2002 CHRYSLER VOYAGER jump cable

(3) The calibration procedure should take less than
two minutes to complete for the manual heater-A/C
control, and less than twenty seconds for the ATC
heater-A/C control. When the LEDs or graphics stop
flashing, the calibration procedure is complete.
(4) If the LEDs or graphics continue to flash
beyond the normal three minute (manual) or twenty
second (ATC) calibration time, it indicates that the
heater-A/C control has detected a failure and a Diag-
nostic Trouble Code (DTC) has been set. Use a
DRBIIItscan tool to perform further diagnosis. Refer
to the appropriate diagnostic information. The LEDs
or graphics will continue to flash even after the igni-
tion switch is cycled Off and On, until a successful
calibration is completed or until the vehicle has been
driven about 13 kilometers (8 miles).
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 center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) Place the instrument panel center bezel unit
face down on a suitable work surface. Take the
proper precautions to protect the center bezel from
cosmetic damage.
(4) If the vehicle is equipped with the optional
Automatic Temperature Control (ATC) system, dis-
connect the infrared sensor jumper harness connector
from the receptacle on the back of the heater-A/C
control (Fig. 1).
(5) Remove the six screws that secure the heater-
A/C control to the back of the instrument panel cen-
ter bezel.
(6) Remove the heater-A/C control from the instru-
ment panel center bezel.
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 heater-A/C control onto the back of
instrument panel center bezel.
(2) Install and tighten the six screws that secure
the heater-A/C control to the back of the instrument
panel center bezel. Tighten the screws to 2 N´m (17
in. lbs.).
(3) If the vehicle is equipped with the optional
ATC system, reconnect the infrared sensor jumper
harness connector to the receptacle on the back of
the heater-A/C control.
(4) Reinstall the center bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(5) Reconnect the battery negative cable.
Fig. 1 Heater-A/C Control
1 - INFRARED SENSOR JUMPER CONNECTOR (ATC ONLY)
2 - INFRARED SENSOR JUMPER HARNESS (ATC ONLY)
3 - HEATER-A/C CONTROL
4 - SCREW (6)
5- INSTRUMENT PANEL CENTER BEZEL
RSCONTROLS - FRONT24-9
A/C HEATER CONTROL (Continued)
ProCarManuals.com

or damaged, the instrument panel top cover must be
replaced.
²Demister Outlets- There are two side window
demisters that aid in defogging and defrosting the
front door windows. One demister outlet is located at
each outboard end of the instrument panel top pad,
near the belt line at the A-pillars. The demister out-
lets can be removed from the top pad individually for
service replacement.
²Instrument Panel Outlets- There are five
panel outlets in the instrument panel, one located
near each outboard end of the instrument panel fac-
ing the rear of the vehicle, and three located near the
top of the instrument panel center bezel. On models
with manual temperature control, all five of these
outlets are fully adjustable. On models with Auto-
matic Temperature Control (ATC), the center outlet
in the center bezel has fixed vanes because it also
houses the remote infrared temperature sensors for
the front seat positions. The outboard outlets can be
removed individually for service replacement. The
center bezel outlets are serviced as a gang of three
outlets and, on models with ATC, also includes the
infrared sensors.
²Front Door Rear Outlets- A fully adjustable
outlet located at the rear of each front door trim
panel supplies only cooled air to the intermediate
seat passengers. Air is supplied to these outlets from
the instrument panel through ducts in the doors that
use molded seals at the instrument panel to prevent
air leakage. The door ducts are integral to the front
door trim panels. These outlets also incorporate a red
reflector to improve the safety and visibility of an
opened front door to traffic approaching the vehicle
from the rear at night. These outlets can be removed
from the door trim panels for service replacement.
²Front Floor Outlets- There are two front floor
outlets, one located above each side of the floor panel
center tunnel below the instrument panel. These out-
lets are integral to the front heater-A/C unit distri-
bution housing.
²Rear Floor Outlets- Wide rear floor outlets
located under each front seat have integral, fixed
directional dividers to distribute heated air across
the floor for intermediate seat passengers. These out-
lets are integral to the floor distribution ducts routed
under the front floor carpet from an outlet nozzle on
the bottom of the front heater-A/C unit distribution
housing.
