2001 CHRYSLER VOYAGER service

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)

BLOWER MOTOR RESISTOR
DESCRIPTION
A blower motor resistor is used on this model when
it is equipped with the manual heater-A/C control
(Fig. 9). Models equipped with the optional Auto-
matic Temperature Control (ATC) use a blower power
module, instead of the blower motor resistor. The
blower motor resistor is installed in a mounting hole
in the heater/AC housing, directly behind the glove
box opening of the instrument panel. The resistor
consists of a molded plastic mounting plate with two
integral connector receptacles. Concealed behind the
mounting plate within the heater/AC housing are
four coiled resistor wires contained within a protec-
tive stamped steel cage. The resistor mounting plate
is secured with two screws to the heater/AC housing
and is accessed for service by rolling down the glove
box from the instrument panel.
The blower motor resistor wires will get hot when
in use. Do not touch the resistor wires or the protec-
tive cage if the blower motor has been running. The
blower motor resistor cannot be adjusted or repaired
and, if faulty or damaged, it must be replaced.
OPERATION
The blower motor resistor is connected to the vehi-
cle electrical system through a dedicated take out
and connector of the instrument panel wire harness.
A second connector receptacle receives the pigtail
wire connector from the blower motor. The blower
motor resistor has multiple resistor wires (Fig. 10),
each of which will reduce the current flow through
the blower motor to change the blower motor speed.
The blower motor switch in the manual heater-A/C
control directs the ground path for the blower motor
through the correct resistor wire to obtain the
selected speed. With the blower motor switch in the
lowest speed position, the ground path for the motor
is applied through all of the resistor wires. Each
higher speed selected with the blower motor switch
applies the blower motor ground path through fewer
of the resistor wires, increasing the blower motor
speed. When the blower motor switch is in the high-
est speed position, the blower motor resistor wires
are bypassed and the blower motor receives a direct
path to ground through the blower motor switch. The
blower motor resistor may be diagnosed using con-
ventional diagnostic tools and methods.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RESISTOR
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
Fig. 8 Intelligent Power Module
1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 9 Blower Motor Resistor
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING LOWER REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE
6 - EVAPORATOR HOUSING
RSCONTROLS - FRONT24-15
BLOWER MOTOR RESISTOR (Continued)

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) Disconnect the instrument panel wire harness
connector for the blower motor resistor and the
blower motor pigtail wire connector from the resistor
connector receptacles.
(3) Check for continuity between each of the
blower motor switch input terminals of the blower
motor resistor and the resistor output terminal. In
each case there should be continuity. If OK, repair
the instrument panel wire harness circuits between
the blower motor switch and the blower motor resis-
tor or the blower motor pigtail wires 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 COMPONENTDIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING:
THE BLOWER MOTOR RESISTOR MAY GET VERY
HOT DURING NORMAL OPERATION. IF THE
BLOWER MOTOR WAS TURNED ON, WAIT FIVE
MINUTES TO ALLOW THE BLOWER MOTOR RESIS-
TOR TO COOL BEFORE PERFORMING DIAGNOSIS
OR SERVICE. FAILURE TO TAKE THIS PRECAU-
TION CAN RESULT IN PERSONAL INJURY.
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box downward.
(4) Reach through the glove box opening to access
and disconnect the instrument panel wire harness
connector for the blower motor resistor from the
resistor connector receptacle (Fig. 11).
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the resistor connector receptacle.
(6) Remove the two screws that secure the blower
motor resistor to the evaporator housing.
(7) Remove the blower motor resistor from the
evaporator housing.
INSTALLATION
CAUTION: Do not operate the blower motor with the
blower motor resistor removed from the circuit.
Failure to take this precaution can result in vehicle
damage.
(1) Position the blower motor resistor into the
evaporator housing (Fig. 11).
Fig. 10 Blower Motor Resistor - Typical
1 - MOUNTING PLATE
2 - RESISTOR WIRES
24 - 16 CONTROLS - FRONTRS
BLOWER MOTOR RESISTOR (Continued)

