2001 CHRYSLER VOYAGER light

cloudy days and at night it will probably be slightly
warmer. Infrared Three-Zone Temperature Control
provides side-to-side and front-to-rear variation in
comfort temperature settings. The Infrared Three-
Zone Automatic Temperature Control fan provides a
continuously variable air flow rate to meet occupant
comfort requirements.
FRONT CONTROL PANEL
²AUTO HI/LO± This system features two sets of
automatic control logic that allow either a rapid cool-
down rate or a somewhat slower cool-down rate with
less fan noise. HI-AUTO controls the system to reach
its assigned temperature quickly with a higher fan
speed. LO-AUTO controls the system to reach its
assigned temperature somewhat slower with less fan
noise. Both modes will automatically engage auto
recirculation.
²DE-FROST± The front de-frost function is
active when the rear window defogger function is
active or when the defog/defrost mode is selected.
²RECIRC± The RECIRC button will close the
air inlet door. If the system is in auto recirc (indica-
tor being displayed automatically), pressing the man-
ual recirc button will disable the auto recirc function
until one of the auto keys are pressed or the ignition
is cycled. If Auto HI/LO is pressed while manual
recirc is active, manual recirc will be deactivated.
²REAR WINDOW DEFOGGER± Pushing the
button sends a PCI bus message to the Intelligent
Power Module which controls the Rear Window
Defogger and side view mirror (if equipped) circuitry.
The defogger function will be active for 10 minutes
and can be turned off by a switch press. The defogger
will function while the control is in the OFF mode.
²FAN/MODE± The Fan and Mode knobs have
17 manual selectable positions. Manually changing
either of the rotary knobs for mode or fan speed set-
tings makes control of that function alone manual for
as long as the ignition is on. If only one is changed
manually, the other remains under automatic control.
Pressing the HI-AUTO/LO-AUTO rocker switch
restores full automatic control.
²REAR CONTROL± When the Rear System
control knob is moved to the OFF position, there will
be a delay of approximately 1 second before the sys-
tem actually turns off. This delay is to prevent an
undesired blower dropout if the knob is moved
through OFF to the other selections.
²BLOWER DELAY TIMER± The word DELAY
is displayed at start-up to signify that the system is
waiting so that cold air will not be blowing. This tells
the operator that it is unnecessary to turn the sys-
tem off, raise the temperature setting or turn the fan
speed setting down to prevent cold air from blowing.
A countdown in minutes and seconds until the engineis warm enough to begin delivering heat to the pas-
sengers alternates with the DELAY message at 25
second intervals. This countdown is based on actual
measurement of the rate of engine coolant tempera-
ture change. During the delay time, Defrost mode is
selected and the fan operates at a low speed to keep
the windshield fog free.
REAR CONTROL PANEL
Primary control of the rear compartment unit is in
the instrument panel center stack. The rear unit con-
trol knob there allows the driver to turn the rear
unit off, allow control by the intermediate seat occu-
pants by switching to the REAR position, or provide
fully automatic control based on the temperature set-
ting shown on the front control display.
²REAR CONTROL± Selecting automatic control
of the rear unit at the instrument panel, illuminates
a Locked Padlock in the rear control panel display.
Selecting REAR activates the rear control panel and
the Padlock then appears unlocked.
²FAN KNOB± The rear fan control has Off and
AUTO positions and a range of manual speed set-
tings that override the AUTO setting.
²MODE KNOB± The mode control allows inter-
mediate seat occupants to manually override the
automatic mode and select any balance of air flow
between overhead and floor outlets from full over-
head to full floor.
²SET TEMP± The rear set temp control will
operate identical to the front controls. If the front
control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the a/c system is
operating properly, or use a DRBIIItscan tool to
diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
24 - 4 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

