2001 CHRYSLER VOYAGER heating

receptacles in the two lower finger formations of the
evaporator housing near the dash panel.
(5) Install and tighten the three screws that secure
the heater core shield to the left end of the heater/air
conditioner housing. Tighten the screws to 2 N´m (17
in. lbs.).
(6) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(7) Reconnect the battery negative cable.
(8) 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).
BLOWER MOTOR RELAY
DESCRIPTION
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
The blower motor relay (Fig. 7) is a International
Standards Organization (ISO) mini-relay. Relays con-
forming to the ISO specifications have common phys-
ical dimensions, current capacities, terminal
patterns, and terminal functions. The ISO mini-relay
terminal functions are the same as a conventional
ISO relay. However, the ISO mini-relay terminal pat-
tern (or footprint) is different, the current capacity is
lower, and the physical dimensions are smaller than
those of the conventional ISO relay. The blower
motor relay is located in the Intelligent Power Mod-
ule (IPM), which is in the engine compartment near
the battery. See the fuse and relay layout map
molded into the inner surface of the IPM cover for
blower motor relay identification and location.
The black, molded plastic case is the most visible
component of the blower motor relay. Five male
spade-type terminals extend from the bottom of the
base to connect the relay to the vehicle electrical sys-
tem, and the ISO designation for each terminal is
molded into the base adjacent to each terminal. The
ISO terminal designations are shown in (Fig. 8).
Fig. 6 Blend Door Actuator
1 - CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE-ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
Fig. 7 Blower Motor Relay
RSCONTROLS - FRONT24-13
BLEND DOOR ACTUATOR (Continued)

ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION - PCM OPERATION).
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between 0.5 and 0.9 mm
(0.020 and 0.035 in.), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
check that the compressor clutch coil is performing to
specifications. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH COIL - DIAGNOSIS AND TESTING). If
the clutch coil is performing to specifications, per-
form the compressor clutch break-in procedure. This
procedure (burnishing) will seat the opposing friction
surfaces and provide a higher compressor clutch
torque capability.
(1) Set the heater-A/C controls to the A/C mode,
with the blower switch in the highest speed position.
(2) Start the engine and hold the engine speed at
1500 to 2000 rpm.
(3) Cycle the compressor clutch On and Off about
twenty times (five seconds On, then five seconds Off).
REMOVAL
The refrigerant system can remain fully charged
during compressor clutch, pulley, or coil replacement.
Although the compressor assembly must be removed
from its mounting, the compressor clutch can be ser-
vice with the compressor in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
(3) Remove the serpentine drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
2.4L - REMOVAL) or (Refer to 7 - COOLING/ACCES-SORY DRIVE/DRIVE BELTS - 3.3/3.8L - REMOV-
AL).
(4) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil pig-
tail wire connector on the top of the compressor.
(5) On models with the 3.3L and 3.8L engines, dis-
engage the retainer on the engine wire harness com-
pressor clutch coil take out from the bracket on the
top of the compressor.
(6) On models with the 2.4L engine, remove all of
the compressor mounting screws except the upper
left (rear of the compressor) screw, which should only
be loosened. Allow the front (pulley end) of the com-
pressor to tilt downward far enough to access the
clutch for removal, then tighten the loosened upper
left compressor mounting screw.
(7) On models with the 3.3L and 3.8L engines,
remove the three screws and one nut that secure the
compressor to the engine. Disengage the mounting
ear at the front of the compressor from the stud on
the engine, allow the front (pulley end) of the com-
pressor to tilt downward far enough to access the
clutch for removal, then reinstall and tighten the
upper left compressor mounting screw.
(8) Remove the compressor shaft bolt (Fig. 13). If
necessary, a band-type oil filter wrench or a strap
wrench can be placed around the clutch plate to aid
in bolt removal.
(9) Tap the clutch plate lightly with a plastic ham-
mer and remove the clutch plate and shim(s) from
Fig. 13 Compressor Shaft Bolt and Clutch Plate
1 - COMPRESSOR SHAFT BOLT
2 - COMPRESSOR CLUTCH PLATE
24 - 18 CONTROLS - FRONTRS
COMPRESSOR CLUTCH (Continued)

packing from around the compressor shaft in the
compressor front cover. If the felt is saturated with
oil, the compressor front shaft seal is leaking and the
compressor will also have to be replaced.
(3) Check the clutch pulley bearing for roughness
or excessive leakage of grease. Replace the clutch
pulley and clutch plate if the bearing is faulty.
INSTALLATION
The refrigerant system can remain fully charged
during compressor clutch, pulley, or coil replacement.
