air conditioning (HVAC) housing (Fig.
1). The system combines air conditioning, heating,
and ventilating capabilities in a single unit housingmounted within the passenger compartment under
the instrument panel. The HVAC housing includes:
²Blower motor
²Blower motor resistor block or power module
(depending on application)
²Heater core
²Evaporator coil
²Blend door and actuator
²Mode door and actuator
²Recirculation door and actuator
Based upon the system and mode selected, condi-
tioned air can exit the HVAC housing through one or
Fig. 1 HVAC Housing - LHD Shown, RHD Typical
1 - HVAC HOUSING
2 - BOLT
3 - BRACKET
4 - DASH PANEL
RSHEATING & AIR CONDITIONING24-1

²a rotary adjustment knob for temperature.
²a rotary adjustment for fan speed control.
AUTOMATIC TEMPERATURE CONTROL
Two different automatic temperature control (ATC)
heating-A/C systems are available for this model
depending on the market.
The Dual-Zone ATC system allows the driver and
front occupants to each select individual comfort tem-
peratures.
The Three-Zone ATC system allows both the driver
and front occupants and the rear intermediate occu-
pants to select individual comfort temperatures.
NOTE: Individual comfort temperatures are the per-
ceived temperature level at the individual seating
areas, NOT the actual passenger compartment air
temperature.
The ATC system includes a particulate air filter.
The filter element is the same size as the A/C evap-
orator to ensure ample capacity. A door at the base of
the HVAC housing below the glove box provides easy
access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the programmable communi-
cations interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine rpm, vehicle speed and mani-
fold absolute pressure information from the
powertrain control module (PCM).
²Coolant Temperature± ATC computer moni-
tors coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors ambient temperature from the compass mini trip
computer (CMTC) and converts it to degrees Fahren-
heit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors barometric pressure, intake air temperature,
high side pressure and methanol content as broad-
cast by the PCM.
²Door Ajar Status± The ATC computer moni-
tors driver front door, passenger front door, left rear
door, right rear door and liftgate ajar information, as
identified by the body control module (BCM), to
determine if all in-car temperatures should be main-
tained.²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the vacuum-flourescent (VF) dig-
ital display icons if the manual motor calibration or
manual cool down tests have failed. Flashing of the
display icons will cease when the vehicle odometer is
greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for evaporator temperature too
low, fan blower relay status, evaporator sensor fail-
ure, rear window defogger relay and A/C select.
FRONT CONTROL PANEL
The front A/C-heater control and integral computer
is mounted in the instrument panel and contains:
²a power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²a rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²three rocker switches that select comfort temper-
atures from 15É to 30É C (59É to 85É F), which are
shown in the VF digital display. If the set temp is 15É
C (59É F) and the down button is pressed, the set
temp value will become 13É C (55É F) but the display
will show LO. If the set temp is 29É C (85É F) and the
up button is pressed, the set temp value will become
32É C (90É F) but the display will show HIGH. Tem-
peratures can be displayed in either metric or Fahr-
enheit, which is controlled from the overhead console.
²an air conditioning button that allows the com-
pressor to be turned off. A Snowflake symbol is illu-
minated when air conditioning is on, whether under
manual or automatic control.
²an air recirculation button. A Recirculation sym-
bol appears in the display when the button is
pressed, or when the system exceeds 80 percent recir-
culated air under automatic control due to high air
conditioning demand.
²a rear window defogger on/off switch. A graphic
symbol shows when the defroster is on.
RSHEATING & AIR CONDITIONING24-3
HEATING & AIR CONDITIONING (Continued)

MANUAL DUAL ZONE
²The two slide controls enable continuously vari-
able proportioning of the conditioned air.
²The mode control knob enables continuously
variable proportioning of air flow between modes and
has detents adjacent to each icon.
²The blower control provides four separate speeds
and an Off position.
²When the heater-A/C system is off, the HVAC
computer closes the recirculation door to prevent out-
side air from entering the passenger compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the A/C-
heater control.
²To reduce humidity for rapid defogging, the A/C
compressor runs automatically in modes from ªmixº
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off button.
MANUAL THREE ZONE
FRONT CONTROL PANEL
²Primary control of the rear heater-A/C system is
on the instrument panel. This control allows the
driver to set the rear compartment fan speed, to turn
the rear heater-A/C system off, or to give control to
the intermediate seat occupants by switching to the
Rear position. When the rear heater-A/C system is
controlled from the instrument panel, rear air tem-
perature is based on the driver-side temperature con-
trol position, and the mode (floor or overhead air) is
based on the front control's mode position.