REMOVAL
REMOVAL - CENTER BEZEL OUTLETS
The three outlets located near the top of the
instrument panel center bezel are serviced only as a
set of all three outlets. If the vehicle is equipped withthe optional Automatic Temperature Control (ATC)
system, the center outlet of the three has fixed vanes
and also houses the remote front infrared tempera-
ture sensors.
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 center bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - REMOV-
AL).
(3) Place the center bezel face down on a suitable
work surface. Be certain to take the proper precau-
tions to protect the face of the center bezel from cos-
metic damage.
(4) If the vehicle is equipped with the optional
ATC system, disconnect the ATC remote infrared
temperature sensor jumper harness from the sensor
connector receptacle located on the bottom of the cen-
ter outlet housing (Fig. 3).
(5) Remove the three screws that secure the bot-
tom of the outlet housing to the center bezel.
(6) Roll the bottom of the outlet housing upwards
towards the top of the center bezel far enough to dis-
engage the retainer features on the top of the outlet
housing from their receptacles at the top of the cen-
ter bezel.
(7) Remove the center bezel outlets and housing
from the center bezel as a unit.
REMOVAL - DEMISTER OUTLET
(1) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the outer perimeter of the
demister outlet away from the instrument panel top
pad until the snap features on the outlet are released
(Fig. 4).
(2) Remove the demister outlet from the demister
duct opening in the instrument panel top pad.
REMOVAL - FRONT DOOR REAR OUTLET
(1) Disconnect and isolate the battery negative
cable.
RSDISTRIBUTION - FRONT24-41
AIR OUTLETS (Continued)
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INSTALLATION
INSTALLATION - CENTER BEZEL OUTLETS
(1) Position the center bezel outlets and housing
onto the center bezel as a unit.
(2) Engage the retainer features on the top of the
outlet housing with their receptacles at the top of the
center bezel, then roll the bottom of the outlet hous-
ing downwards towards the center bezel.
(3) Install and tighten the three screws that secure
the bottom of the outlet housing to the center bezel.
Tighten the screws to 2 N´m (17 in. lbs.).
(4) If the vehicle is equipped with the optional
ATC system, reconnect the ATC remote infrared tem-
perature sensor jumper harness to the sensor connec-
tor receptacle located on the bottom of the center
outlet housing.
(5) Reinstall the center bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL CENTER BEZEL - INSTAL-
LATION).
(6) Reconnect the battery negative cable.
INSTALLATION - DEMISTER OUTLET
(1) Position the demister outlet over the demister
duct opening in the instrument panel top pad.
(2) Using hand pressure, press the demister outlet
firmly and evenly into the instrument panel top pad
opening until the snap features on the outlet are
fully engaged.
INSTALLATION - FRONT DOOR REAR OUTLET
(1) Position the front door rear outlet through the
outside of the front door trim panel outlet opening.
(2) While keeping the outlet aligned with the door
duct opening behind the trim panel, use hand pres-
sure to press the outlet firmly and evenly through
the outside of the front door trim panel outlet open-
ing until the four latch features (two top and two bot-
tom) that secure the outlet to the inside of the
opening are fully engaged.
(3) Reinstall the trim panel onto the front door
inner panel. (Refer to 23 - BODY/DOOR - FRONT/
TRIM PANEL - INSTALLATION).
(4) Reconnect the battery negative cable.
INSTALLATION - INSTRUMENT PANEL OUTLET
(1) Position the instrument panel outlet into the
panel duct opening in the instrument panel top pad.
(2) Using hand pressure, press the instrument
panel outlet firmly and evenly into the instrument
panel top pad opening until the snap features on the
outlet are fully engaged.
BLOWER MOTOR
DESCRIPTION
The blower motor is a 12-volt, Direct Current (DC)
motor with a squirrel cage-type blower wheel that is
secured to the blower motor shaft (Fig. 7). The
blower motor and wheel are located near the passen-
ger side end of the heater-A/C unit within the two
halves of the intake air housing in the passenger
compartment below the instrument panel. The
blower motor and blower motor wheel are a factory
balanced unit and cannot be adjusted or repaired. If
faulty or damaged, the blower motor and blower
wheel must be replaced as a unit.
