DODGE TOWN AND COUNTRY 2004 Service Manual

BLOWER MOTOR RESISTOR
BLOCK
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C system.
Models equipped with the optional Automatic Tem-
perature Control (ATC) system use a blower power
module, instead of the blower motor resistor block
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/POWER MODULE - DESCRIPTION).
The blower motor resistor block is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The resistor
block consists of a molded plastic mounting plate
with two integral connector receptacles. Concealed
behind the mounting plate are four coiled resistor
wires contained within a protective stamped steel
cage. The blower motor resistor block is accessed for
service by removing the glove box from the instru-
ment panel.
OPERATION
The blower motor resistor block is connected to the
vehicle electrical system through a dedicated take
out and connector of the instrument panel wire har-
ness. A second connector receptacle receives the pig-
tail wire connector from the blower motor. The
blower motor resistor has multiple resistor wires,
each of which will reduce the current flow through
the blower motor to change the blower motor speed.
The blower motor switch in the manual heater-A/C
system directs the ground path for the blower motor
through the correct resistor wire to obtain the
selected speed.
With the blower motor switch in the lowest speed
position, the ground path for the motor is applied
through all of the resistor wires. Each higher speed
selected with the blower motor switch applies the
blower motor ground path through fewer of the resis-
tor wires, increasing the blower motor speed.
The blower motor resistor cannot be adjusted or
repaired and, if faulty or damaged, it must be
replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR BLOCK
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.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block.
(4) Check for continuity between each of the
blower motor switch input terminals of the resistor
and the resistor output terminal. In each case there
should be continuity. If OK, repair the wire harness
circuits between the blower motor switch and the
blower motor resistor, blower motor or blower motor
relay as required. If not OK, replace the faulty
blower motor resistor block.
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.
WARNING: THE BLOWER MOTOR RESISTOR
BLOCK MAY GET VERY HOT DURING NORMAL
OPERATION. IF THE BLOWER MOTOR WAS
TURNED ON PRIOR TO SERVICING THE BLOWER
MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES
TO ALLOW THE BLOWER MOTOR RESISTORS TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
24 - 26 CONTROLS - FRONTRS

CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor resistor block (Fig. 14).
(4) Remove the two screws that secure the blower
motor resistor block to the HVAC housing.
(5) Remove the resistor block from the HVAC
housing.
INSTALLATION
(1) Position the blower motor resistor block into
the HVAC housing.
(2) Install the two screws that secure the blower
motor resistor block to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the resistor
block.
(4) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
EVAPORATOR TEMPERATURE
SENSOR
DESCRIPTION
NOTE: The following applies to RS models only. RG
models use an expansion valve mounted evapora-
tor temperature sensor for both manual and auto-
matic temperature control systems due to A/C-
heater control calibration requirements.
The evaporator temperature sensor used for the
manual temperature control (MTC) system is
installed on the top of the HVAC housing behind the
instrument panel and measures the air temperature
downstream of the evaporator (Fig. 15). The sensor is
an electrical thermistor in a plastic housing that is
inserted into the HVAC housing. Two terminals
within the molded plastic connector receptacle on the
sensor connect it to the vehicle electrical system
through a take out and connector of the HVAC wire
harness.
The evaporator temperature sensor used for the
automatic temperature control (ATC) system is
installed on the top of the expansion valve in the
right rear corner of the engine compartment and
measures the temperature of the evaporator coils
(Fig. 16). The sensor has a small probe that is
Fig. 14 Blower Motor Resistor Block - Typical
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE HARNESS
6 - HVAC HOUSING
Fig. 15 Evaporator Temperature Sensor - MTC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - HVAC HOUSING
3 - A/C EVAPORATOR
RSCONTROLS - FRONT24-27
BLOWER MOTOR RESISTOR BLOCK (Continued)

inserted in a small well in the body of the expansion
valve that is filled with a special silicone-based ther-
mal grease. A small molded plastic push-in retainer
secures the sensor to a threaded hole in the top sur-
face of the expansion valve. Two terminals within a
molded plastic connector receptacle on the sensor
connect it to the vehicle electrical system through a
take out and connector of the HVAC wire harness.
