instrument panel JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

WIND DEFLECTOR
REMOVAL
(1) Open sunroof glass panel to the full open posi-
tion.
(2) Remove screws attaching wind deflector straps
to front crossmember (Fig. 6).(3) Rotate wind deflector back about 110É and slide
backwards to disengage from the spring hook.
INSTALLATION
(1) Place wind deflector in position 110É to roof.
(2) Push arms down and forward to engage spring
hooks.
(3) Rotate wind deflector forward into correct posi-
tion. Depress wind deflector down onto front cross-
member to check spring function.
(4) Install fasteners attaching wind deflector
straps to front crossmember.
(5) Test sunroof operation.
OPENING TRIM LACE
REMOVAL
(1) Remove lace by starting at the joint center of
the opening on driver's side.
(2) Pull one end of the lace away from the head-
liner until the entire lace is removed.
INSTALLATION
(1) Place end of trim lace into position starting at
center of the opening on driver's side.
(2) Push lace into position.
(3) Ensure that the corner radii is fully engage.
(4) Once trim lace is attached to sunroof module
begin tucking the headline under the lip on the trim
lace working all the way around the opening.
DRAIN TUBE
REMOVAL
FRONT DRAIN TUBES
(1) Move glass panel to the fully closed position.
(2) Remove sunroof opening trim lace.
(3) Remove the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - REMOVAL)
(4) Disconnect the drain hose from the sunroof
housing (Fig. 7).
(5) Drain any liquid from hose connection, if nec-
essary.
(6) Remove the instrument panel top panel. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL)
(7) Disconnect the grommet, attachment clips and
remove the drain tube.
REAR DRAIN TUBES
(1) Move glass panel to the fully closed position.
(2) Remove sunroof opening trim lace.
(3) Remove headliner.
Fig. 5 TROUGH GUIDE REMOVAL
1 - TROUGH GUIDE
2 - NOTCH
3 - SLIDER
Fig. 6 SUNSHADE
1 - WIND DEFLECTOR
2 - SCREW
3 - SPRING
23 - 180 SUNROOFKJ
GUIDE ASSEMBLY (Continued)

(4) Disconnect the drain hose from the sunroof
housing (Fig. 8).
(5) Drain any liquid from hose connection, if nec-
essary.
(6) Disconnect the grommet, attachment clips and
remove the drain tube.
INSTALLATION
FRONT DRAIN TUBES
(1) Connect the drain hose to the sunroof housing
and test drainage.
(2) Connect the body grommet and attachment
clips.
(3) Install the instrument panel top panel. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION)
(4) Install the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION)
(5) Install sunroof opening trim lace. (Refer to 23 -
BODY/SUNROOF/OPENING TRIM LACE - INSTAL-
LATION)
REAR DRAIN TUBES
(1) Connect the drain hose to the sunroof housing
and test drainage.
(2) Connect the body grommet and attachment
clips.
(3) Install the headliner.(4) Install sunroof opening trim lace.
MODULE ASSEMBLY
REMOVAL
(1) Move glass panel to the fully closed position.
(2) Disconnect and isolate the negative battery
cable.
(3) Remove sunroof opening trim lace.
(4) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(5) Disconnect wire harness push in fasteners and
electrical connector. (Fig. 9)
(6) Disconnect the drain tubes from sunroof hous-
ing.
(7) Loosen fasteners attaching sunroof module
assembly.
(8) With the aid of a helper, remove fasteners
attaching sunroof module assembly to roof panel
(Fig. 10).
INSTALLATION
(1) With the Glass panel in the fully closed posi-
tion.
(2) Raise rear end of sunroof module assembly and
guide into position and start fasteners.
(3) Tighten the fasteners to 9 N´m (80 in. lbs.).
(4) Connect the drain tubes.
Fig. 7 FRONT DRAIN TUBE
1 - TUBE
2 - CLIPS
3 - GROMMET
Fig. 8 REAR DRAIN TUBE
1 - GROMMET
2 - TUBE
3 - CLIPS
KJSUNROOF 23 - 181
DRAIN TUBE (Continued)

HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER........................1
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS.......................1
DESCRIPTION - REFRIGERANT SYSTEM
SERVICE PORT........................2
OPERATION
OPERATION - HEATER AND AIR
CONDITIONER........................2
OPERATION - REFRIGERANT SYSTEM
SERVICE PORT........................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE.......................2DIAGNOSIS AND TESTING - HEATER
PERFORMANCE.......................6
DIAGNOSIS AND TESTING - VACUUM
SYSTEM.............................6
STANDARD PROCEDURE - DIODE
REPLACEMENT.......................9
SPECIFICATIONS
A/C APPLICATION TABLE................9
SPECIFICATIONS.....................10
CONTROLS.............................11
DISTRIBUTION..........................29
PLUMBING.............................38
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - HEATER AND AIR
CONDITIONER
All vehicles are equipped with a common HVAC
housing assembly (Fig. 1). The system combines air
conditioning, heating, and ventilating capabilities in
a single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil is
omitted from the housing.
DESCRIPTION - COOLING SYSTEM
REQUIREMENTS
To maintain the performance level of the HVAC
system, the engine cooling system must be properly
maintained. The use of a bug screen is not recom-
mended. Any obstructions in front of the radiator or
condenser will reduce the performance of the air con-
ditioning and engine cooling systems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Engine Cooling for
more information before the opening of, or attempt-
ing any service to the engine cooling system.
Fig. 1 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
4- BLOWER MOTOR HOUSING
5- EVAPORATOR (A/C ONLY)
6- LOWER HVAC CASE ASSEMBLY
KJHEATING & AIR CONDITIONING 24 - 1

Use an adjustable vacuum test set (Special Tool
C-3707-B) and a suitable vacuum pump to test the
HVAC vacuum control system. With a finger placed
over the end of the vacuum test hose probe (Fig. 3),
adjust the bleed valve on the test set gauge to obtain
a vacuum of exactly 27 kPa (8 in. Hg.). Release and
block the end of the probe several times to verify that
the vacuum reading returns to the exact 27 kPa (8
in. Hg.) setting. Otherwise, a false reading will be
obtained during testing.
VACUUM CHECK VALVE
(1) Remove the vacuum check valve. The valve is
located in the vacuum supply tube (black) at the
HVAC system vacuum tee.
(2) Connect the test set vacuum supply hose to the
A/C Heater Control side of the valve. When con-
nected to this side of the check valve, no vacuum
should pass and the test set gauge should return to
the 27 kPa (8 in. Hg.) setting. If OK, go to Step 3. If
not OK, replace the faulty valve.
(3) Connect the test set vacuum supply hose to the
engine vacuum side of the valve. When connected to
this side of the check valve, vacuum should flow
through the valve without restriction. If not OK,
replace the faulty valve.
A/C HEATER CONTROLS
(1) Connect the test set vacuum probe to the
HVAC vacuum supply (black) tube at the tee in the
engine compartment. Position the test set gauge so
that it can be viewed from the passenger compart-
ment.(2) Place the A/C Heater Mode Control switch
knob in each mode position, one position at a time,
and pause after each selection. The test set gauge
should return to the 27 kPa (8 in. Hg.) setting
shortly after each selection is made. If not OK, a
component or vacuum line in the vacuum circuit of
the selected mode has a leak. See the procedure in
Locating Vacuum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
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) Disconnect the vacuum harness connector from
the back of the HVAC control head(Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL).
(2) Connect the test set vacuum hose probe to each
port in the HVAC housing half of the vacuum har-
ness connector, one port at a time, and pause after
each connection. The test set gauge should return to
the 27 kPa (8 in. Hg.) setting shortly after each con-
nection is made. If OK, replace the faulty A/C Heater
Control. If not OK, go to Step 3.
(3) Determine the vacuum line color of the vacuum
circuit that is leaking. To determine the vacuum line
colors, refer to the Vacuum Circuits chart (Fig. 4).
(4) Disconnect and plug the vacuum line from the
component (fitting, actuator, valve, switch, or reser-
voir) on the other end of the leaking circuit. Instru-
ment panel disassembly or removal may be necessary
to gain access to some components. See the appropri-
ate service procedures.
Fig. 3 ADJUST VACUUM TEST BLEED VALVE
1 - VACUUM PUMP TOOL C-4289
2 - VACUUM TEST SET C-3707
3 - BLEED VALVE
4 - PROBE
KJHEATING & AIR CONDITIONING 24 - 7
HEATING & AIR CONDITIONING (Continued)