OPERATION
The blower motor will operate whenever the igni-
tion switch is in the On position and the heater-A/C
control power is turned on. The blower motor can
only be turned off by turning off the power at the
heater-A/C control. The blower motor receives battery
current whenever the front blower motor relay is
energized. The front blower motor relay output cir-
cuit is protected by a fuse in the Intelligent Power
Module (IPM) located in the engine compartment
near the battery. In the Manual system, the blower
motor speed is controlled by regulating the path to
ground through the blower control switch and the
blower motor resistor. In the ATC system, the blower
motor speed is controlled by an electronic blower
power module, which uses a pulse width modulated
input from the ATC module and feedback from the
blower motor to regulate the blower motor ground
Fig. 7 Blower Motor
1 - BLOWER MOTOR
2 - RUBBER GROMMET
3 - BLOWER MOTOR CONNECTOR
4 - MOUNTING TABS
RSDISTRIBUTION - FRONT24-43
AIR OUTLETS (Continued)
ProCarManuals.com

path it provides. The blower motor and wheel are
used to control the velocity of air moving through the
heater-A/C unit housing. The blower motor controls
the velocity of the air flowing through the heater-A/C
housing by spinning the blower wheel within the
housing at the selected speed or, in the ATC system,
at the selected or programmed speed.
DIAGNOSIS AND TESTING - BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
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) Check the fuse (Fuse 10 - 40 ampere) in the
Intelligent Power Module (IPM). 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 On position. Be
certain that the heater-A/C control power is turned
on. Check for battery voltage at the fuse (Fuse 10 -
40 ampere) in the IPM. If OK, go to Step 3. If not
OK, proceed to diagnosis of the front blower motor
relay. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/BLOWER MOTOR
RELAY - DIAGNOSIS AND TESTING).
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the front HVAC wire harness connector
for the front blower motor resistor (Manual Temper-
ature Control) or the front blower power module
(Automatic Temperature Control) from the resistor or
module connector receptacle. Reconnect the battery
negative cable. Turn the ignition switch to the On
position. Be certain that the heater-A/C control
power is turned on. Check for battery voltage at the
fused front blower motor relay output circuit cavity
of the front HVAC wire harness connector for the
front blower motor resistor (MTC) or the front blower
power module (ATC). If OK, go to Step 4. If not OK,
repair the open fused front blower motor relay output
circuit to the IPM as required.
(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.Disconnect the front blower motor pigtail wire con-
nector from the connector receptacle of the front
blower motor resistor (MTC) or the front blower
power module (ATC). Use jumper wires to connect a
battery and ground feeds to the blower motor pigtail
wire connector. The blower motor should operate. If
OK with MTC, proceed to diagnosis of the front
blower motor resistor. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS - FRONT/BLOWER
MOTOR RESISTOR - DIAGNOSIS AND TESTING).
If OK with ATC, use a DRBIII scan tool to diagnose
the front blower power module. Refer to the appropri-
ate diagnostic information. If not OK with MTC or
ATC, replace the faulty front blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart (Fig. 8).
REMOVAL
The blower motor and blower wheel are serviced
only as a balanced unit. If either component is faulty
or damaged, the entire unit must be replaced.
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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Disconnect the blower motor pigtail harness
connector from the connector receptacle of either the
blower motor resistor or power module, depending
how vehicle is equipped (Fig. 9).
(2) Remove the lower right trim panel and roll
back the carpet.
(3) Remove the two screws that secure the recircu-
lation door actuator and disengage the wire harness
from the routing clips molded into the bottom of the
lower air intake housing.
(4) Remove the one screw (from the top) that
secures the lower air intake housing to the upper air
intake housing.
(5) Remove the four screws (from the bottom) that
secures the lower air intake housing to the lower half
of the evaporator housing and the upper air intake
housing.
