Connector pin JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

REMOVAL - PANEL/DEFROST DOOR VACUUM
ACTUATOR
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.
This actuator is used only on models equipped with
the standard manual temperature control system.
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Unplug the vacuum harness connector from the
heat/defrost door vacuum actuator (Fig. 20).(3) Disengage the panel/defrost door pivot connec-
tion from the panel/defrost door pivot pin.
(4) Remove the screws that secure the panel/de-
frost door vacuum actuator to the HVAC housing.
(5) Remove the panel/defrost door vacuum actuator
from the HVAC housing.INSTALLATION
INSTALLATION - HEAT/DEFROST - PANEL/
DEFROST DOOR ELECTRIC ACTUATOR
(1) Install the heat/defrost-panel/defrost door
actuator on the HVAC housing, and tighten the three
mounting screws to 2.2 N´m (20 in. lbs.).
(2) Plug in the wire harness connector to the heat/
defrost - panel/defrost door actuator.
(3) Install the center instrument panel support
bracket on the vehicle.
(4) Install the two bolts that secure the center
instrument panel support bracket to the instrument
panel.
(5) Install the two bolts that secure the center
instrument panel support bracket to the left side of
the floor panel transmission tunnel.
(6) Connect the battery negative cable.
Fig. 19 MODE DOOR ACTUATORS-MANUAL
SYSTEM
1 - VACUUM LINES
2 - ACTUATING LEVERS
3 - LINKAGE
4 - VACUUM ACTUATORS
5 - ACTUATING LEVER
Fig. 20 PANEL/DEFROST DOOR ACTUATOR
1 - VACUUM LINE
2 - PANEL/DEFROST DOOR ACTUATOR
3 - SHAFT RETAINER
24 - 32 CONTROLSWJ
MODE DOOR ACTUATOR (Continued)

INSTALLATION - HEAT/DEFROST DOOR
VACUUM ACTUATOR
(1) Install the heat/defrost door vacuum actuator
on the HVAC housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Engage the heat/defrost door pivot connection
with the heat/defrost door pivot pin.
(3) Plug in the vacuum harness connector to the
heat/defrost door vacuum actuator.
(4) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
INSTALLATION - PANEL/DEFROST DOOR
VACUUM ACTUATOR
(1) Install the panel/defrost door vacuum actuator
on the HVAC housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Engage the panel/defrost door pivot connection
with the panel/defrost door pivot pin.
(3) Plug in the vacuum harness connector to the
heat/defrost door vacuum actuator.
(4) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
RECIRCULATION DOOR
ACTUATOR
DESCRIPTION
The recirculation door actuator for vehicles
equipped with the standard equipment manual tem-
perature control system is vacuum controlled. The
optional Automatic Zone Control (AZC) system uses
an electric recirculation door actuator. In the follow-
ing procedures, service for both types of actuators is
covered.
REMOVAL
REMOVAL - RECIRCULATION DOOR VACUUM
ACTUATOR
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 AIRBAGSYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
This actuator is used only on models equipped with
the standard manual temperature control system.
(1) Remove the instrument panel from the vehicle.
Refer to Instrument Panel System for the procedures.
(2) Unplug the vacuum harness connector from the
recirculation door vacuum actuator.
(3) Disengage the recirculation door pivot connec-
tion from the door pivot pin.
(4) Disengage the recirculation door actuating rod
from the recirculation door lever.
(5) Remove the screws that secure the recircula-
tion door vacuum actuator to the HVAC housing.
(6) Remove the recirculation door vacuum actuator
from the HVAC housing.
REMOVAL - RECIRCULATION DOOR ELECTRIC
ACTUATOR
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.
This actuator is used only on models equipped with
the optional Automatic Zone Control (AZC) system.
(1) Remove the instrument panel from the vehicle.
Refer to Instrument Panel System for the procedures.
(2) Unplug the wire harness connector from the
recirculation door actuator.
(3) Remove the 2 screws securing the recirculation
door housing to the HVAC unit (Fig. 21). Tilt the
front of the housing up while reaching around the
back releasing 2 tangs holding the rear of the hous-
ing down.
(4) Remove the recirculation door housing from the
HVAC unit.
(5) Remove the screws that secure the recircula-
tion door actuator to the HVAC housing.
(6) Remove the recirculation door actuator from
the HVAC housing.
WJCONTROLS 24 - 33
MODE DOOR ACTUATOR (Continued)