(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 67.5 to 82.5 ohms. If OK, go to
Step 3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, see Relay Circuit Test. If not OK,
replace the faulty relay.
RELAY CIRCUIT TEST
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
(1) The relay common feed terminal cavity (30) is
connected to fused battery feed. There should be bat-
tery voltage at the cavity for relay terminal 30 at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is not
used in this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the compressor clutch coil. There should
be continuity between this cavity and the A/C com-
pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
to Step 4. If not OK, repair the open circuit as
required.
(4) The relay coil battery terminal (86) is con-
nected to the fused ignition switch output (run/start)circuit. There should be battery voltage at the cavity
for relay terminal 86 with the ignition switch in the
On position. If OK, go to Step 5. If not OK, repair the
open circuit to the fuse in the junction block as
required.
(5) The coil ground terminal cavity (85) is switched
to ground through the Powertrain Control Module
(PCM). There should be continuity between this cav-
ity and the A/C compressor clutch relay control cir-
cuit cavity of the PCM wire harness connector C
(gray) at all times. If not OK, repair the open circuit
as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
A/C HEATER CONTROL
DESCRIPTION
Both the heater-only and A/C heater systems use a
combination of mechanical, electrical, and vacuum
controls. These controls provide the vehicle operator
with a number of setting options to help control the
climate and comfort within the vehicle. Refer to the
owner's manual in the vehicle glove box for more
information on the features, use, and suggested oper-
ation of these controls.
The heater-only or A/C heater control panel is
located to the right of the instrument cluster on the
instrument panel. The control panel contains a rota-
ry-type temperature control knob, a rotary-type mode
control switch knob, and a rotary-type blower motor
speed switch knob. The control also has a push but-
ton to activate the rear window defogger.
The heater-only or A/C heater control panel cannot
be repaired. If faulty or damaged, the entire unit
must be replaced. The illumination lamps are avail-
able for service replacement.
Fig. 10 COMPRESSOR CLUTCH RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
24 - 16 CONTROLSKJ
A/C COMPRESSOR CLUTCH RELAY (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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the center bezel from the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - REMOVAL).
(3) Release the vacuum harness from the A/C
Heater control.
(4) Remove the four screws that secure the A/C
Heater control to the instrument panel (Fig. 11).(5) Pull the A/C Heater control assembly away
from the instrument panel far enough to access the
connections on the back of the control.
(6) Unplug the wire harness connectors from the
back of the A/C Heater control (Fig. 12).
INSTALLATION
(1) Plug the two wire harness connectors and one
vacuum connector into the back of the A/C Heater
control.
(2) Position the A/C Heater control in the instru-
ment panel bezel and secure it with four screws.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(3) Reinstall the center bezel onto the instrument
panel(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - INSTALLA-
TION).
(4) Connect the battery negative cable.
A/C HIGH PRESSURE SWITCH
DESCRIPTION
The A/C high pressure switch controls both A/C
compressor clutch engagement/disengagement, and
Fig. 11 A/C HEATER CONTROL
1 - REAR WINDOW DEFOGGER SWITCH
2 - BLOWER SPEED CONTROL
3 - MODE SELECT CONTROL
4 - TEMPERATURE SELECT CONTROL
Fig. 12 A/C HEATER CONTROL HEAD (Rear View)
1 - A/C HEATER CONTROL HEAD
2 - A/C HEATER CONTROL HEAD LIGHT
3 - REAR WINDOW DEFOGGER SWITCH AND TEMPERATURE
BLEND DOOR- CONNECTOR B (12 PIN)
4 - A/C HEATER CONTROL HEAD LIGHT
5 - MODE SELECT CONTROL
6 - BLOWER SPEED CONTROL- CONNECTOR A (7 PIN)
7 - MOUNTING SCREWS (4)
KJCONTROLS 24 - 17
A/C HEATER CONTROL (Continued)