(6) Push the rubber grommet on the blower motor
pigtail wires through the hole in the lower intake air
housing (Fig. 10).
24 - 44 DISTRIBUTION - FRONTRS
BLOWER MOTOR (Continued)
ProCarManuals.com

system control switch on the front heater-A/C control
is not in the Off position. The blower motor can only
be turned off by turning off the rear system at the
front heater-A/C control. The blower motor receives
battery current whenever the rear blower motor
relay is energized. The rear blower motor relay out-
put circuit is protected by a fuse in the Intelligent
Power Module (IPM) located in the engine compart-
ment near the battery. In the MTC system, the
blower motor speed is controlled by regulating the
path to ground through the blower control switch and
the blower motor resistor. In the ATC system, the
blower motor speed is controlled by an electronic
blower power module, which uses a pulse width mod-
ulated input from the ATC module and feedback from
the blower motor to regulate the blower motor
ground path it provides. The blower motor and wheel
are used to control the velocity of air moving through
the rear heater-A/C unit housing. The blower motor
controls the velocity of the air flowing through the
rear heater-A/C housing by spinning the blower
wheel within the housing at the selected speed or, in
the ATC system, at the selected or programmed
speed.
DIAGNOSIS AND TESTING - BLOWER MOTOR
BLOWER MOTOR INOPERATIVE
(1) Check the fuse (Fuse 12 - 25 ampere) in the
Intelligent Power Module (IPM). 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 On position. Be
certain that the rear heater-A/C control power is
turned on. Check for battery voltage at the fuse
(Fuse 12 - 25 ampere) in the IPM. If OK, go to Step
3. If not OK, proceed to diagnosis of the rear blower
motor relay. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - REAR/BLOWER MOTOR
RELAY - DIAGNOSIS AND TESTING).
(3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear HVAC wire harness connector for
the rear blower motor resistor (Manual Temperature
Control) or the rear blower power module (Automatic
Temperature Control) from the resistor or module
connector receptacle. Reconnect the battery negative
cable. Turn the ignition switch to the On position. Be
certain that the rear heater-A/C control power is
turned on. Check for battery voltage at the fused
rear blower motor relay output circuit cavity of the
rear HVAC wire harness connector for the rear
blower motor resistor (MTC) or the rear blower
power module (ATC). If OK, go to Step 4. If not OK,
repair the open fused front blower motor relay output
circuit to the IPM as required.(4) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the rear blower motor pigtail wire connec-
tor from the take out and connector of the rear
HVAC wire harness (MTC) or the connector recepta-
cle of the rear blower power module (ATC). Use
jumper wires to connect a battery and ground feeds
to the blower motor pigtail wire connector. The
blower motor should operate. If OK with MTC, pro-
ceed to diagnosis of the rear blower motor resistor.
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS - REAR/BLOWER MOTOR RESISTOR -
DIAGNOSIS AND TESTING). If OK with ATC, use a
DRBIII scan tool to diagnose the rear blower power
module. Refer to the appropriate diagnostic informa-
tion. If not OK with MTC or ATC, replace the faulty
rear blower motor.
BLOWER MOTOR NOISE OR VIBRATION
Refer to the Blower Motor Noise/Vibration Diagno-
sis chart (Fig. 4).
REMOVAL
The rear blower motor and blower wheel are ser-
viced only as a balanced unit. If either component is
faulty or damaged, the entire unit must be replaced.
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 - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Remove the rear heater-A/C unit housing from
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - REAR/REAR HEATER-
A/C HOUSING - REMOVAL).
(2) Disconnect the rear blower motor pigtail wire
connector. With manual temperature control, the
blower pigtail wire is connected to a take out and
connector of the rear HVAC wire harness. With auto-
matic temperature control, the blower pigtail wire is
connected to a receptacle on the blower power mod-
ule.
(3) Remove the three screws that secure the
blower motor to the outboard side of the rear heater-
A/C unit housing (Fig. 5).
(4) Remove the blower motor and blower wheel
from the rear heater-A/C unit housing.
RSDISTRIBUTION - REAR24-53
BLOWER MOTOR (Continued)
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