INSTALLATION
INSTALLATION - RECIRCULATION DOOR
VACUUM ACTUATOR
(1) Install the recirculation door vacuum actuator
on the HVAC housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Engage the recirculation door actuating rod
with the recirculation door lever.
(3) Engage the recirculation door pivot connection
with the door pivot pin.
(4) Plug in the vacuum harness connector to the
recirculation door vacuum actuator.
(5) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
INSTALLATION - RECIRCULATION DOOR
ELECTRIC ACTUATOR
(1) Install the recirculation door actuator on the
recirculation door housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Install the recirculation door housing on the
HVAC unit and tighten the mounting screws to 2.2
N´m (20 in. lbs.).
(3) Plug in the wire harness connector to the recir-
culation door actuator.
(4) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
VACUUM CHECK VALVE
DESCRIPTION
Two vacuum check valves (non AZC only) are
installed on the vacuum supply system. One is on the
accessory vacuum supply line in the engine compart-
ment, near the vacuum tap on the engine intake
manifold. A second vacuum check valve is located on
the bottom of the HVAC unit behind the passenger
front floor duct on the black vacuum line. The vac-
uum check valves are designed to allow vacuum to
flow in only one direction through the accessory vac-
uum supply circuits.
OPERATION
The use of a vacuum check valve helps to maintain
the system vacuum needed to retain the selected A/C
Heater mode settings. The check valve will prevent
the engine from bleeding down system vacuum
through the intake manifold during extended heavy
engine load (low engine vacuum) operation.
The vacuum check valve cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Unplug the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
(2) Note the orientation of the check valve in the
vacuum supply line for correct installation.
(3) Unplug the vacuum check valve from the vac-
uum supply line fittings.
INSTALLATION
(1) Plug in the vacuum check valve at the vacuum
supply line fittings, noting the orientation of the
check valve in the vacuum supply line for correct
installation.
(2) Plug in the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is mounted in the right front
of the vehicle behind the headlamp mounting module
(Fig. 22). The headlamp mounting module and head-
lamp assembly must be removed from the vehicle to
access the vacuum reservoir for service. Refer to
Lamps/Lighting for the procedures.
OPERATION
Engine vacuum is stored in the vacuum reservoir.
The stored vacuum is used to operate the vacuum-
Fig. 21 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
24 - 34 CONTROLSWJ
RECIRCULATION DOOR ACTUATOR (Continued)

BLOWER MOTOR
DESCRIPTION
The blower motor and blower wheel are located in
the passenger side end of the HVAC housing, below
the glove box module. The blower motor controls the
velocity of the air flowing through the HVAC housing
by spinning a squirrel cage-type blower wheel within
the housing at the selected speed. The blower motor
and blower wheel can be serviced from the passenger
compartment side of the housing.
OPERATION
The blower motor will only operate when the igni-
tion switch is in the On position, and the a/c heater
mode control switch is in any position, except off. The
blower motor circuit is protected by a fuse in the
junction block. On models with the standard manual
temperature control system, the blower motor speed
is controlled by regulating the battery feed through
the blower motor switch and the blower motor resis-
tor. On models with the optional Automatic Zone
Control (AZC) system, the blower motor speed is con-
trolled by using Pulse Width Modulation (PWM). The
blower motor controller adjusts the battery feed volt-
age to the blower motor, based upon an input from
the blower motor switch, through the AZC control
module. Pulse width modulation of blower power
allows the blower to operate at any speed from sta-
tionary, to full speed.
The blower motor and blower motor wheel cannot
be repaired, and if faulty or damaged, they must be
replaced. The blower motor and blower wheel are
each serviced separately.
DIAGNOSIS AND TESTING - BLOWER MOTOR
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.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. Possible causes of an
inoperative blower motor include:
²Faulty fuse²Faulty blower motor circuit wiring or wire har-
ness connections
²Faulty blower motor resistor (if the vehicle is so
equipped)
²Faulty blower motor controller (if the vehicle is
so equipped)
²Faulty blower motor switch
²Faulty a/c heater mode control switch
²Faulty blower motor.
Possible causes of the blower motor not operating
in all speeds include:
²Faulty fuse
²Faulty blower motor switch
²Faulty blower motor resistor (if the vehicle is so
equipped)
²Faulty blower motor controller (if the vehicle is
so equipped)
²Faulty AZC module (if the vehicle is so
equipped)
²Faulty blower motor circuit wiring or wire har-
ness connections.
VIBRATION
Possible causes of blower motor vibration include:
²Improper blower motor mounting
²Improper blower wheel mounting
²Blower wheel out of balance or bent
²Blower motor faulty.
NOISE
To verify that the blower is the source of the noise,
unplug the blower motor wire harness connector and
operate the HVAC system. If the noise goes away,
possible causes include:
²Foreign material in the HVAC housing
²Improper blower motor mounting
²Improper blower wheel mounting
²Blower motor faulty.
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.
WJDISTRIBUTION 24 - 37

