2003 JEEP GRAND CHEROKEE Passenger door module

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Output Speed Sensor (4.0L) GY Left Side of Transmission 12
Output Speed Sensor (4.7L) BK Left Side of Transmission 16
Overhead Map/Courtesy Lamp WT At Overhead Console N/S
Oxygen Sensor 1/1 Upstream
(4.0L)GY Left Side of Engine at Exhaust 9, 12
Oxygen Sensor 1/1 Upstream
(4.7L)GY Left Side of Engine at Exhaust 17
Oxygen Sensor 1/2
Downstream (4.0L)BK Rear of Transmission 9, 12
Oxygen Sensor 1/2
Downstream (4.7L)BK Rear of Transmission 17
Oxygen Sensor 2/1 Upstream Rear of Transmission N/S
Oxygen Sensor 2/2
DownstreamRear of Transmission N/S
Park Brake Switch Center Console Area, Near Airbag
Control Module20, 21, 22
Park/Neutral Position Switch
(4.0L)BK Left Side of Transmission 12
Park/Neutral Position Switch
(Diesel)BK Left Side of Transmission N/S
Passenger Airbag YL Passenger Side of Instrument Panel 19, 20
Passenger Blend Door
Motor/Actuator (AZC)BK Passenger Side of Instrument Panel N/S
Passenger Door Lock
Motor/Ajar SwitchBK In Passenger Door 26, 27
Passenger Door Module - C1 WT In Passenger Door 26, 27
Passenger Door Module - C2 BK In Passenger Door N/S
Passenger Front Door
Courtesy LampBK In Passenger Door N/S
Passenger Front Power
Window MotorBK In Passenger Door 26, 27
Passenger Heated Seat Back
(Premium I/III)GN At Passenger Seat N/S
Passenger Heated Seat
Cushion (Premium I/III)BK At Passenger Seat N/S
Passenger Heated Seat Switch BK Center of Instrument Panel 19, 20, 21
Passenger Lumbar Motor
(Midline/Premium)BK At Passenger Seat N/S
Passenger Lumbar Switch
(Midline/Premium)WT At Passenger Seat N/S
Passenger Power Mirror BK In Passenger Door N/S
Passenger Power Seat Front
Riser MotorRD At Passenger Seat N/S
Passenger Power Seat
Horizontal MotorRD At Passenger Seat N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/
NUMBERCOLOR LOCATION FIG.
Passenger Power Seat Rear
Riser MotorRD At Passenger Seat N/S
Passenger Power Seat
Recliner Motor (Midline/
Premium)BK At Passenger Seat N/S
Passenger Power Seat Switch
(Midline/Premium)GN At Passenger Seat N/S
Passenger Rear Power
Window MotorBK In Right Rear Door 29
Passenger Rear Power
Window SwitchBL In Right Rear Door 29
Passenger Seat Belt Switch t Switch N/S
Power Amplifier - C1 WT Under Rear Seat 34, 36
Power Amplifier - C2 WT Under Rear Seat 34, 36
Power Connector WT Center of Instrument Panel 21, 22
Powertrain Control Module -
C1 (Gas)BK Rear of Engine Compartment 5, 10, 11, 14, 15, 18
Powertrain Control Module -
C2 (Gas)WT Rear of Engine Compartment 5, 10, 11, 14, 15, 18
Powertrain Control Module -
C3 (Gas)WT Rear of Engine Compartment N/S
Radiator Fan Motor BK At Radiator 5
Radiator Fan Relay BK Right Side of Engine Compartment 5
Radio - C1 GY Center of Instrument Panel 19, 20
Radio - C2 BK Center of Instrument Panel 19, 20
Rain Sensor BK Front Center Overhead N/S
Rear Power Outlet RD Right Rear Quarter Panel 37
Rear Washer Pump BK Left Front of Engine Compartment 3, 4
Rear Window Defogger BK Right Upper Coner of Liftgate 38
Rear Wiper Motor BK In Liftgate 38
Recirculation Door Motor/
Actuator (AZC)BK Center of Instrument Panel N/S
Red Brake Warning Indicator
SwitchGY At Master Cylinder 4
Remote Keyless Module
(Japan)BL In Driver Door 25
Right Courtesy Lamp BK At Lamp 20 21, 22
Right Curtain Airbag BK Near Right C Pillar 37
Right Door Handle Courtesy
LampBK At Lamp N/S
Right Fog Lamp BK At Right Front Fascia 5
Right Front Door Speaker WT In Right Front Door 25, 26
Right Front Impact Sensor BK Near Right Verticle Radiator Support N/S
Right Front Park Lamp WT At Lamp N/S
WJ8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE
NUMBERLOCATION FIG.