Although the compressor assembly must be removed
from its mounting, the compressor clutch can be ser-
vice with the compressor in the vehicle.
(1) Align the dowel pin on the back of the clutch
coil with the hole in the compressor front cover, and
position the clutch coil onto the compressor. Be cer-
tain that the clutch coil pigtail wires are properly ori-
ented and routed so that they are not pinched
between the compressor front cover and the clutch
coil.
NOTE: A new snap ring must be used to secure the
clutch coil to the compressor. The bevel side of the
snap ring must face outward.
(2) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring that
secures the clutch coil to the front cover of the com-
pressor (Fig. 16). The bevel side of the snap ring
must face outward and both snap ring eyelets must
be oriented to the right or the left of the clutch coil
dowel pin location on the compressor. Be certain that
the snap ring is fully and properly seated in the
groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the compressor front
cover.
(3) Install and tighten the screw that secures the
clutch coil pigtail wire connector bracket and ground
clip to the top of the compressor housing.
(4) Install the pulley onto the front cover of the
compressor. If necessary, tap the pulley gently with a
block of wood placed on the pulley friction surface
(Fig. 17).
CAUTION: Do not mar the friction surfaces of the
pulley.
NOTE: A new snap ring must be used to secure the
clutch pulley to the compressor. The bevel side of
the snap ring must face outward.(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
front cover of the compressor (Fig. 15). Be certain
that the snap ring is fully and properly seated in the
groove.
(6) If the original clutch plate and clutch pulley
are to be reused, reinstall the original shim(s) on the
compressor shaft against the shoulder (Fig. 14). If a
new clutch plate and/or clutch pulley are being used,
install a trial stack of shims 1.0 mm (0.040 in.) thick
on the compressor shaft against the shoulder.
(7) Install the clutch plate onto the compressor
shaft.
(8) Install and tighten the compressor shaft nut
(Fig. 13). If necessary, a band-type oil filter wrench
or a strap wrench can be placed around the clutch
plate to aid in bolt tightening. Tighten the bolt to
17.5 N´m (155 in. lbs.).
(9) If a new clutch plate and/or clutch pulley are
being installed, the air gap between the clutch plate
and clutch pulley must be checked. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH - STANDARD
PROCEDURE - COMPRESSOR CLUTCH AIR GAP).
(10) On models with the 2.4L engine only, loosely
install the four screws that secure the compressor to
the mounting bracket on the engine. Tighten the
screws to 28 N´m (21 ft. lbs.).
Fig. 17 Install Clutch Pulley
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
24 - 20 CONTROLS - FRONTRS
COMPRESSOR CLUTCH (Continued)

(11) On models with the 3.3L and 3.8L engines
only, loosely install the three screws and one nut that
secure the compressor to the engine. Tighten each of
the fasteners using the following sequence to 54 N´m
(40 ft. lbs.).
²The upper screw at the rear of the compressor.
²The lower screw at the rear of the compressor.
²The lower screw at the front of the compressor.
²The upper nut at the front of the compressor.
(12) On models with the 3.3L and 3.8L engines
only, engage the retainer on the engine wire harness
compressor clutch coil take out with the bracket on
the top of the compressor.
(13) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(14) Reinstall the serpentine accessory drive belt
onto the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTAL-
LATION).
(15) Lower the vehicle.
(16) Reconnect the battery negative cable.
(17) If a new clutch plate and/or clutch pulley are
being installed, the new clutch components must be
burnished. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH - STANDARD PROCEDURE - COMPRES-
SOR CLUTCH BREAK-IN).
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL
The air conditioning compressor clutch coil electri-
cal circuit is controlled by the Powertrain Control
Module (PCM) through the compressor clutch relay,
which is located in the Intelligent Power Module
(IPM) in the engine compartment near the battery.
Begin testing of a suspected compressor clutch coil
problem by performing the preliminary checks.
PRELIMINARY CHECKS
(1) If the compressor clutch will not engage, verify
the refrigerant charge level. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - FRONT/RE-
FRIGERANT - DIAGNOSIS AND TESTING -
REFRIGERANT CHARGE LEVEL). If the refriger-
ant charge level is OK, go to Step 2. If the refriger-
ant charge level is not OK, adjust the refrigerant
charge as required.
(2) If the a/c compressor clutch still will not
engage, disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer andcheck for battery current at the connector with the
engine running and the heater-A/C control set to the
A/C mode. If OK, go to TESTS . If not OK, use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information.
TESTS
(1) Verify the battery state of charge. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY -
DIAGNOSIS AND TESTING).