²The mode control knob enables continuously
variable proportioning of air flow between modes but
has detents adjacent to each icon.
²The blower control provides four separate speeds
and an Off position. When the heater-A/C system is
off, the HVAC computer closes the recirculation door
to prevent outside air from entering the passenger
compartment.
²Interior air may be recirculated to speed up
heating or cooling in all modes except defrost and
mix by pressing the Recirculate button on the control
panel.
²To reduce humidity for rapid defogging the A/C
compressor runs automatically in modes from ªmix'
to full defrost when outside temperatures are above
freezing.
²Air conditioning is available in any mode by
pressing the snowflake, A/C on/off, button.
REAR CONTROL PANEL
With the rear control active, temperature selection
dictates the air distribution mode (floor or overhead
air) of the rear unit: a cool temperature setting
directs flow to the overhead outlets and a warm tem-
perature setting to the floor.
AUTOMATIC TEMPERATURE CONTROL
Comfort temperature or perceived temperature is
affected by air flow, sun levels on exposed skin, etc.
The air temperature may be higher or lower than the
comfort temperature. The automatic temperature
control (ATC) system uses two infrared sensors in the
instrument panel center stack to measure the tem-
perature of the front occupants in order determine
their comfort level relative to their selected comfort
temperature. The integral HVAC computer adjusts
temperature and air flow rates to maintain the cus-
tomer-perceived comfort temperatures. The air tem-
perature in the passenger compartment may be
slightly higher or lower than the comfort tempera-
ture at any time. For instance, on sunny summer
days the air flow will probably be cooler than the
comfort temperature; on cold or cloudy days and at
night it will probably be slightly warmer.
The Three-Zone ATC system uses the infrared sen-
sors located in the instrument panel center stack
along with an offset calibration strategy to meet the
comfort requirements of the rear seat occupants.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DEFROST± The defrost function must be man-
ually selected to direct air flow to the windshield to
remove fog or ice. The ATC system cannot automati-
cally sense the presence of fog or ice on the wind-
shield.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the intelligent
power module which controls the rear window defog-
ger and side view mirror (if equipped) circuitry. The
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)

defogger function will be active for 10 minutes and
can be turned off by a switch press. The defogger will
function while the control is in the ON mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that blower motor manual. If
only one is changed manually, the other remains
under automatic control. Pressing the HI-AUTO/LO-
AUTO rocker switch restores full automatic control.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-
tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engine
is warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, mix mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
²REAR CONTROL (Three-Zone only)± When
the Rear System control knob is moved to the OFF
position, there will be a delay of approximately 1 sec-
ond before the system actually turns off. This delay
is to prevent an undesired blower dropout if the knob
is moved through OFF to the other selections.
REAR CONTROL PANEL ± THREE ZONE ATC
SYSTEM
Primary control of the rear compartment heating-
A/C system for the Three-Zone ATC system is in the
instrument panel center stack. This control allows
the driver to turn the rear heating-A/C system off, or
allows the intermediate seat occupants control of the
rear system by switching to the REAR position, or
provides fully automatic control based on the temper-
ature setting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the frontcontrol rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
A/C COOL DOWN TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the A/C system is
operating properly, or use a DRBIIItscan tool to
diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
MANUAL TEMPERATURE CONTROL
The front blower speed and rear blower speed (if
equipped with rear HVAC) must be set to High and
the evaporator temperature sensor must be greater
than 13É C (55É F) or the test will fail immediately.
The test is activated by depressing the A/C and Rear
Wipe/Wash buttons simultaneously and holding them
depressed for no less than five seconds. The Rear
Wipe/Wash and A/C LEDs will blink on and off until
the test is complete. If the LEDs stop blinking before
two minutes, then the cool down test has been com-
pleted successfully. If the two minutes expire without
the expansion valve temperature reaching -6É C (20É
F) less than the outside air temperature, then the
cool down test has been failed and further A/C sys-
tem diagnosis is required. If the test is failed, the
LEDs will continue to blink until the vehicle has
been driven for greater than 13 km (8 miles).