S326 Near T/O for C200 34, 35
S327 Near T/O for c307 34, 35
S328 In Sill Trough Near T/O for G300 34
S329 In Sill Trough Near T/O for G300 34
S330 Near T/O for G300 34
S331 In Sill Trough Near T/O for C303 34, 36
S332 In Sill Trough Near T/O for C303 34, 36
S333 Near T/O for Power Amplifiers 36
S334 In T/O for Power Amplifier - C2 34
S335 Near T/O for C314 36
S336 Near T/O for Driver Power Window Motor 24, 25
S338 Near T/O for Passenger Power Window Motor 26, 27
S339 Near T/O for Passenger Power Window Motor 26 27
S340 In T/O for Passenger Door Module - C1 26, 27
S341 Near T/O for C306 N/S
S345 Near T/O for Sunroof Switch 32
S346 Near T/O for Left Visor/Vanity Lamp 32
S347 Near T/O for Left Visor/Vanity Lamp 32
S348 Near T/O for Automatic Day/Night Mirror 32
S349 Near T/O for Automatic Day/Night Mirror 32
S351 Near T/O for Seat Belt Switch N/S
S352 Near T/O for Seat Belt Switch N/S
S353 Near T/O for Driver Lumbar Switch N/S
S355 Near T/O for C304 and C306 N/S
S356 In T/O for Left Rear Door Lock Motor/Ajar Switch 28
S357 In T/O for Right Rear Door Lock Motor/Ajar Switch 29
S358 Near Left B Pillar Sill Trough 35
S359 Near T/O for C302 34
S360 In T/O for C302 N/S
S362 In T/O for C200 34
S363 In T/O for C200 34
S364 Near B Pillar Sill Trough 36
S365
JapanNear T/O for Remote Keyless Entry Module 24, 25
S366 Near T/O for Junction Block C1 N/S
S367 (RHD) Near T/O for C310 N/S
S368 Near T/O for Power Amplifier - C1 34
S369 Near T/O for Left Visor Vanity Lamp N/S
S370 Near T/O for Sunroof Module 32
S400 Near Rear Window Defogger Ground Connector 38
S401 Near Rear Window Defogger Ground Connector 38
S402 Near T/O for Liftgate Flip-Up Ajar Switch 38
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONWJ
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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) Prior to installing the instrument panel into
the vehicle, loosen the three nuts that secure the
instrument panel intermediate bracket and the accel-
erator pedal assembly to the studs on the dash panel
(Fig. 8).
(2) With the aid of an assistant, load the instru-
ment panel assembly through the driver side front
door of the vehicle and hang it on the studs on the
dash panel near the windshield fence line (Fig. 1).
(3) Be certain that the molded plastic hook forma-
tions on the instrument panel structural duct are
inserted into and seated in the guide holes at each
cowl side inner panel.
(4) Loosely install the two screws that secure each
end of the instrument panel to the cowl side inner
panels.
(5) Install and tighten the two screws that secure
the passenger side instrument panel structural duct
to the heater and air conditioner housing (Fig. 13).
Tighten the screws to 11.8 N´m (105 in. lbs.).
(6) Install and tighten the one screw that secures
the instrument panel steering column support
bracket to the driver side end of the heater and air
conditioner housing (Fig. 7). Tighten the screw to
11.8 N´m (105 in. lbs.).
(7) Tighten the two screws that secure each end of
the instrument panel to the cowl side inner panels
(Fig. 10) and (Fig. 14). Tighten the screws to 11.8
N´m (105 in. lbs.).
(8) Install and tighten the one screw that secures
the instrument panel steering column support
bracket to the intermediate bracket on the driver
side dash panel (Fig. 8). Tighten the screw to 11.3
N´m (100 in. lbs.).
(9) Tighten the three nuts that secure the instru-
ment panel intermediate bracket and the accelerator
pedal assembly to the studs on the dash panel.
Tighten the nuts to 11.3 N´m (100 in. lbs.).(10) Install and tighten the four nuts that secure
the instrument panel to the studs on the dash panel
near the windshield fence line. Tighten the nuts to
11.8 N´m (105 in. lbs.).
(11) Install and tighten the nut that secures the
instrument panel steering column support bracket to
the stud on the driver side cowl plenum panel (Fig.
9). Tighten the nut to 28.2 N´m (250 in. lbs.).