(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the heater-A/C control in the A/C mode
and the blower at low speed, start the engine and
allow it to run at a normal idle speed.
(4) The compressor clutch should engage immedi-
ately, and the clutch coil voltage should be within
two volts of the battery voltage. If the coil voltage is
not within two volts of battery voltage, test the
clutch coil feed circuit for excessive voltage drop. If
the compressor clutch does not engage, use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information.
(5) With the ambient temperature at 21É C (70É F),
the compressor clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5 to 12.5 volts at the
clutch coil. If the voltage is more than 12.5 volts, add
electrical loads by turning on electrical accessories
until the voltage reads below 12.5 volts.
(a) If the compressor clutch coil current reading
is zero, the coil is open and must be replaced.
(b) If the compressor clutch coil current reading
is four amperes or more, the coil is shorted and
must be replaced.
COMPRESSOR CLUTCH RELAY
DESCRIPTION
The compressor clutch relay (Fig. 18) is a Interna-
tional Standards Organization (ISO) micro-relay.
Relays conforming to the ISO specifications have
common physical dimensions, current capacities, ter-
minal patterns, and terminal functions. The ISO
micro-relay terminal functions are the same as a con-
ventional ISO relay. However, the ISO micro-relay
terminal pattern (or footprint) is different, the cur-
rent capacity is lower, and the physical dimensions
are smaller than those of the conventional ISO relay.
The compressor clutch relay is located in the Intelli-
gent Power Module (IPM), which is in the engine
compartment near the battery. See the fuse and relay
layout map molded into the inner surface of the IPM
RSCONTROLS - FRONT24-21
COMPRESSOR CLUTCH (Continued)

peratures it monitors. The heater-A/C control module
is connected to the sensor through a sensor ground
circuit and a sensor signal circuit. As the evaporator
temperature increases, the resistance of the sensor
decreases and the voltage monitored by the module
decreases. The module uses this monitored voltage
reading to an indication of the evaporator tempera-
ture. The heater-A/C control module is programmed
to respond to this input by sending electronic mes-
sages to the Powertrain Control Module (PCM) over
the Programmable Communications Interface (PCI)
data bus, and the PCM then cycles the air condition-
ing compressor clutch as necessary to optimize air
conditioning system performance and to protect the
system from evaporator freezing. The external loca-
tion of the sensor and the use of a push-in plastic
retainer allows the sensor to be removed or installed
from the expansion valve without disturbing the
refrigerant in the system. The evaporator tempera-
ture sensor is diagnosed using a DRBIIItscan tool.
Refer to the appropriate diagnostic information.
REMOVAL
(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 attaching
screw from the expansion valve.
(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 lock and
remove the HVAC wire harness connector from the
temperature sensor.
(6) Remove the evaporator temperature sensor
from the engine compartment. Please note that any
grease removed with the old temperature sensor
must be replaced, failure to do so could result in poor
a/c performance.
INSTALLATION
(1) Position the evaporator temperature sensor
into the right rear corner of the engine compartment.
(2) Reconnect the HVAC wire harness connector
for the evaporator temperature sensor to the sensor
connector receptacle.
(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
(Fig. 19).
(4) Install the temperature sensor retaining screw
and tighten.(5) Install the window wiper assembly to the vehi-
cle (REFER to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - INSTALLATION).
(6) Reinstall the air cleaner housing into the right
side of the engine compartment.
(7) Reconnect the battery negative 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. 20). These sensors are used only on mod-
els equipped with the optional Automatic Tempera-
ture Control (ATC) heating and air conditioning
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 har-
ness routed behind the center bezel connects the sen-
sors directly to the ATC heater-A/C control module
near the bottom 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.
Fig. 20 Infrared Temperature Sensor
1 - INSTRUMENT PANEL CENTER BEZEL
2 - CENTER BEZEL OUTLETS
3 - INFRARED TEMPERATURE SENSOR
24 - 24 CONTROLS - FRONTRS
EVAPORATOR TEMPERATURE SENSOR (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) 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 HVAC wire harness connector
for the mode door actuator from the actuator connec-
tor receptacle (Fig. 22).
(4) Remove the two screws that secure the mode
door actuator to the distribution housing.
(5) Remove the mode door actuator from the distri-
bution housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the mode door actuator onto the heat-
er/AC housing (Fig. 22). If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the mode door linkage.
(2) Install and tighten the two screws that secure
the mode door actuator to the distribution housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the mode door actuator to the actuator connector
receptacle.
(4) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(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).