AUTOMATIC TEMPERATURE CONTROL
The ambient air temperature in the room where
the vehicle will be tested must be a minimum of 21É
C (70ÉF) for this test. The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking before two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-
perature reaching -6É C (20É F) less than the evapo-
24 - 6 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

A/C PERFORMANCE TEMPERATURE AND PRESSURE
Ambient
Temperature21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Left Center Panel
Outlet Discharge
Air Temperature1to8ÉC
(34 to 46É F)3to9ÉC
(37 to 49É F)4 to 10ÉC
(39 to 50É F)6to11ÉC
(43 to 52É F)7 to 18É C
(45 to 65É F)
Discharge
Pressure (High
Side Service Port)1034 to 1724
kPa
(150 to 250 psi)1517 to 2275
kPa
(220 to 330 psi)1999 to 2620
kPa
(290 to 380 psi)2068 to 2965
kPa
(300 to 430 psi)2275 to 3421
kPa
(330 to 450 psi)
Suction Pressure
(Low Side Service
Port)103 to 207 kPa
(15 to 30 psi)117 to 221 kPa
(17 to 32 psi)138 to 241 kPa
(20 to 35 psi)172 to 269 kPa
(25 to 39 psi)207 to 345 kPa
(30 to 50 psi)
(8) If the air outlet temperature fails to meet the
specifications in the A/C Performance Temperature
and Pressure chart, or if the compressor discharge
pressure is high, refer to the A/C Pressure Diagnosis
Chart.
A/C PRESSURE DIAGNOSIS
Condition Possible Causes Correction
Rapid A/C compressor clutch
cycling (ten or more cycles
per minute).1. Low refrigerant system
charge.1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.1. No refrigerant in the
refrigerant system.1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
2. Faulty fuse. 2. Check the fuses in the Integrated Power
Module. Repair the shorted circuit or component
and replace the fuses, if required. Refer to Group
8.
3. Faulty A/C compressor
clutch coil.3. See A/C Compressor Clutch Coil in this group.
Test the compressor clutch coil and replace, if
required.
4. Faulty A/C compressor
clutch relay.4. See A/C Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty evaporator temperature
sensor.5. See Evaporator Temperature Sensor in this
group. Test the sensor and replace, if required.
6. Faulty A/C pressure
transducer.6. See A/C Pressure Transducer in this group.
Test the sensor and replace, if required.
7. Faulty Powertrain Control
Module (PCM).7. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
24 - 8 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
A/C-heater control panel, the following could require
service:
²Blend door binding.
²Faulty blend door actuator.
²Faulty A/C-heater control.
²Faulty related wiring harness or connectors.²Improper engine coolant temperature.
SPECIFICATIONS
A/C SYSTEM
The R-134a refrigerant system charge capacity for
this vehicle can be found on the underhood Specifica-
tion Label.
SYSTEM SPECIFICATIONS
Item Description Notes
A/C Compressor Denso 10S17 ± 2.4L/2.5L/2.8L/3.3L
without rear A/C
Denso 10S20 ± 3.3L/3.8L with rear
A/CND-8 PAG Oil
Freeze±up Control Evaporator temperature sensor HVAC housing mounted (RS models),
Evaporator mounted (RG models) - input to
A/C-heater control module
Low PSI Control A/C pressure transducer Liquid line mounted - input to Powertrain Control
Module (PCM) - PCM opens compressor clutch
relay above 200 kPa (29 psi)
High PSI Control A/C pressure transducer Liquid line mounted - input to PCM - PCM
opens compressor clutch relay below 3100 kPa
(450 psi)
High Pressure relief valve Compressor mounted - opens above 3445-4135
kPa (500-600 psi), closes below 2756 kPa (400
psi)
Compressor Clutch Coil
DrawDenso 10S17 ± 3.3 amps @ 12V  
0.5V @ 21É C (70É F)
Denso 10S20 ± 2.2 amps @ 12V  
0.5V @ 21É C (70É F)
Compressor Clutch Air
Gap0.35 - 0.60 mm (0.014 - 0.024 in.)
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A/C Compressor Shaft Bolt 17.5 ± 155
A/C Compressor Mounting Bolts (2.4L/2.5L/2.8L) 28 21 ±
A/C Compressor Mounting Bolts (3.3L/3.8L) 54 40 ±
A/C Compressor Mounting Bracket Bolts (2.4L) 54 40 ±
A/C Condenser Mounting Bracket Screws 5 ± 45
A/C Expansion Valve Screws 11 ± 97
A/C-Heater Control Screws 2 ± 17
Blend Door Actuator Screws 2 ± 17
Blower Motor Screws 2 ± 17
Blower Motor Power Module Screws (ATC) 2 ± 17
Blower Motor Resistor Block Screws (MTC) 2 ± 17
Center Bezel Outlet Screws 2 ± 17
RSHEATING & AIR CONDITIONING24-11
HEATING & AIR CONDITIONING (Continued)

Description N´m Ft. Lbs. In. Lbs.