(12) Reinstall the instrument panel to center floor
tunnel bracket onto the instrument panel and the
floor panel transmission tunnel. (Refer to 23 - BODY/
INSTRUMENT PANEL/IP CENTER FLOOR TUN-
NEL BRACKET - INSTALLATION).
(13) Reconnect the two instrument panel wire har-
ness connectors to the two heater and air conditioner
housing connectors located near the blower motor on
the passenger side end of the housing (Fig. 12).
(14) Reconnect the two halves of the radio antenna
coaxial cable connector near the right cowl side inner
panel under the end of the instrument panel.
(15) Reconnect the instrument panel wire harness
connector to the lower cavity of the inline connector
on the passenger side cowl side inner panel and
tighten the connector screw (Fig. 11). Tighten the
screw to 4 N´m (36 in. lbs.).
(16) Reinstall the lower right center bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP LOWER RIGHT CENTER BEZEL
- INSTALLATION).
(17) Reinstall the end cap onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL END CAP - INSTALLA-
TION).
(18) If the vehicle is equipped with the manual
heating and air conditioning system, reconnect the
vacuum harness connector located near the driver
side of the floor panel transmission tunnel behind
the driver side floor duct.
(19) Position the driver side floor duct to the
heater and air conditioner housing near the driver
side of the floor panel transmission tunnel (Fig. 7).
(20) Install and tighten the one screw that secures
the driver side floor duct to the heater and air con-
ditioner housing near the driver side of the floor
panel transmission tunnel. Tighten the screw to 2.2
N´m (20 in. lbs.).
(21) Route the instrument panel wire harness to
the floor panel transmission tunnel and engage the
retainers that secure the harness to the mounting
brackets on the tunnel (Fig. 6).
(22) Install the instrument panel wire harness
ground eyelets to the studs on the floor panel trans-
mission tunnel in front of and behind the airbag con-
trol module and secure the eyelets with nuts. Tighten
the nuts to 7.3 N´m (65 in. lbs.).
WJINSTRUMENT PANEL SYSTEM 23 - 43
INSTRUMENT PANEL SYSTEM (Continued)

OPERATION
OPERATION - HEATER AND AIR CONDITIONER
Outside fresh air enters the vehicle through the
cowl top opening at the base of the windshield, and
passes through a plenum chamber to the HVAC sys-
tem blower housing. Air flow velocity can then be
adjusted with the blower motor speed selector switch
on the a/c heater control panel. The air intake open-
ings must be kept free of snow, ice, leaves, and other
obstructions for the HVAC system to receive a suffi-
cient volume of outside air.
It is also important to keep the air intake openings
clear of debris because leaf particles and other debris
that is small enough to pass through the cowl ple-
num screen can accumulate within the HVAC hous-
ing. The closed, warm, damp and dark environment
created within the HVAC housing is ideal for the
growth of certain molds, mildews and other fungi.
Any accumulation of decaying plant matter provides
an additional food source for fungal spores, which
enter the housing with the fresh air. Excess debris,
as well as objectionable odors created by decaying
plant matter and growing fungi can be discharged
into the passenger compartment during HVAC sys-
tem operation.
Both the manual and AZC heater and air condi-
tioner are blend-air type systems. In a blend-air sys-
tem, a blend door controls the amount of
unconditioned air (or cooled air from the evaporator)
that is allowed to flow through, or around, the heater
core. A temperature control knob on the a/c heater
control panel determines the discharge air tempera-
ture by energizing the blend door actuator, which
operates the blend door. This allows an almost imme-
diate control of the output air temperature of the sys-
tem. The AZC system will have separate blend doors
and temperature controls for each front seat occu-
pant.
The mode control knob on the a/c heater control
panel is used to direct the conditioned air to the
selected system outlets. On manual temperature con-
trol systems, the mode control knob switches engine
vacuum to control the mode doors, which are oper-
ated by vacuum actuators. On AZC systems, the
mode control knob switches electrical current to con-
trol the mode doors, which are operated by electronic
actuators.
The outside air intake can be shut off on manual
temperature control systems by selecting the Recircu-
lation Mode with the mode control knob. The outside
air intake can be shut off on Automatic Zone Control
(AZC) type system by pushing the Recirculation
Mode button. This will operate the recirculation door
that closes off the outside fresh air intake and recir-
culates the air that is already inside the vehicle.The air conditioner for all models is designed for
the use of non-CFC, R-134a refrigerant. The air con-
ditioning system has an evaporator to cool and dehu-
midify the incoming air prior to blending it with the
heated air. This air conditioning system uses a ther-
mal expansion valve to meter refrigerant flow to the
evaporator coil. To maintain minimum evaporator
temperature and prevent evaporator freezing, the
system utilizes an evaporator thermister probe with
the appropriate operating logic located in the body
control module (BCM).