(1) Disconnect and isolate the battery negative
cable.
(2) Pinch the connector retainer and unplug the
blower motor wire harness from the blower motor
(Fig. 2).
(3) Remove the three screws that secure the
blower motor and blower wheel assembly to the
HVAC housing, using either a T-25 Torxthead or
flat-bladed screwdriver.
(4) Lower the blower motor and wheel from the
HVAC housing.
(5) Remove the blower wheel retainer clip (Fig. 3).
(6) Remove the wheel from the blower motor shaft.
INSTALLATION
(1) Press the blower wheel hub onto the blower
motor shaft. Be sure the flat on the blower motor
shaft is indexed to the flat on the inside of the blower
wheel hub.
(2) Install the retainer clip over the blower wheel
hub.
(3) Install the blower motor in the HVAC housing
with three mounting screws. Tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(4) Plug the blower motor wire harness connector
into the blower motor socket.
(5) Connect the battery negative cable.
DEFROSTER DUCTS
REMOVAL
(1) Remove the instrument panel assembly from
the vehicle(Refer to 23 - BODY/INSTRUMENT
PANEL - REMOVAL).
(2) Remove the three screws that secure the
defroster duct to the HVAC unit housing (Fig. 4).
(3) Remove the defroster duct from the HVAC unit
housing.
Fig. 2 BLOWER MOTOR (HOUSING REMOVED
FROM VEHICLE)
1 - BLOWER MOTOR RESISTOR
2 - BLOWER MOTOR
3 - GROUND STRAP
4 - ELECTRICAL CONNECTORS
5 - HEATER CORE TUBES
Fig. 3 BLOWER MOTOR WHEEL REMOVE/INSTALL
1 - BLOWER MOTOR WHEEL
2 - RETAINER CLIP
Fig. 4 HVAC DEFROSTER DUCT
1 - HVAC UNIT HOUSING
2 - INSTRUMENT PANEL
3 - SCREWS
4 - DEFROSTER DUCT
24 - 38 DISTRIBUTIONWJ
BLOWER MOTOR (Continued)