Distribution Housing Screws 2 ± 17
Discharge Line to Compressor Nut 23 17 ±
Discharge Line to Condenser Nut 23 17 ±
Front Fascia Screws 6 ± 53
Front Fascia Grille Insert Screws 2 ± 17
Heater Core Mounting Plate Screws 2 ± 17
Heater Core Sealing Plate Screws 3 ± 26
Hood Latch Screws 14 ± 123
HVAC Housing Bracket Bolt 3 ± 26
HVAC Housing Mounting Nuts 7 ± 62
HVAC Housing Mounting Bolts 4 ± 35
Liquid Line to Condenser Nut 23 17 ±
Liquid Line to Receiver/drier Bolt 11 ± 97
Lower Air inlet Housing Screws 2 ± 17
Mode Door Actuator Screws 2 ± 17
Quarter Trim Panel Attaching Bracket Screws 2 ± 17
Rear Blower Motor Screws 2 ± 17
Rear Blower Motor Power Module Screws (ATC) 2 ± 17
Rear Blower Motor Resistor Block Screws (MTC) 2 ± 17
Rear Capture Plate Screw 2 ± 17
Rear Evaporator Line Seal Plate to Rear Expansion
Valve Nut23 17 ±
Rear Expansion Valve Bracket Nut 23 17 ±
Rear Expansion Valve Bracket Screws 2 ± 17
Rear Expansion Valve to Rear Evaporator Screws 11 ± 97
Rear Floor Heat Duct Screws 2 ± 17
Rear HVAC Housing Screws 2 ± 17
Rear HVAC Housing Mounting Screws 11 ± 97
Rear HVAC Housing Stud Nuts 9 ± 80
Rear Mode Door Actuator Screws 2 ± 17
Receiver/drier Bracket Nuts 10 ± 89
Recirculation Door Actuator Screws 2 ± 17
Refrigerant Lines to Expansion Valve Nut 23 17 ±
Suction Line to Compressor Nut 23 17 ±
Cabin Heater Air Intake Pipe Screws 7 ± 62
Cabin Heater M6 Bolts 7 ± 62
Cabin Heater M8 Bolts 23 17 ±
Cabin Heater Seat Hex Nut 60 44 ±
Underbody Liquid Line Fitting 23 17 ±
Underbody Refrigerant Line Sealing Plate Bolt/Nut 23 17 ±
Underbody Suction Line Fitting 23 17 ±
Upper Air Inlet Housing Screws 2 ± 17
24 - 12 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING
A/C COMPRESSOR CLUTCH COIL........14
STANDARD PROCEDURE
CLUTCH INSPECTION.................15
A/C CLUTCH BREAK-IN................15
REMOVAL.............................15
INSTALLATION.........................16
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................18
OPERATION...........................18
REMOVAL.............................19
INSTALLATION.........................19
A/C HEATER CONTROL
DESCRIPTION.........................19
STANDARD PROCEDURE
A/C-HEATER CONTROL CALIBRATION.....19
REMOVAL.............................20
INSTALLATION.........................20
A/C PRESSURE TRANSDUCER
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER..........21
REMOVAL.............................21
INSTALLATION.........................21
BLEND DOOR ACTUATOR
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................22
BLOWER MOTOR RELAY
DESCRIPTION.........................23
OPERATION...........................23
REMOVAL.............................24INSTALLATION.........................24
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION.........................24
OPERATION...........................24
DIAGNOSIS AND TESTING
FRONT BLOWER MOTOR RESISTOR
BLOCK.............................25
REMOVAL.............................25
INSTALLATION.........................25
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................26
OPERATION...........................27
REMOVAL
RG MODELS.........................27
RS MODELS.........................27
INSTALLATION
RG MODELS.........................27
RS MODELS.........................28
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................28
OPERATION...........................28
MODE DOOR ACTUATOR
DESCRIPTION.........................29
OPERATION...........................29
REMOVAL.............................29
INSTALLATION.........................30
POWER MODULE - BLOWER MOTOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................31
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL.............................32
INSTALLATION.........................32
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). These components provide
the means to engage and disengage the A/C compres-
sor from the engine accessory drive belt.The A/C clutch field coil and the pulley bearing
and pulley assembly are both retained on the nose of
the A/C compressor with snap rings. The clutch plate
is splined to the compressor shaft and secured with a
bolt.
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
RSCONTROLS - FRONT24-13