Performance Temperature and Pressure
Ambient Temperature 21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Left Center Panel
Outlet Discharge Air
Temperature1to8ÉC
(34 to 46É F)3to9ÉC
(37 to 49É F)4 to 10ÉC
(39 to 50É F)6to11ÉC
(43 to 52É F)7 to 18É C
(45 to 65É F)
Discharge Pressure
(High Side Service
Port)1034 to 1724
kPa
(150 to 250
psi)1517 to 2275
kPa
(220 to 330
psi)1999 to 2620
kPa
(290 to 380
psi)2068 to 2965
kPa
(300 to 430
psi)2275 to 3421
kPa
(330 to 450 psi)
Suction Pressure (Low
Side Service Port)103 to 207 kPa
(15 to 30 psi)117 to 221 kPa
(17 to 32 psi)138 to 241 kPa
(20 to 35 psi)172 to 269 kPa
(25 to 39 psi)207 to 345 kPa
(30 to 50 psi)
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
Check the coolant level, drive belt tension, radiator
air flow, and cooling fan operation. Start the engine
and allow it to warm up to normal temperature.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With the engine idling at normal running tempera-
ture, set the heater-A/C controls as follows. Temper-
ature control to full Heat, Mode control to Floor,
Blower control to the highest speed setting. Using a
test thermometer, check the air temperature coming
from the center floor outlets and compare this read-
ing to the Temperature Reference table.
TEMPERATURE REFERENCE
AMBIENT
TEMPERATUREMINIMUM FLOOR
OUTLET TEMPERATURE
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153ÉIf the floor outlet air temperature is insufficient,
check that the cooling system is operating to specifi-
cations. (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Both heater hoses should be
HOT to the touch (the coolant return hose should be
slightly cooler than the supply hose). If the coolant
return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction
in heater system.
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED
COOLANT FLOW
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at cooling system connections.
²Plugged heater core.
²Air locked heater core.
²Restrictor in backwards.
If coolant flow is verified and the heater floor out-
let temperature is insufficient, a mechanical problem
may exist.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend-air door not functioning properly.
TEMPERATURE CONTROL
If heater floor outlet temperature cannot be
adjusted with the heater-A/C control temperature
control lever, one of the following could require ser-
vice:
²Blend-air door binding.
²Faulty blend-air door motor.
²Improper engine coolant temperature.
²Faulty heater-A/C control.
24 - 6 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C-HEATER CONTROL
STANDARD PROCEDURE...................8
HEATER-A/C CONTROL CALIBRATION.......8
REMOVAL...............................9
INSTALLATION............................9
A/C PRESSURE TRANSDUCER
DESCRIPTION...........................10
OPERATION.............................10
DIAGNOSIS AND TESTING.................10
A/C PRESSURE TRANSDUCER............10
REMOVAL..............................11
INSTALLATION...........................11
BLEND DOOR ACTUATOR
DESCRIPTION...........................11
OPERATION.............................12
REMOVAL..............................12
INSTALLATION...........................12
BLOWER MOTOR RELAY
DESCRIPTION...........................13
OPERATION.............................14
DIAGNOSIS AND TESTING.................14
BLOWER MOTOR RELAY.................14
REMOVAL..............................14
INSTALLATION...........................14
BLOWER MOTOR RESISTOR
DESCRIPTION...........................15
OPERATION.............................15
DIAGNOSIS AND TESTING.................15
BLOWER MOTOR RESISTOR.............15
REMOVAL..............................16
INSTALLATION...........................16
COMPRESSOR CLUTCH
DESCRIPTION...........................17
OPERATION.............................17
STANDARD PROCEDURE..................18
COMPRESSOR CLUTCH AIR GAP..........18
COMPRESSOR CLUTCH BREAK-IN.........18REMOVAL..............................18
INSPECTION............................19
INSTALLATION...........................20
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING.................21
COMPRESSOR CLUTCH COIL.............21
COMPRESSOR CLUTCH RELAY
DESCRIPTION...........................21
OPERATION.............................22
DIAGNOSIS AND TESTING.................22
COMPRESSOR CLUTCH RELAY...........22
REMOVAL..............................23
INSTALLATION...........................23
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION...........................23
OPERATION.............................23
REMOVAL..............................24
INSTALLATION...........................24
INFRARED TEMPERATURE SENSOR
DESCRIPTION...........................24
OPERATION.............................25
MODE DOOR ACTUATOR
DESCRIPTION...........................25
OPERATION.............................25
REMOVAL..............................26
INSTALLATION...........................26
POWER MODULE
DESCRIPTION...........................26
OPERATION.............................27
REMOVAL..............................27
INSTALLATION...........................27
RECIRCULATION DOOR ACTUATOR
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................29
INSTALLATION...........................29
A/C-HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION
The heater-A/C control module must be recali-
brated each time an actuator motor or the control
module is replaced. This is necessary so that the con-
trol module can ªlearnº the feedback voltages for
each actuator motor at both stop positions of each
door in the front HVAC unit housing. If the vehicle isso equipped, the calibration procedure also includes
rear HVAC positions for each actuator motor.
(1) Turn the ignition switch to the On position.
(2) Simultaneously depress and hold the Power
and Recirculation buttons on the heater-A/C control
for at least five seconds. The manual heater-A/C con-
trol Delay Light Emitting Diode (LED) and Recircu-
lation LED, or the Automatic Temperature Control
(ATC) heater-A/C control Delay and Recirculation
graphics will begin to flash when the calibration pro-
cedure has begun.
24 - 8 CONTROLS - FRONTRS