The evaporator temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the tem-
peratures it monitors. The A/C-heater control is con-
nected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator tem-
perature increases, the resistance of the sensor
decreases and the voltage monitored by the control
decreases. The control uses this monitored voltage
reading to an indication of the evaporator tempera-
ture. The A/C-heater control is programmed to
respond to this input by sending electronic messages
to the powertrain control module (PCM) over the pro-
grammable communications interface (PCI) data bus,
and the PCM then cycles the A/C compressor clutch
as necessary to optimize A/C system performance andto protect the system from evaporator freezing. The
external location of the sensor allows the sensor to be
removed or installed without disturbing the refriger-
ant in the system. The evaporator temperature sen-
sor is diagnosed using a DRBIIItscan tool. Refer to
Body Diagnostic Procedures.
REMOVAL
REMOVAL - AUTOMATIC TEMPERATURE
CONTROL (ATC)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the air cleaner housing from the right
side of the engine compartment.
(3) Remove the windshield wiper assembly from
the vehicle (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Remove the temperature sensor retainer from
the expansion valve (Fig. 17).
(5) Pull the evaporator temperature sensor away
from the expansion valve far enough to access the
red release ring on the wiring connector. Push the
red ring toward the connector to release the lock and
disconnect the wire harness connector from the tem-
perature sensor.
(6) Remove the evaporator temperature sensor
from the engine compartment.
Fig. 16 Evaporator Temperature Sensor - ATC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - A/C EXPANSION VALVE
Fig. 17 Evaporator Temperature Sensor - ATC
System
1 - RIGHT FRONT STRUT TOWER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - DASH PANEL
5 - RETAINER
24 - 28 CONTROLS - FRONTRS
EVAPORATOR TEMPERATURE SENSOR (Continued)

REMOVAL - MANUAL TEMPERATURE
CONTROL (MTC)
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel from the vehicle
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).
(3) Disconnect the wire harness connector from the
evaporator temperature sensor located on the top of
the HVAC housing (Fig. 18).
(4) Remove the evaporator temperature sensor
from the HVAC housing.
INSTALLATION
INSTALLATION - AUTOMATIC TEMPERATURE
CONTROL (ATC)
NOTE: Any grease removed with the evaporator
temperature sensor must be replaced. Failure to do
so could result in poor A/C performance.
(1) Position the evaporator temperature sensor
into the right rear corner of the engine compartment.
(2) Reconnect the wire harness connector to the
evaporator temperature sensor.
(3) Position the evaporator temperature sensor
onto the top of the expansion valve with the sensor
probe inserted into the well in the expansion valve.(4) Install the temperature sensor retainer.
(5) Install the window wiper module (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION).
(6) Reinstall the air cleaner housing into the right
side of the engine compartment.
(7) Reconnect the battery negative cable.
(8) Run the HVAC Cool Down test to verify system
is operating properly (Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND TESTING).
INSTALLATION - MANUAL TEMPERATURE
CONTROL (MTC)
(1) Install the evaporator temperature sensor into
the top of the HVAC housing.
(2) Connect the wire harness connector to the
evaporator temperature sensor.
(3) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(4) Reconnect the negative battery cable.
INFRARED TEMPERATURE
SENSOR
DESCRIPTION
The infrared temperature sensor consists of two
infrared transducers that are concealed behind a
clear lens located near the bottom of the center panel
outlet near the top of the instrument panel center
bezel (Fig. 19). These sensors are used only on mod-
els equipped with the optional automatic tempera-
ture control (ATC) heating-A/C system. A molded
plastic connector receptacle on the bottom of the
panel outlet unit is concealed behind the center
bezel. A short, dedicated jumper wire harness routed
behind the center bezel connects the sensors directly
to the ATC A/C-heater control module near the bot-
tom of the center bezel. The infrared temperature
sensor is integral to the center bezel panel outlet
unit. The infrared sensors cannot be adjusted or
repaired and, if faulty or damaged, the center bezel
panel outlet unit must be replaced.