(2) Install and tighten the a/c low pressure switch
on the accumulator fitting. The switch should be
hand-tightened onto the accumulator fitting.
(3) Plug the wire harness connector into the a/c
low pressure switch.
(4) Connect the battery negative cable.
BLEND DOOR ACTUATOR
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) Disconnect and isolate the battery negative
cable.
(2) Remove A/C housing from vehicle(Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(3) Remove the screws that secure the blend door
actuator to the top of the HVAC housing. (Fig. 14).
(4) Remove the blend door actuator.
INSTALLATION
(1) Install the blend door actuator in place.
(2) Install and tighten the screws that secure the
blend door actuator to the housing. Tighten the
mounting screws to 2.4 ( .34) N´m (21 ( 3) in. lbs.).
(3) Install the HVAC housing into the vehicle(Re-
fer to 24 - HEATING & AIR CONDITIONING/DIS-
TRIBUTION/HVAC HOUSING - INSTALLATION).
(4) Install the blend door actuator electrical con-
nector from the wiring harness through the glove
box.
(5) Connect the battery negative cable.
BLOWER MOTOR RELAY
DESCRIPTION
The blower motor relay is a International Stan-
dards Organization (ISO)-type relay. The relay is a
electromechanical device that switches battery cur-
rent from a fuse in the Power Distribution Center
(PDC) directly to the blower motor. The relay is ener-
gized when the relay coil is provided a voltage signal
by the ignition switch. (Refer to 24 - HEATING &
AIR CONDITIONING/CONTROLS/BLOWER
MOTOR RELAY - DIAGNOSIS AND TESTING)
OPERATION
The blower motor relay is installed in a wire har-
ness connector that is secured to the passenger side
outboard end of the HVAC housing in the passenger
compartment, next to the HVAC wire harness con-
nector.
The blower motor relay cannot be repaired and, if
faulty or damaged, it must be replaced.
Fig. 14 HEATER CORE REMOVAL/INSTALLATION
1 - HEATER CORE
2- MOUNTING SCREW HOLE
3- INLET AND OUTLET TUBES
4- VACUUM HARNESS
5- ACTUATOR SCREWS (3)
6- ELECTRIC BLEND DOOR ACTUATOR
7- MOUNTING SCREW HOLE
8- HEATER CORE RETAINER TABS (4)
24 - 20 CONTROLSKJ
A/C LOW PRESSURE SWITCH (Continued)

DIAGNOSIS AND TESTING - BLOWER MOTOR
RELAY
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.
RELAY TEST
The blower motor relay (Fig. 15) is located in the
PDC which is located under the hood.. Remove the
relay from the PDC to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 60.7 to 80.3 ohms. If OK, go to
Step 3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, see the Relay Circuit Test. If not OK,
replace the faulty relay.
RELAY CIRCUIT TEST
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
(1) The relay common feed terminal cavity (30) is
connected to fused battery feed directly from a fuse
in the Power Distribution Center (PDC), and should
be hot at all times. Check for battery voltage at the
connector cavity for relay terminal 30. If OK, go to
Step 2. If not OK, repair the open circuit to the PDC
fuse as required.
(2) The relay normally closed terminal cavity (87A)
is not used for this application. Go to Step 3.
(3) The relay normally open terminal cavity (87) is
connected to the blower motor. When the relay is
energized, terminal 87 is connected to terminal 30
and provides full battery current to the blower motor
feed circuit. There should be continuity between the
connector cavity for terminal 87 and the blower
motor at all times. If OK, go to Step 4. If not OK,
repair the open circuit to the blower motor as
required.
(4) The coil battery terminal cavity (86) is con-
nected to the ignition switch. When the ignition
switch is placed in the On position, fused ignition
switch output is directed from a fuse in the junction
block to the relay electromagnetic coil to energize the
relay. There should be battery voltage at the connec-
tor cavity for relay terminal 86 with the ignition
switch in the On position. If OK, go to Step 5. If not
OK, repair the open circuit to the junction block fuse
as required.
(5) The coil ground terminal cavity (85) is con-
nected to ground. This terminal supplies the ground
for the relay electromagnet coil. There should be con-
tinuity between the connector cavity for relay termi-
nal 85 and a good ground at all times. If not OK,
repair the open circuit as required.
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.
Fig. 15 BLOWER MOTOR RELAY
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
KJCONTROLS 24 - 21
BLOWER MOTOR RELAY (Continued)