NOTE: The blend door sub-assembly is attached to
the housing with 2 screws, and may be removed for
service (Fig. 19).
ASSEMBLY
(1) Place the top half of the HVAC housing on the
bottom half. Be certain that each of the door pivot
pins align with the pivot holes in the HVAC housing.
(2) Install the 10 screws that secure the two hous-
ing halves to each other. Tighten the HVAC housing
screws to 2.2 N´m (20 in. lbs.).
(3) Attach the wire harness electrical connector(s)
to the mounts on the lower case at the blower motor
end of the unit.
(4) Install the 5 clips that secure the two housing
halves to each other. Check doors for binding after
replacement, and after assembly of housing.
(5) Install the screw with plastic washer holding
the lever assembly to the upper case section.
(6) Install the mode door actuator on the left side
of the housing.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct mounting holes.
(2) Install the HVAC housing mounting nuts to the
studs on the passenger compartment side of the dash
panel. Tighten the nuts to 4.5 N´m (40 in. lbs.).
(3) Connect the HVAC housing wire harness con-
nectors.
(4) Reinstall the rear floor heat ducts to the center
floor heat duct outlets.
(5) Install and tighten the nuts onto the HVAC
housing mounting studs on the engine compartment
side of the dash panel. Tighten the nuts to 7 N´m (60
in. lbs.).
(6) Reinstall the PCM to the passenger side dash
panel in the engine compartment. Refer to Electronic
Control Modules for the procedures.
(7) Reinstall the coolant reserve/overflow bottle to
the passenger side inner fender shield. Refer to Cool-
ing for the procedures.
(8) If the vehicle is equipped with the manual tem-
perature control system, connect the HVAC system
vacuum supply line connector to the tee fitting near
the heater core tubes.
(9) Unclamp/unplug the heater core hoses and
tubes. Connect the heater hoses to the heater core
tubes and fill the engine cooling system. Refer to
Cooling for the procedures.
(10) Unplug or remove the tape from the suction
line and the evaporator outlet tube fittings. Connect
the suction line to the evaporator outlet tube.
Tighten retaining nut to 28 N´m (250 in. lbs.).
(11) Unplug or remove the tape from the liquid
line and the evaporator inlet tube fittings. Connect
the liquid line to the evaporator inlet tube. Tighten
retaining nut to 28 N´m (250 in. lbs.).
(12) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
Fig. 19 BLEND DOOR SUB-ASSEMBLY (AZC)
1 - PASSENGER SIDE BLEND DOOR
2 - BLEND DOOR SUB-ASSEMBLY
3 - DOOR PIVOT SHAFT BUSHING
4 - DOOR SHAFT LEVER
5 - DRIVER SIDE BLEND DOOR
WJDISTRIBUTION 24 - 45
HVAC HOUSING (Continued)

INSTALLATION
INSTALLATION - PANEL OUTLET DOOR
(1) Snap the panel outlet door pivot shaft retainer
on the pivot shaft.
(2) Attach the panel outlet door pivot shaft to the
HVAC case.
(3) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
INSTALLATION - HEAT/DEFROST DOOR
(1) Install the heat/defrost door by snapping the
heat/defrost door pivot shaft into the HVAC case.
(2) Install the heat/defrost door sub-assembly and
tighten the mounting screws to 2.2 N´m (20 in. lbs.).
(3) Attach the metal linkage to the heat/defrost
door lever.
(4) Snap the duct adapter to the bottom of the
heat/defrost door sub-assembly.
(5) Install the 2 floor heat ducts and tighten the
mounting screws to 2.2 N´m (20 in. lbs.)..
(6) Install the evaporator, and styrofoam tray in
the lower case.
(7) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
INSTALLATION - PANEL/DEFROST DOOR
(1) Snap the panel/defrost door pivot shaft retainer
on the pivot shaft.
(2) Attach the panel/defrost door pivot shaft to the
HVAC case.
(3) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
RECIRCULATION DOOR
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.
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Place the HVAC housing right side up on the
work bench.
(3) Unplug the wire/vacuum connector from the
recirculation door actuator.
(4) Remove the 2 screws fastening the recircula-
tion door sub-assembly to the main housing (Fig. 26).
Fig. 26 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
WJDISTRIBUTION 24 - 49
MODE DOOR (Continued)

(5) Raise the front of the door sub-assembly while
releasing the 2 tabs holding the rear to the main
housing, and remove the recirculation door housing.
(6) Remove the electric/vacuum actuator from the
recirculation door sub-assembly and set aside.
(7) Pinch the retention tabs holding the recircula-
tion door pivot shaft to the case. The 3 plastic tabs,
located on the inside of the case, are part of the shaft
retainer.
(8) Remove the recirculation door from the recircu-
lation air door housing.
INSTALLATION
(1) Install the recirculation door in the recircula-
tion air door housing by snapping the pivot shaft
retention tabs into the case.
(2) Install the electric/vacuum actuator on the
recirculation door sub-assembly. Check door for bind-
ing after replacement.
(3) Install the recirculation door housing on the
HVAC case and tighten the 2 screws to 2.2 N´m (20
in. lbs.).
(4) Plug in the wire/vacuum connector to the recir-
culation door actuator.
(5) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
24 - 50 DISTRIBUTIONWJ
RECIRCULATION DOOR (Continued)

pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) When installing individual tubes, insert tube
into core ensuring that tube O-ring is seated in core
and not pinched. Hold tube in seated position while
installing the round tube-to-core clamp (Fig. 14).
NOTE: The round tube-to-heater-core clamp should
be left loose enough to turn the tube in the core.
Position the core in the housing, and then tighten
the tube-to-heater-core clamp after orienting the
tubes to the molded HVAC housing.
(2) Lower the heater core into the HVAC housing.
(3) Install the mode door actuator, if removed from
housing for core removal.
(4) Position the retainers over the heater core
tubes. Install and tighten the screws that secure the
heater core and retainers to the HVAC housing.
Tighten the screws to 2.2 N´m (20 in. lbs.).NOTE: The grounding strap is to be attached to the
lower heater core tube retainer.
(5) Reinstall the HVAC housing to the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - INSTALLA-
TION)
RECEIVER / DRIER
DESCRIPTION
The receiver/drier is mounted in the engine com-
partment between the condenser and is part of the
liquid line assembly. The filter/drier cannot be
repaired, if the filter/drier is faulty, damaged, left
open to the atmosphere or contaminated the line
assembly must be replaced.
OPERATION
The filter-drier performs a filtering action to pre-
vent foreign material in the refrigerant from contam-
inating the expansion valve. A desiccant bag is
mounted inside the filter-drier canister to absorb any
Fig. 13 HEATER CORE AND TUBES - (Typical)
1 - ELECTRICAL CONNECTORS
2 - EXPANSION VALVE
3 - ELECTRIC ACTUATOR
4 - OUTLET TO DEFROSTER DUCTS
5 - ELECTRIC ACTUATOR
6 - FLOOR DUCT
7 - TO REAR PASSENGER FLOOR AIR DUCTS8 - FLOOR DUCT
9 - HEATER CORE AND TUBES
10 - HOUSING DRAIN
11 - BLOWER MOTOR RESISTOR/CONTROLLER
12 - BLOWER MOTOR
13 - GROUND STRAP
24 - 72 PLUMBINGWJ
HEATER CORE (Continued)

(4) Unplug the clutch coil wire harness connector.
(5) Remove the bolts that secure the viscous
heater to the mounting bracket.
(6) Remove the viscous heater from the mounting
bracket. Support the viscous heater in the engine
compartment while servicing the clutch.
(7) Insert the two pins of the spanner wrench (spe-
cial Tool C-4489 or equivalent) into the holes of the
clutch plate. Hold the clutch plate stationary and
remove the hex nut (Fig. 18).
(8) Remove the clutch plate.
(9) Remove the clutch shims.
(10) Remove the external front housing snap ring
with snap ring pliers (Fig. 19).(11) Install the lip of the rotor puller (Special Tool
C-6141±1 or equivalent) into the snap ring groove
exposed in the previous step, and install the shaft
protector (Special Tool C-6141±2 or equivalent) (Fig.
20).
(12) Install the puller through bolts (Special Tool
C-6461 or equivalent) through the puller flange and
into the jaws of the rotor puller and tighten. Turn
the puller center bolt clockwise until the rotor is free
(Fig. 21).
(13) Remove the screw and retainer from the
clutch coil lead wire harness on the viscous heater
housing.
Fig. 18 CLUTCH NUT REMOVE-typical
1 - CLUTCH PLATE
2 - SPANNER
Fig. 19 EXTERNAL SNAP RING REMOVE- typical
1 - PULLEY
2 - SNAP RING PLIERS
Fig. 20 SHAFT PROTECTOR AND PULLER- typical
1 - PULLER JAW
2 - SHAFT PROTECTOR
Fig. 21 INSTALL PULLER PLATE- typical
1 - PULLER JAW
2 - PULLER
WJPLUMBING 24 - 77
VISCOUS HEATER (Continued)