OPERATION
The dual infrared temperature sensors provide
independent measurement inputs to the Automatic
Temperature Control (ATC) heater-A/C control mod-
ule that indicates the surface temperature of the
driver seat and front seat passenger seat occupants.
By using a surface temperature measurement, rather
than an air temperature measurement, the ATC sys-
tem is able to adjust itself to the comfort level as per-
ceived by the occupant. This allows the system to
detect and compensate for other ambient conditions
Fig. 18 Evaporator Temperature Sensor - MTC
System
1 - EVAPORATOR TEMPERATURE SENSOR
2 - WIRE HARNESS CONNECTOR
3 - HVAC HOUSING
RSCONTROLS - FRONT24-29
EVAPORATOR TEMPERATURE SENSOR (Continued)

affecting comfort levels, such as solar heat gain or
evaporative heat loss. The ATC system logic responds
to the infrared sensor inputs by calculating and
adjusting the air flow temperature and air flow rate
needed to properly obtain and maintain the individ-
ually selected comfort level temperatures of both the
driver and passenger seat occupants. The ATC heat-
er-A/C control module continually monitors the infra-
red sensor circuits, and will store a Diagnostic
Trouble Code (DTC) for any problem it detects. This
DTC information can be retrieved and the infrared
temperature sensor diagnosed using a DRBIIItscan
tool. Refer to Body Diagnostic Procedures.
MODE DOOR ACTUATOR
DESCRIPTION
The mode door actuator is a reversible, 12-volt
Direct Current (DC), servo motor. The single mode
door actuator is located on the driver's side end of
the HVAC housing, close to the top of the distribution
housing. The mode door actuator is mechanically con-
nected to the mode door.
The mode door actuator is interchangeable with
the actuators for the blend air door(s) and the recir-
culation air door. Each actuator 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 distribution housing. Each actuator
also has an identical output shaft with splines that
connects it to the linkage that drives the mode door.
The mode door actuator does not require mechanical
indexing to the mode door linkage, as it is electroni-
cally calibrated by the heater-A/C control module.
OPERATION
The mode 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 mode door actuator can
move the mode 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 mode door will move in one direction. When the
A/C-heater control reverses the polarity of the volt-
age to the motor, the mode door moves in the oppo-
site direction. When the A/C-heater control makes
the voltage to both connections high or both connec-
tions low, the mode door stops and will not move.
These same motor connections also provide a feed-
back signal to the A/C-heater control. This feedback
signal allows the A/C-heater control to monitor the
operation and relative position of the mode door
actuator and the mode door. The A/C-heater control
learns the mode door stop positions during the cali-
bration procedure and will store a diagnostic trouble
code (DTC) for any problems it detects in the mode
door actuator circuits.
The mode door actuator can be diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures for more information. The mode door actuator
cannot be adjusted or repaired and, if damaged or
faulty, it 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.
(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
mode door actuator (Fig. 20).
(4) Remove the two screws that secure the mode
door actuator to the HVAC distribution housing.
Fig. 19 Infrared Temperature Sensor
1 - INSTRUMENT PANEL CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - INFRARED TEMPERATURE SENSOR
24 - 30 CONTROLS - FRONTRS
INFRARED TEMPERATURE SENSOR (Continued)

(5) Remove the mode door actuator from the distri-
bution housing.
INSTALLATION
(1) Position the mode door actuator onto the HVAC
distribution housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft with those in the mode door linkage.
(2) Install the two screws that secure the mode
door actuator to the distribution housing. Tighten the
screws to 2 N´m (17 in. lbs.).
(3) Connect the wire harness connector to the
mode door actuator.