OPERATION
Each blend door actuator is connected to the heat-
er-A/C control module through the vehicle electrical
system by a dedicated two-wire take out and connec-
tor of the HVAC wire harness. The blend door actua-
tor can move the blend air door in two directions.
When the heater-A/C control module pulls the volt-
age 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 direction. When the module makes
the voltage to both connections high or both connec-
tions low, the blend air door stops and will not move.
These same motor connections also provide a feed-
back signal to the heater-A/C control module. This
feedback signal allows the module to monitor the
operation and relative positions of the blend door
actuator and the blend air door. The heater-A/C con-
trol 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 blend
door actuator can be diagnosed using a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
REMOVAL
The single zone heating and air conditioning sys-
tem is equipped with a single blend door actuator.
The dual zone system has two blend door actuators,
one for the driver side blend air door and one for the
passenger side blend air door. The same service pro-
cedures can be used for each of these actuators.
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) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 5).
(4) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the heater/ air conditioner hous-
ing near the dash panel.
(5) Remove the heater core shield from the distri-
bution housing.
(6) Disconnect the HVAC wire harness connector
for the blend door actuator from the actuator connec-
tor receptacle (Fig. 6).
(7) Remove the two screws that secure the blend
door actuator to the distribution housing.
(8) Remove the blend door actuator from the dis-
tribution housing.
INSTALLATION
(1) Position the blend door actuator onto the heat-
er/air conditioner housing (Fig. 6). If necessary,
rotate the actuator slightly to align the splines on
the actuator output shaft with those in the blend air
door linkage.
(2) Install and tighten the two screws that secure
the blend 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 blend door actuator to the actuator connector
receptacle.
(4) Position the heater core shield onto the distri-
bution housing (Fig. 5). Be certain that the two loca-
tion tabs on the front of the shield are engaged in the
Fig. 5 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
24 - 12 CONTROLS - FRONTRS
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)

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)

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 direction. When the mod-
ule 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 con-
trol module. This feedback signal allows the module
to monitor the operation and relative 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 cir-
cuits. A DTC can be retrieved and the blend door
actuator can be diagnosed using a DRBIIItscan tool.
Refer to the appropriate diagnostic information.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right quarter trim panel and right
D-pillar trim panel from the quarter inner panel.
(Refer to 23 - BODY/INTERIOR/QUARTER TRIM
PANEL - REMOVAL).
(3) Remove the two screws that secure the top of
the quarter trim panel attaching bracket to the quar-
ter inner panel.
(4) Remove the screw that secures the back of the
rear heater-A/C unit housing to the right D-pillar.
(5) Remove the screw that secures the front of the
rear heater-A/C unit housing to the right quarter
inner panel.
(6) Carefully pull the top of the rear heater-A/C
unit housing away from the right quarter inner panel
far enough to reach between the rear heater-A/C unit
housing and the quarter inner panel to access the
blend door actuator (Fig. 4).
(7) Remove the two screws that secure the blend
door actuator to the rear heater-A/C unit housing.
(8) Pull the blend door actuator away from the
rear heater-A/C unit housing far enough to disengage
the actuator output shaft from the blend air door
pivot.
(9) Raise the blend door actuator far enough to
access and disconnect the rear HVAC wire harness
connector for the actuator from the actuator connec-
tor receptacle.
(10) Remove the blend door actuator from between
the rear heater-A/C unit housing and the quarter
inner panel.
INSTALLATION
(1) Position the blend door actuator between the
rear heater-A/C unit housing and the quarter inner
panel.
(2) Reconnect the rear HVAC wire harness connec-
tor for the blend door actuator to the actuator con-
nector receptacle (Fig. 4).
(3) Position the blend door actuator onto the rear
heater-A/C unit housing. If necessary, rotate the
actuator slightly to align the splines on the actuator
output shaft with those in the blend air door pivot.
(4) Install and tighten the two screws that secure
the blend door actuator to the rear heater-A/C unit
housing. Tighten the screws to 2 N´m (18 in. lbs.).
(5) Push the top of the rear heater-A/C unit hous-
ing back into position against the right quarter inner
panel.
(6) Install and tighten the screw that secures the
front of the rear heater-A/C unit housing to the right
Fig. 4 Blend Door Actuator
1 - SCREW (2)
2 - MODE DOOR ACTUATOR
3 - SCREW (2)
4 - CONNECTOR
5 - BLEND DOOR ACTUATOR
6 - CONNECTOR
24 - 32 CONTROLS - REARRS
BLEND DOOR ACTUATOR (Continued)