(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the blower motor relay from the PDC
located under the hood.
(3) Remove the blower motor relay.
INSTALLATION
(1) Install the blower motor relay by aligning the
relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Connect the battery negative cable.
(3) Test the relay operation.
BLOWER MOTOR RESISTOR
DESCRIPTION
The blower motor resistor is mounted to the rear
side of the HVAC housing on the passenger side of
the vehicle.
OPERATION
The resistor is a credit card resistor that utilizes
resistor circuit tracers to reduce current flow to the
blower. The blower motor switch directs the ground
path through the correct resistor circuit to obtain the
selected speed.
The blower motor resistor cannot be repaired and,
if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
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) Disconnect and isolate the battery negative
cable.(2) Open the glove box door and reach in and
unplug the wire harness connector from the blower
motor resistor.
(3) 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 or blower motor relay as
required. If not OK, replace the faulty blower motor
resistor.
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) Disconnect and isolate the battery negative
cable.
(2) Open the glove box door to gain access to the
blower motor resistor.
(3) Pull out the lock on the blower motor resistor
wire harness connector to unlock the connector latch.
(4) Depress the latch on the blower motor resistor
wire harness connector and unplug the connector
from the resistor.
(5) Remove the two screws that secure the resistor
to the HVAC housing.
(6) Remove the resistor from the HVAC housing.
INSTALLATION
(1) Install the new resistor in the HVAC housing.
(2) Install the two screws that secure the resistor
to the HVAC housing and tighten to 2.2 N´m (20 in.
lbs.).
(3) Plug in the blower motor harness connector.
(4) Push in the lock on the blower motor resistor
harness connector.
(5) Close the glove box door.
(6) Connect the battery negative cable.
24 - 22 CONTROLSKJ
BLOWER MOTOR RELAY (Continued)

BLOWER MOTOR SWITCH
DESCRIPTION
The heater-only or A/C Heater blower motor is con-
trolled by a four position rotary-type blower motor
switch, mounted in the A/C Heater control panel. The
switch allows the selection of one of four blower
motor speeds, but can only be turned off by selecting
the Off position with the heater-only or A/C Heater
mode control switch knob.
OPERATION
The blower motor switch directs the blower motor
ground path through the mode control switch to the
blower motor resistor, or directly to ground, as
required to achieve the selected blower motor speed.
The blower motor switch cannot be repaired and, if
faulty or damaged, the entire heater-only or A/C
Heater control unit must be replaced.
DIAGNOSIS AND TESTING - BLOWER MOTOR
SWITCH
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
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) Check for battery voltage at the fuse in the
Power Distribution Center (PDC). 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 Off position.
Disconnect and isolate the battery negative cable.
Remove the A/C Heater control from the instrument
panel. Check for continuity between the ground cir-
cuit cavity of the A/C Heater control wire harness
connector and a good ground. There should be conti-
nuity. If OK, go to Step 3. If not OK, repair the open
circuit to ground as required.
(3) With the A/C Heater control wire harness con-
nector unplugged, place the A/C Heater mode control
switch knob in any position except the Off position.
Check for continuity between the ground circuit ter-minal and each of the blower motor driver circuit ter-
minals of the A/C Heater control as you move the
blower motor switch knob to each of the four speed
positions. There should be continuity at each driver
circuit terminal in only one blower motor switch
speed position. If OK, test and repair the blower
driver circuits between the A/C Heater control con-
nector and the blower motor resistor as required. If
not OK, replace the faulty A/C Heater control unit.
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.
The blower motor switch cannot be repaired and, if
faulty or damaged, the entire heater-only or A/C
Heater control unit must be replaced. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
HEATER CONTROL - REMOVAL)
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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) The blower motor switch cannot be repaired
and, if faulty or damaged the entire heater-only or
A/C heater control unit must be replaced(Refer to 24
- HEATING & AIR CONDITIONING/CONTROLS/
A/C HEATER CONTROL - INSTALLATION).
KJCONTROLS 24 - 23