(4) Install the silencer under the driver side end of
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL SILENCER -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) Perform the A/C-heater control calibration pro-
cedure (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
POWER MODULE - BLOWER
MOTOR
DESCRIPTION
A blower motor power module is used on this
model when it is equipped with the optional Auto-
matic Temperature Control (ATC) system. Modelsequipped with the standard manual heater-A/C sys-
tem use a blower motor resistor block, instead of the
blower motor power module (Refer to 24 - HEATING
& AIR CONDITIONING/CONTROLS/BLOWER
MOTOR RESISTOR BLOCK - DESCRIPTION).
The blower motor power module is mounted to the
rear of the HVAC housing, directly behind the glove
box opening in the instrument panel. The module
consists of a molded plastic mounting plate with two
integral connector receptacles. Concealed behind the
mounting plate is the power module electronic cir-
cuitry and a large finned, heat sink. The blower
motor power module is accessed for service by remov-
ing the glove box from the instrument panel.
OPERATION
The blower motor power module is connected to the
vehicle electrical system through a dedicated lead
and connector from the instrument panel wire har-
ness. A second connector receptacle receives a wire
lead connector from the blower motor. The blower
motor power module allows the microprocessor-based
Automatic Temperature Control (ATC) heater-A/C
control module to calculate and provide infinitely
variable blower motor speeds based upon either man-
ual blower switch input or the ATC programming
using a Pulse Width Modulated (PWM) circuit strat-
egy. The PWM voltage is applied to a comparator cir-
cuit which compares the PWM signal voltage to the
blower motor feedback voltage. The resulting output
drives the power module circuitry, which adjusts the
voltage output received from the blower motor relay
to change or maintain the desired blower speed. The
blower motor power module is diagnosed using a
DRBIIItscan tool. Refer to Body Diagnostic Proce-
dures.
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.
Fig. 20 Mode Door Actuator - LHD Shown, RHD
Typical
1 - WIRE HARNESS CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
RSCONTROLS - FRONT24-31
MODE DOOR ACTUATOR (Continued)

WARNING: THE HEAT SINK FOR THE BLOWER
MOTOR POWER MODULE MAY GET VERY HOT
DURING NORMAL OPERATION. IF THE BLOWER
MOTOR WAS TURNED ON PRIOR TO SERVICING
THE BLOWER MOTOR POWER MODULE, WAIT
FIVE MINUTES TO ALLOW THE HEAT SINK TO
COOL BEFORE PERFORMING DIAGNOSIS OR SER-
VICE. FAILURE TO TAKE THIS PRECAUTION CAN
RESULT IN PERSONAL INJURY.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) Disconnect the two wire harness connectors
from the blower motor power module (Fig. 21).
(4) Remove the two screws that secure the blower
motor power module to the HVAC housing.
(5) Remove the blower motor power module from
the HVAC housing.
INSTALLATION
(1) Position the blower motor power module into
the HVAC housing.
(2) Install the two screws that secure the blower
motor power module to the HVAC housing. Tighten
the screws to 2 N´m (17 in. lbs.).
(3) Connect the two wire connectors to the blower
motor power module.
(4) Install the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - INSTALLA-
TION).
(5) Reconnect the negative battery cable.
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The recirculation door actuator is a reversible,
12-volt direct current (DC), servo motor. The single
recirculation door actuator is located on the passen-
ger side end of the HVAC housing, on the air inlet
housing. The recirculation door actuator is mechani-
cally connected to the recirculation-air door. The
recirculation door actuator is interchangeable with
the actuators for the blend-air door(s) and the mode
door. Each actuator 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 air inlet housing. Each actuator also has an iden-
tical output shaft with splines that connects it to the
linkage that drives the recirculation-air door. The
recirculation door actuator does not require mechan-
ical indexing to the recirculation-air door, as it is
electronically calibrated by the A/C-heater control.
OPERATION
The recirculation door actuator is connected to the
heater-A/C control module through the vehicle elec-
trical system by a dedicated two-wire lead and con-
nector of the HVAC wire harness. The recirculation
door actuator can move the recirculation door in two
directions. When the heater-A/C control module pulls
the voltage on one side of the motor connection high
and the other connection low, the recirculation air
door will move in one direction. When the module
reverses the polarity of the voltage to the motor, the
recirculation air door moves in the opposite direction.