OPERATION - REFRIGERANT SYSTEM SERVICE
PORT
The high pressure service port is located on the liq-
uid line near the receiver/drier. The low pressure ser-
vice port is located on the suction line near the
evaporator at the rear of the engine compartment.
Each of the service ports has a threaded plastic
protective cap installed over it from the factory. After
servicing the refrigerant system, always reinstall
both of the service port caps.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C
PERFORMANCE
The air conditioning system is designed to provide
the passenger compartment with low temperature
and low specific humidity air. The evaporator, located
in the HVAC housing on the dash panel below the
instrument panel, is cooled to temperatures near the
freezing point. As warm damp air passes through the
cooled evaporator, the air transfers its heat to the
refrigerant in the evaporator and the moisture in the
air condenses on the evaporator fins. During periods
of high heat and humidity, an air conditioning sys-
tem will be more effective in the Recirculation Mode.
With the system in the Recirculation Mode, only air
from the passenger compartment passes through the
evaporator. As the passenger compartment air dehu-
midifies, the air conditioning system performance
levels improve.
Humidity has an important bearing on the tempera-
ture of the air delivered to the interior of the vehicle. It
is important to understand the effect that humidity has
on the performance of the air conditioning system.
When humidity is high, the evaporator has to perform a
double duty. It must lower the air temperature, and it
must lower the temperature of the moisture in the air
that condenses on the evaporator fins. Condensing the
moisture in the air transfers heat energy into the evap-
orator fins and tubing. This reduces the amount of heat
the evaporator can absorb from the air. High humidity
greatly reduces the ability of the evaporator to lower
the temperature of the air.
24 - 2 HEATING & AIR CONDITIONINGWJ
HEATING & AIR CONDITIONING (Continued)

INSTALLATION
INSTALLATION - RECIRCULATION DOOR
VACUUM ACTUATOR
(1) Install the recirculation door vacuum actuator
on the HVAC housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Engage the recirculation door actuating rod
with the recirculation door lever.
(3) Engage the recirculation door pivot connection
with the door pivot pin.
(4) Plug in the vacuum harness connector to the
recirculation door vacuum actuator.
(5) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
INSTALLATION - RECIRCULATION DOOR
ELECTRIC ACTUATOR
(1) Install the recirculation door actuator on the
recirculation door housing and tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(2) Install the recirculation door housing on the
HVAC unit and tighten the mounting screws to 2.2
N´m (20 in. lbs.).
(3) Plug in the wire harness connector to the recir-
culation door actuator.
(4) Install the instrument panel in the vehicle.
Refer to Instrument Panel System for the procedures.
VACUUM CHECK VALVE
DESCRIPTION
Two vacuum check valves (non AZC only) are
installed on the vacuum supply system. One is on the
accessory vacuum supply line in the engine compart-
ment, near the vacuum tap on the engine intake
manifold. A second vacuum check valve is located on
the bottom of the HVAC unit behind the passenger
front floor duct on the black vacuum line. The vac-
uum check valves are designed to allow vacuum to
flow in only one direction through the accessory vac-
uum supply circuits.
OPERATION
The use of a vacuum check valve helps to maintain
the system vacuum needed to retain the selected A/C
Heater mode settings. The check valve will prevent
the engine from bleeding down system vacuum
through the intake manifold during extended heavy
engine load (low engine vacuum) operation.
The vacuum check valve cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Unplug the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
(2) Note the orientation of the check valve in the
vacuum supply line for correct installation.
(3) Unplug the vacuum check valve from the vac-
uum supply line fittings.
INSTALLATION
(1) Plug in the vacuum check valve at the vacuum
supply line fittings, noting the orientation of the
check valve in the vacuum supply line for correct
installation.
(2) Plug in the HVAC vacuum supply line connec-
tor at the vacuum check valve near the engine intake
manifold vacuum adapter fitting.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is mounted in the right front
of the vehicle behind the headlamp mounting module
(Fig. 22). The headlamp mounting module and head-
lamp assembly must be removed from the vehicle to
access the vacuum reservoir for service. Refer to
Lamps/Lighting for the procedures.
OPERATION
Engine vacuum is stored in the vacuum reservoir.