(2) Install and tighten the two screws that secure
the blower motor resistor to the evaporator housing.
Tighten the screws to 2 N´m (17 in. lbs.).
(3) Reconnect the blower motor pigtail wire con-
nector to the blower motor resistor connector recep-
tacle.
(4) Reconnect the instrument panel wire harness
connector for the blower motor resistor to the resistor
connector receptacle.
(5) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box upward.
(6) Close and latch the glove box.
(7) Reconnect the battery negative cable.
COMPRESSOR CLUTCH
DESCRIPTION
The compressor clutch assembly consists of a sta-
tionary electromagnetic coil with a zener diode, a hub
bearing and pulley assembly, and a clutch plate (Fig.
12). The electromagnetic coil unit and the hub bear-
ing and pulley assembly are each retained on the
nose of the compressor front housing with snap rings.
The clutch plate is keyed or splined to the compres-
sor shaft, and secured with a bolt.
The compressor clutch plate and pulley unit, or the
clutch coil are available for separate service replace-
ment. The clutch coil zener diode is integral to the
clutch coil pigtail wire and connector and, if faulty ordamaged, the clutch electromagnetic coil unit must
be replaced.
OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and
drives the compressor shaft. When the coil is not
energized, the pulley freewheels on the clutch hub
bearing, which is part of the pulley.
A zener diode is connected in parallel with the
clutch electromagnetic coil. This diode controls the
dissipation of voltage induced into the coil windings
by the collapsing of the electromagnetic fields that
occurs when the compressor clutch is disengaged.
The zener diode dissipates this induced voltage by
regulating a current path to ground. This arrange-
ment serves to protect other circuits and components
from potentially damaging voltage spikes in the vehi-
cle electrical system that might occur if the voltage
induced in the clutch coil windings could not be dis-
sipated.
The compressor clutch engagement is controlled by
several components: the heater-A/C controls in the
passenger compartment, the A/C pressure transducer
on the liquid line, the evaporator temperature sensor
on the expansion valve, the Powertrain Control Mod-
ule (PCM) in the engine compartment, and the com-
pressor clutch relay in the Intelligent Power Module
(IPM). The PCM may delay compressor clutch
engagement for up to thirty seconds. (Refer to 8 -
Fig. 11 Blower Motor Resistor
1 - BLOWER MOTOR RESISTOR
2 - INSTRUMENT PANEL WIRE HARNESS
3 - SCREW (2)
4 - GLOVE BOX OPENING LOWER REINFORCEMENT
5 - BLOWER MOTOR PIGTAIL WIRE
6 - EVAPORATOR HOUSING
Fig. 12 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (SOME MODELS)
3 - PULLEY AND BEARING
4 - CLUTCH COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
RSCONTROLS - FRONT24-17
BLOWER MOTOR RESISTOR (Continued)

the compressor shaft (Fig. 14).Be certain not to
lose the shim or shims.
CAUTION: Do not pry between the clutch plate unit
and the pulley to remove the clutch plate from the
compressor shaft as this may damage the clutch
plate.
(10) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the pulley to the front cover of the compres-
sor, then slide the pulley off of the compressor (Fig.
15).
(11) Remove the screw that secures the clutch coil
pigtail wire connector bracket and ground clip to the
top of the compressor housing.
(12) Using snap ring pliers (Special Tool C-4574 or
equivalent), remove the external snap ring that
secures the clutch coil to the front cover of the com-
pressor housing, then slide the clutch coil off of the
compressor (Fig. 16).
INSPECTION - COMPRESSOR CLUTCH/COIL
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the fac-
tory using a burnishing operation. No attempt should
be made to separately replace the compressor clutch
pulley or clutch plate. The clutch coil may be serviced
separately.
(1) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for wear. The clutch pulley
and clutch plate should be replaced if there is exces-
sive wear or scoring.
(2) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for oil contamination. If thefriction surfaces are oily, the clutch pulley and clutch
plate should be replaced. Also inspect the shaft and
nose area of the compressor for oil. Remove the felt
Fig. 14 Clutch Plate and Shim(s)
1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM
Fig. 15 Remove Clutch Pulley Snap Ring
1 - SNAP RING
Fig. 16 Remove Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - COMPRESSOR
4 - SNAP RING
RSCONTROLS - FRONT24-19
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)

and is accessed for service by rolling down the glove
box from the instrument panel.
The power module heat sink will get hot when in
use. Do not touch the heat sink if the blower motor
has been running. The blower power module cannot
be adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
The blower power module is connected to the vehi-
cle electrical system through a dedicated take out
and connector of the instrument panel wire harness.
A second connector receptacle receives the pigtail
wire connector from the blower motor. The blower
power module allows the microprocessor-based Auto-
matic Temperature Control (ATC) heater-A/C control
module to calculate and provide infinitely variable
blower motor speeds based upon either manual
blower switch input or the ATC programming using a
Pulse Width Modulated (PWM) circuit strategy. The
PWM voltage is applied to a comparator circuit
which compares the PWM signal voltage to the
blower motor feedback voltage. The resulting output
drives the power module circuitry, which adjusts the
voltage output received from the blower motor relay
to change or maintain the desired blower speed. The
blower power module is diagnosed using a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor-
mation.
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) Open the glove box.
(3) Flex both sides of the glove box bin inward
near the top far enough for the rubber glove box stop
bumpers to clear the sides of the glove box opening,
then roll the glove box downward.
(4) Reach through the glove box opening to access
and disconnect the instrument panel wire harness
connector for the power module from the module con-
nector receptacle.
(5) Reach through the glove box opening to access
and disconnect the blower motor pigtail wire connec-
tor from the power module connector receptacle.
(6) Remove the two screws that secure the power
module to the evaporator housing.
(7) Remove the power module from the evaporator
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 power module into the evaporator
housing.
Fig. 23 Power Module
1 - POWER MODULE
2 - LOWER GLOVE BOX OPENING REINFORCEMENT
3 - EVAPORATOR HOUSING
RSCONTROLS - FRONT24-27
POWER MODULE (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)