POWER MODULE
DESCRIPTION
A blower power module is used on this model when
it is equipped with the optional Automatic Tempera-
ture Control (ATC) (Fig. 23). Models equipped with
the standard manual heater-A/C control use a blower
motor resistor, instead of the blower power module.
The blower power module is installed in a mounting
hole in the evaporator housing, directly behind the
glove box opening of the instrument panel. The mod-
ule consists of a molded plastic mounting plate with
two integral connector receptacles. Concealed behind
the mounting plate within the evaporator housing is
the power module electronic circuitry and a large
finned, heat sink. The module mounting plate is
secured with two screws to the evaporator housingFig. 22 Mode Door Actuator
1 - CONNECTOR
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - DRIVER BLEND DOOR ACTUATOR (DUAL-ZONE ONLY)
5 - HEATER CORE
6 - BLEND DOOR ACTUATOR (SINGLE-ZONE) OR PASSENGER
BLEND DOOR ACTUATOR (DUAL-ZONE)
24 - 26 CONTROLS - FRONTRS
MODE DOOR ACTUATOR (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
for the recirculation door actuator from the actuator
connector receptacle (Fig. 25).
(4) Remove the two screws that secure the recircu-
lation door actuator to the lower intake air housing.
(5) Remove the recirculation door actuator from
the lower intake air housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Position the recirculation door actuator onto
the lower intake air housing (Fig. 25). If necessary,
rotate the actuator slightly to align the splines on
the actuator output shaft with those in the recircula-
tion air door.
(2) Install and tighten the two screws that secure
the recirculation door actuator to the lower intake air
housing. Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the HVAC wire harness connector
for the recirculation door actuator to the actuator
connector receptacle.
(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. 25 Recirculation Door Actuator
1 - LOWER INTAKE AIR HOUSING
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC WIRE HARNESS
4 - SCREW (2)
5 - LOWER EVAPORATOR HOUSING
RSCONTROLS - FRONT24-29
RECIRCULATION DOOR ACTUATOR (Continued)

quarter inner panel. Tighten the screw to 11 N´m (97
in. lbs.).
(7) Install and tighten the screw that secures the
back of the rear heater-A/C unit housing to the right
D-pillar. Tighten the screw to 11 N´m (97 in. lbs.).
(8) Install and tighten the two screws that secure
the top of the quarter trim panel attaching bracket to
the quarter inner panel. Tighten the screws to 1.7
N´m (15 in. lbs.).
(9) Reinstall the right quarter trim panel and
right D-pillar trim panel onto the quarter inner
panel. (Refer to 23 - BODY/INTERIOR/QUARTER
TRIM PANEL - INSTALLATION).
(10) Reconnect the battery negative cable.
(11) Perform the heater-A/C control calibration
procedure. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/A/C-HEATER CON-
TROL - STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION).
BLOWER MOTOR RELAY
DESCRIPTION
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
The blower motor relay (Fig. 5) is a International
Standards Organization (ISO) mini-relay. Relays con-
forming to the ISO specifications have common phys-ical dimensions, current capacities, terminal
patterns, and terminal functions. The ISO mini-relay
terminal functions are the same as a conventional
ISO relay. However, the ISO mini-relay terminal pat-
tern (or footprint) is different, the current capacity is
lower, and the physical dimensions are smaller than
those of the conventional ISO relay. The blower
motor relay is located in the Intelligent Power Mod-
ule (IPM), which is in the engine compartment near
the battery. See the fuse and relay layout map
molded into the inner surface of the IPM cover for
compressor clutch relay identification and location.
The black, molded plastic case is the most visible
component of the blower motor relay. Five male
spade-type terminals extend from the bottom of the
base to connect the relay to the vehicle electrical sys-
tem, and the ISO designation for each terminal is
molded into the base adjacent to each terminal. The
ISO terminal designations are as follows:
²30 (Common Feed)- This terminal is con-
nected to the movable contact point of the relay.
²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.
²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
The factory-installed blower motor relay cannot be
adjusted or repaired. If the relay is damaged or
faulty, it must be replaced.
OPERATION
The blower motor relay is an electromechanical
switch that uses a low current input from the Front
Control Module (FCM) to control the high current
output to the blower motor resistor (manual heater-
A/C control) or blower power module (automatic heat-
er-A/C control). The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. The resistor or diode is con-
nected in parallel with the relay coil in the relay, and
helps to dissipate voltage spikes and electromagnetic
interference that can be generated as the electromag-
netic field of the relay coil collapses.
Fig. 5 Blower Motor Relay
RSCONTROLS - REAR24-33
BLEND DOOR ACTUATOR (Continued)