When the module makes the voltage to both connec-
tions high or both connections low, the recirculation
air door stops and will not move. These same motor
connections also provide a feedback signal to the
heater-A/C control module. This feedback signal
allows the module to monitor the operation and rela-
tive position of the recirculation door actuator and
the recirculation air door. The heater-A/C control
module learns the recirculation air door stop posi-
tions during the calibration procedure and will store
a Diagnostic Trouble Code (DTC) for any problems it
detects in the recirculation door actuator circuits.
The recirculation door actuator can be diagnosed
using a DRBIIItscan tool. Refer to Body Diagnostic
Procedures for more information. The recirculation
door actuator cannot be adjusted or repaired and, if
damaged or faulty, it must be replaced.
Fig. 21 Blower Motor Power Module - Typical
1 - POWER MODULE
2 - LOWER GLOVE BOX OPENING REINFORCEMENT
3 - HVAC HOUSING
24 - 32 CONTROLS - FRONTRS
POWER MODULE - BLOWER MOTOR (Continued)

REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the carpet on the passenger side front
floor away from the dash panel far enough to access
the recirculation door actuator.
(3) Disconnect the HVAC wire harness connector
from the recirculation door actuator (Fig. 22).
(4) Remove the two screws that secure the recircu-
lation door actuator to the air inlet housing.
(5) Remove the recirculation door actuator from
the air inlet housing.
INSTALLATION
(1) Position the recirculation door actuator onto
the air intake housing. If necessary, rotate the actua-
tor slightly to align the splines on the actuator out-
put shaft with those in the recirculation air door.
(2) Install the two screws that secure the recircu-
lation door actuator to the air intake housing.
Tighten the screws to 2 N´m (17 in. lbs.).(3) Connect the HVAC wire harness connector to
the recirculation door actuator.
(4) Reposition the carpet on the passenger side
front floor back up to the dash panel.
(5) Reconnect the battery negative cable.
(6) Perform the heater-A/C control calibration pro-
cedure (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
Fig. 22 Recirculation Door Actuator - LHD Shown,
RHD Typical
1 - AIR INLET HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER HVAC HOUSING
RSCONTROLS - FRONT24-33
RECIRCULATION DOOR ACTUATOR (Continued)

CONTROLS - REAR
TABLE OF CONTENTS
page page
A/C-HEATER CONTROL
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................35
BLEND DOOR ACTUATOR
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................36
INSTALLATION.........................36
BLOWER MOTOR RELAY
DESCRIPTION.........................37
OPERATION...........................37
REMOVAL.............................38
INSTALLATION.........................38
BLOWER MOTOR RESISTOR
DESCRIPTION.........................38OPERATION...........................38
DIAGNOSIS AND TESTING - REAR BLOWER
MOTOR RESISTOR BLOCK..............38
REMOVAL.............................39
INSTALLATION.........................39
MODE DOOR ACTUATOR - REAR
DESCRIPTION.........................39
OPERATION...........................40
REMOVAL.............................40
INSTALLATION.........................40
POWER MODULE - REAR BLOWER MOTOR
DESCRIPTION.........................41
OPERATION...........................41
REMOVAL.............................41
INSTALLATION.........................42
A/C-HEATER CONTROL
DESCRIPTION
The rear heater-A/C system is controlled by rotary-
type blower motor and temperature controls, cen-
trally mounted in the headliner. The rear A/C-heater
control allows selection of three blower motor speeds
and an Off position when the center knob on the
front A/C-heater control is set to the Rear position,
otherwise the front unit controls both front and rear
heater-A/C operation.
OPERATION
With the rear A/C-heater control active, tempera-
ture 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 temperature setting to the floor. Refer to Body
Diagnostic Procedures for further diagnostic informa-
tion.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick or another suitable wide flat
bladed tool, gently pry the top edge of the rear A/C-
heater control bezel away from the headliner far
enough to release the two snap clip retainers (Fig. 1).(3) Pull the rear A/C-heater control rearward far
enough to access the headliner wire harness connec-
tor on the back of the control.