The stored vacuum is used to operate the vacuum-
Fig. 21 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
24 - 34 CONTROLSWJ
RECIRCULATION DOOR ACTUATOR (Continued)

HVAC HOUSING
REMOVAL
The HVAC housing assembly must be removed
from the vehicle and the two halves of the housing
separated for service access of the heater core, evap-
orator coil, blend door(s), and each of the various
mode doors.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(3) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line from
the evaporator inlet tube(Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/LIQUID LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/LIQUID LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.
(5) Disconnect the suction line refrigerant line
from the evaporator outlet tube(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/SUCTION
LINE - REMOVAL), (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/SUCTION LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/SUCTION LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.(6) Disconnect the heater hoses from the heater
core tubes. Clamp off the heater hoses to prevent loss
of coolant. Refer to Cooling for the procedures. Install
plugs in, or tape over the opened heater core tubes.
(7) If the vehicle is equipped with the manual tem-
perature control system, unplug the HVAC system
vacuum supply line connector from the tee fitting
near the heater core tubes.
(8) Remove the coolant reserve/overflow bottle
from the passenger side inner fender shield. Refer to
Cooling for the procedures.
(9) Remove the Powertrain Control Module (PCM)
from the passenger side dash panel in the engine
compartment and set it aside. Do not unplug the
PCM wire harness connectors. Refer to Electronic
Control Modules for the procedures.
(10) Remove the nuts from the HVAC housing
mounting studs on the engine compartment side of
the dash panel (Fig. 9).
(11) Remove the rear floor heat ducts from the
floor heat duct outlets (Fig. 10).
(12) Unplug the HVAC housing wire harness con-
nectors.
(13) Remove the HVAC housing mounting nuts
from the studs on the passenger compartment side of
the dash panel (Fig. 11).
Fig. 9 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
WJDISTRIBUTION 24 - 41

NOTE: The blend door sub-assembly is attached to
the housing with 2 screws, and may be removed for
service (Fig. 19).
ASSEMBLY
(1) Place the top half of the HVAC housing on the
bottom half. Be certain that each of the door pivot
pins align with the pivot holes in the HVAC housing.
(2) Install the 10 screws that secure the two hous-
ing halves to each other. Tighten the HVAC housing
screws to 2.2 N´m (20 in. lbs.).
(3) Attach the wire harness electrical connector(s)
to the mounts on the lower case at the blower motor
end of the unit.
(4) Install the 5 clips that secure the two housing
halves to each other. Check doors for binding after
replacement, and after assembly of housing.
(5) Install the screw with plastic washer holding
the lever assembly to the upper case section.
(6) Install the mode door actuator on the left side
of the housing.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct mounting holes.
(2) Install the HVAC housing mounting nuts to the
studs on the passenger compartment side of the dash
panel. Tighten the nuts to 4.5 N´m (40 in. lbs.).
(3) Connect the HVAC housing wire harness con-
nectors.
(4) Reinstall the rear floor heat ducts to the center
floor heat duct outlets.
(5) Install and tighten the nuts onto the HVAC
housing mounting studs on the engine compartment
side of the dash panel. Tighten the nuts to 7 N´m (60
in. lbs.).
(6) Reinstall the PCM to the passenger side dash
panel in the engine compartment. Refer to Electronic
Control Modules for the procedures.
(7) Reinstall the coolant reserve/overflow bottle to
the passenger side inner fender shield. Refer to Cool-
ing for the procedures.
(8) If the vehicle is equipped with the manual tem-
perature control system, connect the HVAC system
vacuum supply line connector to the tee fitting near
the heater core tubes.
(9) Unclamp/unplug the heater core hoses and
tubes. Connect the heater hoses to the heater core
tubes and fill the engine cooling system. Refer to
Cooling for the procedures.
(10) Unplug or remove the tape from the suction
line and the evaporator outlet tube fittings. Connect
the suction line to the evaporator outlet tube.
Tighten retaining nut to 28 N´m (250 in. lbs.).
(11) Unplug or remove the tape from the liquid
line and the evaporator inlet tube fittings. Connect
the liquid line to the evaporator inlet tube. Tighten
retaining nut to 28 N´m (250 in. lbs.).
(12) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
Fig. 19 BLEND DOOR SUB-ASSEMBLY (AZC)
1 - PASSENGER SIDE BLEND DOOR
2 - BLEND DOOR SUB-ASSEMBLY
3 - DOOR PIVOT SHAFT BUSHING
4 - DOOR SHAFT LEVER
5 - DRIVER SIDE BLEND DOOR
WJDISTRIBUTION 24 - 45
HVAC HOUSING (Continued)