(4) Disconnect the wire harness connector from the
rear A/C-heater control.
(5) Remove the rear A/C-heater control from the
headliner.
Fig. 1 Rear A/C-Heater Control
1 - TRIM STICK
2 - BEZEL
3 - REAR A/C-HEATER CONTROL
4 - HEADLINER
24 - 34 CONTROLS - REARRS

(6) If required, remove the three screws that
secure the rear A/C-heater control to the bezel and
remove the control from the bezel (Fig. 2).
INSTALLATION
(1) If removed, position the rear A/C-heater control
onto the bezel.
(2) If removed, install the three screws that secure
the rear A/C-heater control to the bezel. Tighten the
screws to 2 N´m (17 in. lbs.).
(3) Position the rear A/C-heater control near the
headliner.
(4) Connect the wire harness connector to the rear
A/C-heater control.
(5) Insert the locator tabs on the back of the rear
A/C-heater control bezel over the forward edge of the
headliner opening.
(6) Slide the rear A/C-heater control bezel forward
far enough to align the snap clips on the bezel with
the receptacles on the headliner.
(7) Using hand pressure, press the top edge of the
rear A/C-heater control bezel upward until the two
snap clips are fully seated in their receptacles.
(8) Reconnect the battery negative cable.
(9) Using the DRB-IIItreset the Rear Tempera-
ture Selector calibration values.
(10) Verify that the Actuator Calibration of the
Front Control has passed. If an Actuator Calibration
has not passed correct any errors before proceeding
further.
(11) Rotate the Rear Temperature Selector counter
clockwise to the Cold Position, allow the Selector to
remain in the Cold Position for 5 seconds.(12) Rotate the Rear Temperature Selector Clock-
wise to the Hot Position, allow the Selector to remain
in the Cold Position for 5 seconds.
(13) Calibration is now complete.
BLEND DOOR ACTUATOR
DESCRIPTION
The rear blend door actuator is a reversible,
12-volt Direct Current (DC), servo motor. The single
blend door actuator is located on the outboard side of
the rear HVAC housing, below the mode door actua-
tor. The blend door actuator is mechanically con-
nected to the blend air door.
The rear blend door actuator is interchangeable
with the actuator for the mode door. Each actuator 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 rear HVAC housing.
Each actuator also has an identical output shaft with
splines that connects it to the pivot or linkage of the
proper door. The rear blend door actuator does not
require mechanical indexing to the blend air door
pivot, as it is electronically calibrated by the front
heater-A/C control module.
OPERATION
The rear blend door actuator is connected to the
front heater-A/C control module through the vehicle
electrical system by a dedicated two-wire take out
and connector of the rear HVAC wire harness. The
blend door actuator can move the blend air door in
two directions. When the front heater-A/C control
module 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
module reverses the polarity of the voltage to the
motor, the blend air door moves in the opposite direc-
tion. When the module makes the voltage to both
connections high or both connections low, the blend
air door stops and will not move. These same motor
connections also provide a feedback signal to the
front heater-A/C control module. This feedback signal
allows the module to monitor the operation and rela-
tive positions of the blend door actuator and the
blend air door. The front heater-A/C control module
learns the blend air door stop positions during the
calibration procedure and will store a Diagnostic
Trouble Code (DTC) for any problems it detects in
the blend door actuator circuits.
The rear blend door actuator can be diagnosed
using a DRBIIItscan tool. Refer to Body Diagnostic
Procedures for more information. The rear blend door
Fig. 2 Heater-A/C Control Bezel
1 - BEZEL
2 - SNAP CLIP (2)
3 - HEATER-A/C CONTROL
4 - SCREW (3)
5 - LOCATOR TAB (2)
RSCONTROLS - REAR24-35
A/C-HEATER CONTROL (Continued)